Masters thesis of engineering integrated drive using motor windings for electric vehicle application

Integrated Drive Using Motor Windings for Electric Vehicle Application A thesis submitted in fulfilment of the requirements for the degree of Master of Engineering Mehdi Niakinezhad M.Sc Electrical Railway Engineering, IUST School of Engineering College of Science, Technology, Engineering and Maths RMIT University July 2021 i Declaration I certify that except where due acknowledgement has been made, this research is that of the author alone; the content of this research submission is the result of work which has been carried out since the official commencement date of the approved research program; any editorial work, paid or unpaid, carried out by a third party is acknowledged; and, ethics procedures and guidelines have been followed In addition, I certify that this submission contains no material previously submitted for award of any qualification at any other university or institution, unless approved for a joint-award with another institution, and acknowledge that no part of this work will, in the future, be used in a submission in my name, for any other qualification in any university or other tertiary institution without the prior approval of the University, and where applicable, any partner institution responsible for the joint-award of this degree I acknowledge that copyright of any published works contained within this thesis resides with the copyright holder(s) of those works I give permission for the digital version of my research submission to be made available on the web, via the University’s digital research repository, unless permission has been granted by the University to restrict access for a period of time I acknowledge the support I have received for my research through the provision of an Australian Government Research Training Program Scholarship Name: Mehdi Niakinezhad Date: 18 July 2021 ii To my dear Lily, Mom and Dad… iii Acknowledgments I acknowledge the support I have received for this research through the provision of an Australian Government Research Training Program Scholarship I would like to appreciate my supervisor Dr Nuwantha Fernando for his trust, encouragement and supports from the beginning of this study Thanks to him, I could significantly progress in my research skills I wish to thank you my co-supervisor Dr Inam Nutkani for his positive contribution and valuable suggestions and comments Thank, RMIT for resources, co-authors of papers Junaid Saeed, Prof Liuping Wang as well as Dr Arash Vahidnia and Prof Brendan McGrath for their input during milestones iv Table of Contents Acknowledgments iii Table of Contents iv List of Tables vii List of Figures viii Abbreviations xiv Chapter Introduction 1.1 Introduction 1.2 Research Questions 1.2.1 RQ1– What is the best power stage topology of switched reluctance motor drive to perform functions of an integrated drive? 1.2.2 RQ2– What is the best approach to achieve CCCV, PFC, and fault tolerance and battery voltage equalization using a new integrated SRM Drive? 1.3 List of Publication Disclosure Chapter Literature Review 2.1 Electric Vehicle Battery Chargers 2.1.1 Types of Electric Vehicle Battery Chargers 2.1.2 Integrated Chargers 2.2 Integrated Drives with Induction Machines 12 2.2.1 Integrated Drive using Multiphase Induction Machines 12 2.2.2 Integrated Drive for Induction Machine with Split Windings 17 2.3 Integrated Drives with Permanent Magnet Machines 19 2.3.1 Integrated Drive with Split-Phase Dual-Inverter Permanent Magnet Synchronous Motor 19 v 2.3.2 Integrated Drive with Multiphase Permanent Magnet Synchronous Machines 21 2.3.3 Integrated Drives with Two Separated Permanent Magnet Synchronous Machine 22 2.4 Integrated Drives with Switched Reluctance Machines 24 2.4.1 SRM Drive with integrated battery charger suitable for PHEV 24 2.4.2 SRM Drive with Flexible Energy Conversion 27 2.4.3 Integrated Battery Charger based on Split-Winding SRM 29 2.4.4 SRM Integrated Charger using Three-phase Power Module 31 2.4.5 Modular SRM integrated charger with Split Winding SRM 33 2.4.6 Modular Tri-port Integrated Drive for SRM with Split Windings 35 2.4.7 SRM integrated Drive with Solar-Assisted Power source and flexible charging functions 41 2.4.8 Modular SRM based Tri-port Integrated Charger 42 2.4.9 Modular Multilevel converter SRM based Drive