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<p>The world transportation sector has been relying on the oil industry for more than a hundred years, accounting for the largest oil consumption and one third of the greenhouse gas emissions. However, with the boosting demand, escalating national energy security concerns and emerging environmental issues, reducing and displacing petroleum fuel in transportation sector has become an urging global target. As a result, hybrid electric vehicles evolve as one solution to displace petroleum fuel by utilizing vehicle onboard electrical systems, achieving higher fuel economy and less emissions by vehicle electrification and hybridization.</p> <p>However, since hybrid electric vehicles add additional electrical components and systems to realize better fuel economy, the system complexity increases and thus the cost increases. Hence, it is an objective of this thesis research to focus on the integrations and optimizations, aiming to simplify and optimize the hybrid power-trains in both system level and component level.</p> <p>This thesis contributes to a novel integrated electro-mechanical hybrid transmission that is potentially more compact and more operational flexible with fewer components compared to the GM Allison Two-Mode hybrid transmission. Comprehensive commercialized power-train transmissions are reviewed and analyzed to serve as background information for comparison. It also contributes to a family of double-rotor switched reluctance machines that are more integrated and suitable for hybrid electric vehicle applications. A prototype double-rotor switched reluctance machine has been built and tested for concept proving. Detailed machine design process is reported with the emphasis on design novelties. Finite element analysis and optimization techniques are applied and the accuracy is confirmed by the experiments. In addition, methods of machine loss analysis, thermal analysis and drive analysis are established; manufacturing and testing procedures are documented in detail that can be used for future machine designs guidance.</p> / Doctor of Philosophy (PhD)

Closer attention has been given to the acoustic noise performance of electric motors as electrified powertrains penetrate into the transportation system. Particularly, switched reluctance machines (SRMs) introduce a new challenge to the acoustic noise aspects given that the radial force harmonics can excite the natural frequencies of the main circumferential modes. A practical understanding of the radial force density decomposition is crucial in identifying the primary source of acoustic noise at different operating points, and it is one of the contributions of this thesis. An analytical expression is introduced to identify the temporal harmonic orders that excite different spatial mode shapes. The mode excitation is investigated along with the sound pressure level (SPL) produced by the primary vibrating mode shapes. Acoustic noise characteristics for each mode and the corresponding natural frequency at different speeds have been analyzed by using a waterfall plot. The acoustic noise generation by conventionally controlled SRMs prevents its use on applications where acoustic comfort is required. Acoustic noise is radiated by the stator frame when a vibration mode is excited by the respective spatial order at a forcing frequency that is close to the stator's modal natural frequency. The excitation surface wave is the radial force density waveform as a function of time and spatial position. From the harmonic content analysis, a phase radial force shaping method is for switched reluctance machines is proposed. A generic function for the radial force shape is identified, whose parameters are calculated by an optimization algorithm to minimize the torque ripple for a given average torque. From the phase radial force, a current reference is obtained. The proposed methodology is experimentally validated, with a four-phase 8/6 SRM, by acoustic noise measurements at different speeds and load torque conditions. / Thesis / Doctor of Philosophy (PhD)

High-accuracy electromagnetic design and analysis of electric machines is enhanced by the use of various numerical methods. These methods solve Maxwell’s equations to determine the distribution of the electric and magnetic fields throughout the considered machine structure. Due to the complicated architectures of the machines and the nonlinearity of the utilized magnetic materials, it is a very challenging task to obtain an analytical solution and, in most cases, only a numerical solution is possible. The finite element method (FEM) is one of the standard numerical methods for electromagnetic field analysis. The considered machine domain is divided into finite elements to which the field equations are applied. FEM solvers are utilized to develop optimization procedures to assist in achieving a design that meets the required specifications without violating the design constraints. The design process of electric machines involves adjusting the machine parameters. This is usually done through experience, intuition, and heuristic approaches using FEM software which gives results for various parameter changes. There is no guarantee that the achieved design is the optimal one. An alternative approach to the design of electric machines exploits robust gradient-based optimization algorithms that are guaranteed to converge to a locally-optimal model. The gradient-based approaches utilize the sensitivities of the performance characteristics with respect to the design parameters. These sensitivities are classically calculated using finite difference approximations which require repeated simulations with perturbed parameter values. The cost of evaluating these sensitivities can be significant for a slow finite element simulation or when the number of parameters is large. The adjoint variable method (AVM) offers an alternative approach for efficiently estimating response sensitivities. Using at most one extra not-iterative simulation, the sensitivities of the response to all parameters are estimated. Here, a MATLAB tool has been developed to automate the design process of switched reluctance motors (SRMs). The tool extracts the mesh data of an initial motor model from a commercial FEM software, JMAG. It then solves for magnetic vector potential throughout the considered SRM domain using FEM taking into consideration the nonlinearity of the magnetic material and the motor dynamic performance. The tool calculates various electromagnetic quantities such as electromagnetic torque, torque ripple, phase flux linkage, x and y components of flux density, air-region stored magnetic energy, phase voltage, and phase dynamic currents. The tool uses a structural mapping technique to parametrize various design parameters of SRMs. These parameters are back iron thickness, teeth height, pole arc angle, and pole taper angle of both stator and rotor. Moreover, it calculates the sensitivities of various electromagnetic quantities with respect to all these geometric design parameters in addition to the number of turn per phase using the AVM method. The tool applies interior point optimization algorithm to simultaneously optimize the motor geometry, number of turns per phase, and the drive-circuit control parameters (reference current, and turn-on and turn-off angles) to increase the motor average dynamic torque. It also applies the ON/OFF topology optimization algorithm to optimize the geometries of the stator teeth for proper distribution of the magnetic material to reduce the RMS torque ripple. A 6/14 SRM has been automatically designed using the developed MATLAB tool to achieve the same performance specifications as 6110E Evergreen surface-mounted PM brushless DC motor which is commercially available for an HVAC system. / Thesis / Doctor of Philosophy (PhD)

