The source-to-wheel efficiency of today’s electrified vehicles already far surpasses the efficiency of strictly gasoline vehicles. As sources of electricity become cleaner and more efficient, and as gasoline becomes more scarce, the need for transportation electrification is increasingly economically and environmentally driven. The automotive industry primarily makes use of permanent magnet synchronous machines (PMSMs) and induction machines (IMs), the latter has the cost advantage of containing no rare earth metals. This thesis studies two different induction motors for electrified powertrain applications using a novel optimization algorithm to create efficiency maps and compare the efficiencies of the two motors. Induction motors are difficult to banchmark due to their complicated control schemes. Each point in their operating range can be achieved with an infinite number of current/slip combinations and therefore has infinite potential efficiencies. The proposed algorithm limits the number of simulations needed to benchmark an induction machine, and provides a clear and unbiased way to compare machines based on losses at their most efficient current/slip combinations over their entire operating range. The proposed algorithm is able to calculate losses within 5% accuracy of simulation values for both machines. The first motor studied makes use of stranded windings and geometry parameters from the Tesla Motors patents. The efficiency map created has a peak efficiency of 96% and corresponds closely to an efficiency map for a similar motor found in literature. The second motor makes use of copper bar windings, which are easier to manufacture and have lower material costs. Bar windings, typically have lower resistance and stator copper losses at low speeds, but higher effective resistance and stator losses at high speeds due to eddy effects. The motor modelled was intended simply to compare the stranded and bar windings, and to see the advantages and disadvantages. For this reason, no other changes are made to the winding layout or motor geometry, including changes that would reduce the eddy effect. The resultant efficiency map has a peak efficiency of only 90%, performing worse than the stranded wound motor across most of its operating range. At very low speeds, under 1000 rpm, the efficiency of the bar wound machine is better than that of the stranded machine. The bar wound machine also has the advantage of being over 80% efficient everywhere. The author suggests that future research focus on applying the proposed benchmarking algorithm to stator bar motors designed to limit eddy effects. Strategies include changing the slot opening shape, increasing the number of stator bars, and moving the stator bars away from the air gap. / Thesis / Master of Applied Science (MASc)

This work is intended to contribute with knowledge to the area of electic motorsfor propulsion in the vehicle industry. This is done by first studying the differentelectric motors available, the motors suitable for vehicle propulsion are then dividedinto four different types to be studied separately. These four types are thedirect current, induction, permanent magnet and switched reluctance motors. Thedesign and construction are then studied to understand how the different typesdiffer from each other and which differences that are of importance when it comesto vehicle propulsion. Since the amount of available data about different electricmotors turned out to be small a tool was developed to use for collecting data fromthe sources available which can be for instance product sheets or articles with informationabout electric motors. This tool was then used to collect data that wasused to create models for the different motor types. The created motor models foreach motor type could then be used for simulating vehicles to investigate how thespecific motor is suited for different vehicles and applications. The work also containsa summary of different electric motor comparison studies which makes it agood source of information during motor type selection in the process of designingan electric vehicle.

