About the Customer:
This case study highlights a project led by Embitel Technologies, showcasing the successful design and implementation of a 48V 6-phase Permanent Magnet Synchronous Motor (PMSM) system integrated into a two-wheeler or three-wheeler electric vehicle (EV). The insights presented here are crucial for any Tier 1 customer looking to enhance the efficiency and performance of electric mobility solutions.
Business Challenges:
Embitel Technologies was tasked with developing a 48V 6-phase PMSM system that could be seamlessly integrated into a hub or mid-drive motor configuration for EVs. The following challenges were identified during the project:
- Complexity in Control: Managing a 6-phase PMSM requires sophisticated control algorithms that are more complex than those for a 3-phase system. Advanced control strategies and algorithms, such as the 6-phase Space Vector Pulse Width Modulation (SVPWM) technique, were necessary to ensure optimal performance.
- Thermal Management: The increased power density and heat generation of the 6-phase PMSM necessitated effective cooling solutions to maintain system reliability and performance.
- System Integration: Integrating the 48V 6-phase PMSM into different vehicle architectures (hub or mid-drive) required careful design and calibration to achieve optimal performance without compromising vehicle efficiency or safety.
Embitel’s Solution:
Embitel Technologies employed a comprehensive approach to tackle these challenges, involving simulation, design, integration, and extensive testing. The key components and steps of the solution included:
- Simulation and Modeling: The design process began with simulations using MATLAB/Simulink to model the 48V 6-phase PMSM and its control system. This phase was crucial for optimizing control algorithms and validating system performance before physical implementation.
- Integration: The 48V 6-phase PMSM was integrated into both hub and mid-drive motor configurations. For hub motors, integration was straightforward, with the motor built into the wheel hub. For mid-drive systems, the motor was centrally mounted and connected to the drivetrain, enhancing weight distribution and efficiency.
- Operational Modes: The system was designed to support multiple operational modes, including:
- Throttle Mode: Allows direct speed control via the throttle.
- Field Weakening Mode: Extends the vehicle’s maximum speed by adjusting the magnetic field strength in the motor, enabling efficient operation beyond its base speed.
- Regenerative Braking: Efficiently recovers energy during deceleration, with the 6-phase configuration allowing more effective conversion of kinetic energy back into electrical energy.
- Cruise Control Mode: Maintains a constant speed for a comfortable riding experience on longer trips.
- Testing and Calibration: A prototype system was developed and tested in real-world conditions to validate performance across various modes. Calibration was performed to fine-tune control algorithms, ensuring smooth operation and seamless transitions between modes.
Embitel Impact:
The implementation of the 48V 6-phase PMSM system by Embitel Technologies led to significant advantages for the customer, impacting various aspects of the EV’s performance:
- Enhanced Efficiency: The 6-phase configuration improved motor efficiency by reducing harmonic distortion and enhancing torque density, leading to better battery utilization and extended vehicle range.
- Improved Safety: Operating at 48V reduced the risk of electrical hazards, making the system safer than higher voltage alternatives.
- Smooth Operation: The combination of Field Oriented Control (FOC) and the 6-phase PMSM provided smoother motor operation, reducing torque ripple and enhancing the overall riding experience.
- Advanced Control Capabilities: The system’s ability to handle varying loads more effectively, along with advanced control algorithms, resulted in more precise and adaptive motor control.
Tools and Techniques:
- Simulation and Modeling: MATLAB/Simulink
- Motor Control: 6-phase Space Vector Pulse Width Modulation (SVPWM)
- Testing and Calibration: Real-world testing and system calibration for optimal performance
By addressing the business challenges with innovative solutions, we successfully delivered a 48V 6-phase PMSM system that not only improved the efficiency and performance of electric vehicles but also set a new standard for advanced motor control in the EV industry.