Switched reluctance machines (SRMs) are well known for their simple and robust structure, facilitating their increasing application in many sectors, for example vacuum cleaners, where domestic machines operate at high-speed, 50,000 RPM being typical. Conventional SRMs (CSRMs) use a decoupled concentrated phase winding so that torque is predominantly only generated due to the self-inductance, which limits utilization of the machine electrical circuits. In this thesis, the toroidal winding SRM (TSRM) is introduced, which operates based on the variation of mutual inductance between different phases. The toroidal winding introduces additional winding space, and the winding is practically easy to implement, both features that lead to a relatively higher copper filling factor. The toroidal winding also benefits the machine thermal performance, as the winding is directly exposed on the machine periphery and thus accessible to cooling. All these make TSRMs interesting and meaningful for further study. Following a comprehensive comparison of CSRM and TSRM characteristics, a general torque equation is presented that is applicable to both CSRM and TSRM. Two 12-switch converters are proposed to drive three-phase TSRMs. Moreover, sinusoidal current excitation with a commercial three-phase half-bridge converter has been suggested as an alternative converter solution for TSRMs. Accordingly, a three-phase six-stator-pole, four-rotor-pole CSRM is designed and optimized with a speed of up to 50,000 rpm in this thesis. A TSRM is resized to achieve the same envelope dimension as a benchmark CSRM. Thus, a comparative study between high-speed CSRM and TSRMs has been carried out. They have both been prototyped and tested. The findings suggest that the TSRM is superior, considering machine mass and wire temperature management. The TSRM has a better torque output at lower speeds because copper losses are dominant. However, the CSRM has more advantages at higher speeds due to lower iron losses and lower DC voltage requirements. / Thesis / Doctor of Philosophy (PhD)

A novel belt alternator starter (BAS) is proposed to replace the starter and alternator in a hybrid electric vehicle. The BAS designed utilizes an 18 rotor, 12 stator pole switched reluctance machine (SRM) configuration, with concentrated bar windings wound in parallel. Through iteration of various machine geometry parameters, the SRM can meet the torque and speeds demands over standardized drive cycles described by the US Environmental Protection Agency. / With the depletion of oil wells and changing global climate, a large emphasis is placed on the research, development and adoption of electric vehicles (EVs) to replace vehicles driven by internal combustion engines (ICEs). However the global supply chain is still not ready for such a large demand in EVs; therefore hybrid electric vehicles (HEVs) aim to ease the transition between ICEs and EVs. The research outlined in this thesis investigates the design of a 18 stator, 12 rotor pole (18/12) configuration switched reluctance machine (SRM) utilizing novel technologies for use as a belt alternator starter (BAS) motor in an HEV. Background research on current trends and technologies for electric motors and vehicles is performed before evaluating initial geometry for the motor core to be designed. Initial geometry is brought into JMAG to develop an electromagnetic model and begin the geometry optimization. The 18/12 design process highlights how changes to motor parameters from a geometry and winding standpoint will affect motor performance. After the motor core geometry yields suitable performance, a mechanical design is proposed encompassing the rotary assembly, cooling as well as solutions for mounting. / Thesis / Master of Applied Science (MASc) / Hybrid electric vehicles are becoming more prevalent as stricter restrictions are placed on fuel economy and emissions targets. Full electric vehicles on the other hand have not yet become the standard form of transportation due to the limits on range and infrastructure. Because of this, automotive manufacturers are researching and developing new methods in which they can meet these restrictions and limitations. Switched reluctance motors aim to be a solution to meet these demands while forging a new path by alleviating the demand on rare earth metals for the motor core. In this thesis, a design is proposed to fill an existing role in vehicle electrification best suited for a belted alternator starter.