This thesis studies a DC motor for a racing hybrid electric vehicle (HEV) prototype.The development of optimization-based energy management strategies (EMS) necessitates an accurate quasi-static model of the driving motor, which includes a 2D efficiency map with the torque outputand rotating speed as the inputs. However, a DC motor's efficiency varies a lot at differentoperating points and the efficiency map from the technical manual does not match the various applications in reality.In view of this, this thesis investigates a field testing based quasi-static modeling method to construct the DC motor efficiency map with only portable and brief testing resources. Firstly, a testbench is designed, manufactured, integrated, and configured with necessary accessories. The testbench consists of the motor under test, a braking motor to provide load torque, a servo-amplifier for torque control and sensing, a host computer for data acquisition, and power supplies. Then, a self-contained testing plan is designed by which as many as possible different testing points can be covered based on the braking motor's power limit. After that, the experiments are successively performed on the test bench, and the input electric power along with the output mechanical power at steady state are recorded. Multiple data process methods are explored to analyze the collected testing data. Root mean square (RMS) is used to reduce the measuring variance. Invalid outliers are identified and filtered out based on the residuals. The qualified samples are employed to build up the 2D efficiency map by fourth-degree polynomial regression. Then, three methods, linear, quadratic, and cubic fittings are attempted separately to estimate the relationships between the input power and output torque at different speeds. The results show that the quadratic model is the best option which results in smaller root mean square error (RMSE) and fair computation complexity. To conclude, the quasi-static dynamic model of a DC motor, which includes a 2D efficiency map and the speed-based polynomial expression of input power, can be properly established by a new method relying on less and simpler devices in contrast to those traditional methods. This method bypasses a bulk of tedious modulations on precise motor speed control which is heavily dependent on a high-precision sensor. The formulated 2D efficiency map will effectively support the future development of model-based EMS. The polynomial expression provides a more efficient approach to estimate instantaneous energy efficiency for an embedded system application. / Denna avhandling studerar en likströmsmotor för en prototyp av ett elektriskt hybridfordon (HEV) för racing. Utvecklingen av optimeringsbaserade energihanteringsstrategier (EMS) kräver en precis kvasistatisk dynamisk modell av den drivande motorn, som inkluderar en en 2D-karta (effektivetetskarta) som beskriver hur verkningsgraden beror på moment och rotationshastighet. Verkningsgraden hos likströmsmotorn varierar dock mycket beroende på arbetspunkt och verkningsgradskartan från databladen stämmer inte alltid med de olika applikationerna i verkligheten. Givet detta undersöker denna avhandling en fältprovsbaserad kvasistatisk modelleringsmetod för att uppskatta likströmsmotorns effektivitetskarta med endast flyttbara och begränsade testresurser. Till att börja med är en testbänk designad, tillverkad, integrerad och konfigurerad med alla nödvändiga komponenter. Testbänken består av den motor som testas, en bromsmotor för att ge belastningsmoment, en servoförstärkare för vridmomentstyrning och mätning, samt en dator för datainsamling och strömförsörjning. Sedan utformas en fristående testplan som gör att så många olika testpunkter som möjligt kan täckas, baserat på bromsmotorn effektgräns. Därefter utförs experimenten successivt på testbänken där ingående elektrisk effekt och utgående mekanisk effekt mäts i jämviktsläget. Flera olika metoder undersöks för att analysera den insamlade testdatan. Kvadratiskt medelvärde används för att minska variansen i testdatan. Ogiltiga outliers identifieras och filtreras ut baserat på hur mycket de avviker från medelvärdet. De godkända testpunkterna används för att bygga upp 2D-effektivitetskartan genom en fjärde gradens polynom regression. Därefter används tre olika metoder, linjära, kvadratiska och kubiska för att skapa kurvanpassningar genom polynomregression för att beskriva sambandet mellan ingångseffekt och utgångseffekt vid olika hastigheter. Resultaten visar att den kvadratiska metoden är det bästa alternativet eftersom det ger en mindre medelkvadratavvikelse och en hanterbar beräkningskomplexitet. Avslutningsvis kan den kvasistatiska dynamiska modellen för en likströmsmotor, som inkluderar en 2D-effektivitetskarta med det hastighetsbaserade polynomuttrycket för ingångseffekt, skapas av en ny metod som förliter sig på mindre och enklare materiel än traditionella metoder. Denna metod kringår en stor del av den omständiga modulering som precis varvtalsstyrning kräver vilken även är väldigt beroende på högprecisionssensorer. Den formulerade 2D-effektivitetskartan kommer ge betydande stöd till framtida utveckling av modelbaserade energihanteringsstrategier 2 (EMS). Polynomuttrycket ger ett mer effektivt tillvägagångssätt för att uppskatta omedelbar energieffektivitet för en inbäddad systemapplikation.