with Decentralized Battery Packs 43 2.5 Comparison 46 Chapter 47 Integrated Chargers for SRM bases EVs 47 3.1 Split-winding asymmetric half bridge (SW-ASHB) interconnected converter with modular batteries [58]-[59] 47 3.1.1 Battery Charging Mode with SW-ASHB interconnected converter with modular batteries 49 3.1.2 Phase Inductance Variation with Rotor Position in an SW-ASHB interconnected SRM 51 3.1.3 Control Strategy for SW-ASHB interconnected converter with modular batteries 53 3.2 Switched winding circuit integrated multiport converter [61] 56 3.2.1 Analysis of the SWC-IMPC operation 57 3.2.2 Phase Inductance Variation with Rotor Position in an SWC-IMPC interconnected SRM 60 vi 3.2.3 Control design requirements SWC-IMPC interconnected SRM 61 3.3 Split-rail asymmetric half bridge converter with an extra leg [70] 62 3.3.1 Operation analysis of the Split-rail asymmetric half bridge converter with an extra leg 63 3.3.2 Charging Modes of the Split-rail asymmetric half bridge converter with an extra leg 64 3.4 Conclusion 68 Chapter 69 Simulation Setup Implementation 69 4.1 Simulation Set up for Split-winding asymmetric half bridge (SW-ASHB) interconnected converter with modular batteries 69 4.2 Simulation Setup for the Switched winding circuit integrated multiport converter with modular batteries 71 4.3 Split-rail asymmetric half bridge converter with an extra leg Simulation Setup 74 Chapter 76 Simulation Results 76 5.1 Split-winding asymmetric half bridge (SW-ASHB) interconnected converter Simulation Result [58] 76 5.1.1 Simulation result of charging operation with the SW-ASHB interconnected converter 79 5.2 Switched winding circuit integrated multiport converter Simulation Results [59] 82 5.3 Simulation Results for the Split-rail asymmetric half bridge converter with an extra leg [70] 85 5.4 Conclusion 90 Chapter 92 Conclusion 92 6.1 Comparison table 96 References or Bibliography 97 vii List of Tables Table 2.1 Correlations between machines and grid currents 15 Table 2.2 Comparison between different topologies presented in literature review 46 Table 3.1 Switching states of the semiconductor devices in order to utilize voltage equalization in an SW-ASHB interconnected converter 54 Table 5.1 Motor Parameters 78 Table 5.2 Parameters used for Simulations 82 Table 5.3 Parameters used for Simulations 86 Table 6.1 Comparison between different topologies presented in literature review 96 viii List of Figures Fig 2.1 Typical Power Electronic interface inside a PEV [6] Fig 2.2 Full-bridge LLC resonant converter and synchronous rectifier followed by boost PFC [1] Fig 2.3 Different types of Integrated Drives using motor windings based on motor type 11 Fig 2.4 Multiphase machine (a) five-phase (b) six-phase (c) nine-phase [10] 12 Fig 2.5 Integrated charging topologies for multiphase machine (a) nine-phase (b) six-phase (c) five-phase [10] 14 Fig 2.6 N-phase inverter (n equals to the number of machine phase) and a battery pack with/without dc-dc converter [10] 14 Fig 2.7 Integrated charging topologies supplied from a multiphase voltage source and based on (a) six-phase (b) five-phase [10] 16 Fig 2.8 six-phase induction motor with two three-phase drives [29] 17 Fig 2.9 IM integrated drive topology with split windings [30] 17 Fig 2.10 Equivalent charging circuit consists of an AC/DC converter with double three-phase PCF [30] 19 Fig 2.11 Integrated drive and battery charger based on the split-phase IPMSM and dual inverters [34] 20 Fig 2.12 System configuration in charging mode [34] 21 Fig 2.13 Proposed integrated drive with multiphase PMSM [35] 21 Fig 2.14 The equivalent charging circuit for the topology shown in Fig 2.11 [35] 22 Fig 2.15 Integrated drive topology with two PMSM [45] 23 Fig 2.16 Three-phase SRM drive with an on-board charger [21] 24 ix Fig 2.17 Power flow for (a), (b), (c), and (d) driving, (e) charging battery through ICE, and (f) charging battery through AC grid [21] 25 Fig 2.18 (a) Converter configuration for buck charging mode (b-c) current flow in buck charging mode [21] 26 Fig 2.19 Converter configuration for boost charging mode, (a) Inductor charging interval (b) Battery charging interval [21] 27 Fig 2.20 Proposed integrated converter fed by front-end circuit [48] 28 Fig 2.21 Different input voltage levels (a) S01=ON, S2=OFF and I>0 (b) S01=OFF S02=ON and I>0 (c) S01=OFF, S02=OFF and I>0 (d) S01=x, S02=x and I