A novel torque control algorithm, which adopts a two-phase excitation, is proposed to improve the performance of the Switched Reluctance Motor (SRM) drive. By exciting two adjacent phases instead of single phase, the changing rate and the magnitude of the phase currents are much reduced. Therefore the existing problems caused by the single-phase excitation such as large torque ripple during commutation, increased audible noise and fatigue of the rotor shaft are mitigated. The electromagnetic torque is efficiently distributed to each phase by the proposed Torque Distribution Function (TDF) that also compensates the effects of mutual coupling. To describe the effects of mutual coupling between phases, a set of voltage and torque equations is newly derived for the two-phase excitation. Parameters of the SRM are obtained by Finite Element Analysis (FEA) and verified by measurements. It is shown that the mutual inductance of two adjacent phases partly contributes to generate the electromagnetic torque and introduces coupling between two adjacent phases in the current or flux linkage control loop, which has been neglected in the single-phase excitation. The dynamics of the current or flux linkage loop are coupled and nonlinear due to the mutual inductance between two adjacent phases and the time varying nature of inductance. Each phase current or flux linkage needs to be controlled precisely to achieve the required performance. A feedback linearizing current controller is proposed to linearize and decouple current control loop along with a gain scheduling scheme to maintain performance of the current control loop regardless of rotor position as well as a feedback linearizing flux linkage controller. Finally, to reduce current or flux linkage ripple, a unipolar switching strategy is proposed. The unipolar switching strategy effectively doubles the switching frequency without increasing the actual switching frequency of the switches. This contributes to the mitigation of current or flux linkage ripple and hence to the reduction of the torque ripple. / Ph. D.

The use of variable speed drive (VSD) systems in the appliance industry is growing due to emerging high volume of fractional horsepower VSD applications. Almost all of the appliance VSDs have no input power factor correction (PFC) circuits. This results in harmonic pollution of the utility supply which could be avoided. The impact of the PFC circuit in the overall drive system efficiency, harmonic content, magnitude of the system input current and input power factor is particularly addressed in this dissertation along with the development of analytical methods applicable to the steady-state analysis of input power factor corrected VSD systems. Three different types of motors - the switched reluctance motor (SRM), permanent magnet brushless dc motor (PMBDC) and dc motor (DCM) are employed in this study. The C-dump converter topology, a single switch per phase converter, is adopted for the prototype SRM- and PMBDC-based VSD systems. The conventional full-bridge converter is used for DCM-based VSD systems. Four-quadrant controllers, utilizing PI speed and current control loops for the PMBDC- and DCM-based VSD system, are developed and their design results are verified with experiment and simulation. A single-quadrant controller with a PI speed feedback loop is employed for the SRM-based VSD system. The analysis of each type of VSD system includes development of loss models and establishment of proper operational modes. The magnitude of the input current harmonic spectra is measured and compared with and without a front-end PFC converter. One electromagnetic compatibility (EMC) standard, IEC 1000-3-2 which describes the limitation on harmonic current emission is modified for 120V ac system. This modified standard is utilized as the reference to evaluate the measured input current harmonics. The magnitude of input current harmonics for a VSD system are greatly reduced with PFC preregulators. While the input PFC circuit draws a near sinusoidal current from an ac source, it lowers the overall VSD system efficiency and increases cost of the overall system. / Ph. D.

Switched Reluctance Machines (SRMs) are receiving significant attention from industries in the last decade. They are extremely inexpensive, reliable and weigh less than other machines of comparable power outputs. Although the design principles of the machine are available as a concatenation of many different sources, the need for a unified, step-by-step design procedure from first principles of electromagnetics is an absolute requirement. This dissertation discusses a procedure that can be applied by engineers with a basic background in electromagnetics. Subsequent to the design of the machine, existing finite element software can do the analysis of the machine. However, this is a laborious process and the need for an analytical method is preferable to verify the design procedure before the final verification by finite elements. The analytical procedure as well as a procedure to calculate iron losses is also developed in this dissertation. A prototype machine has been developed as an example of the design process and an existing prototype is analyzed to verify the analysis procedure. The similarities between the SRM and the Permanent Magnet Brushless DC Machine (PMDBC) beg the consideration of the development of a converter that can be used to drive either machine. One such converter has been developed in this dissertation. The design of the drive for both the machines is seen to be very similar. As a consequence, a universal controller that can be used to operate both machines has been developed and implemented with a DSP. Simulations and experimental correlation for both drives have been presented. / Ph. D.