In dieser Arbeit verwende ich den Formalismus der endoreversiblen Thermodynamik um ein hydraulisches Rekuperationssystem für Nutzfahrzeuge zu modellieren und zu untersuchen. Dafür führe ich verlustbehaftete Übergänge extensiver Größen zwischen Teilsystemen eines Systems ein. Diese können einerseits der Modellierung von Leckagen und Reibungsverlusten, welche als Partikel- oder Drehmomentverluste dargestellt würden, dienen. Andererseits ermöglichen sie die Modellierung einer endoreversiblen Maschine, welche – durch Definition eines solchen verlustbehafteten, internen Überganges – ein gegebenes Wirkungsgradkennfeld und daraus resultierende Entropieproduktion inne hat. Diese wird infolge zur Modellierung der Hydraulikeinheit des Rekuperationssystems verwendet. Desweiteren basiert die Beschreibung des Rekuperationssystems auf der Modellierung der Hydraulikflüssigkeit als Van-der-Waals-Fluid, sodass Druckverluste im endoreversiblen Sinne konsistent berücksichtigt werden können. Von gegebenen Materialparamtern werden die dafür notwendigen Van-der-Waals-Parameter hergeleitet. Weitere Aspekte sind Wärmeverluste an die Umgebung sowie Wärmeübergänge zwischen Teilsystemen. Auf Grundlage realer Fahrdaten der Nutzfahrzeuge werden verschiedene dynamische und thermodynamische Effekte im Rekuperationssystem analysiert. Ihr Einfluss auf die resultierenden energetischen Einsparungen beim Abbremsen und Beschleunigen wird durch Variation zugehöriger Parameter aufgezeigt. Zuletzt wird mit einem vereinfachten Modell ohne Druck- und Wärmeverluste, aber unter Einbeziehung des Verbrennungsmotors des Fahrzeuges, eine Optimierung der Steuerung des hydraulischen Rekuperationssystems mit Hinblick auf minimalen Kraftstoffverbrauch durchgeführt. Hier zeigt sich eine erhebliche Verbesserung durch die Leistungsaufteilung zwischen Verbrennungsmotor und Rekuperationssystem nach deren Betriebsbereichen mit maximalem Wirkungsgrad. / In this work I use the formalism of endoreversible thermodynamics to model and investigate a hydraulic recuperation system for commercial vehicles. For that, I introduce lossy transfers of extensive quantities between subsystems of an endoreversible system. On the one hand, these allow modeling of leakages and friction losses, which can be represented as particle or torque losses. On the other hand, they can be used as internal extensity transfers in endoreversible engines which, as a result, have a given efficiency or efficiency map and among other things give an expression for their entropy production. Such an engine is used to model the hydraulic unit of the recuperation system. Furthermore, the description of the recuperation system is based on the modeling of the hydraulic fluid as a van der Waals fluid, so that pressure losses can be taken into account in a consistent endoreversible fashion. From given material parameters the necessary van der Waals parameters are derived. Other aspects of the modeling include heat losses to the environment and heat transfers between subsystems. On the basis of real driving data, various dynamic and thermodynamic effects within the recuperation system are observed and their influence as well as the influence of selected parameters on the resulting energy savings for both acceleration and deceleration are shown. Finally, using a simplified model neglecting pressure and heat losses, but including the internal combustion engine of the vehicle, an optimization of the control strategy for the hydraulic recuperation system with regard to minimum fuel consumption is performed. Here, a significant improvement due to a power distribution between combustion engine and recuperation system according to their high efficiency operating ranges can be achieved.

This research introduces a high-performance electric taxiing system (ETS) as a modern solution to improve the on-ground operations of today’s aircraft, which are conventionally powered through the main engines. The presented ETS is propelled by electric motors, integrated into the main landing gear of a state-of-the-art midsize commercial aircraft, and powered by an additional not quantified electrical energy storage system. The proposed system can therefore operate autonomously from any aircraft-internal power source, i.e. Auxiliary Power Unit or equivalent. The main objective of this work is to assess the energy consumption of the introduced ETS while considering energy recuperation due to regenerative braking. The ETS powertrain is sized to match modern conventional taxi performances that were seen in 36 self-recorded takeoff- and landing taxi driving profiles. A custom ETS simulation model was developed and simulated across all available driving profiles to confirm the desired powertrain performance and to predict the system’s energy consumption. For the purpose of enhancing the validity of these energy consumption predictions, a suitable motor controller is then designed by the use of MATLAB Simulink. An easy-to-implement switch loss model was created to predict the ETS motor controller efficiency map. Finally, the former energy consumption predictions were revised for the implementation of the motor controller and an estimated traction motor efficiency map. The results exhibit that the revised ETS simulation model was capable of refining the energy consumption. It was found that the ETS will consume up to 9.89 kWh on average if the full potential of the traction motors energy recuperation capabilities are being used. The simulation outcomes further demonstrate that regenerative braking offers great potential in ETS applications since more than 14 % of required traction energy could be regenerated to yield the above mentioned average energy consumption. / Thesis / Master of Applied Science (MASc)