You

can change this image to be

appropriate for your topic by inserMng
an image in this space or use the
alternate Mtle slide with lines.
Note: only one image should be used
and do not overlap the Mtle text.
Enter your Business Unit or Flagship
name in the ribbon above the url.
Add collaborator logos in the white
space below the ribbon.
[delete instrucMons before use]

Review of CSIRO Research in EVs

Dr. Howard C. Lova- | Team Leader Electrical Machines (Some slides from Dr. Peter A Wa-erson)
Plug In for Power 2012, Swinburne Hawthorn Campus, Melbourne, Australia
CSIRO MATERIALS SCIENCE AND ENGINEERING

Talk Overview
AutoCRC
A SpecicaMon for a Small 4 Wheel Drive Electric Vehicle (EV)
Bicycle In-Wheel Motors
Direct-Drive, In-Wheel Motors
Solar Car In-Wheel Motors
Prototype In-Wheel EV Motors
Interior Permanent Magnet (IPM) Motors?
Transverse Flux (TF) Machine?
Switched Reluctance (SR) Motor?

Conclusions

2 | CSIRO EV Research | Dr. Howard C. Lova-

AutoCRC

EducaMon & Training

Supplier Improvement

3 | CSIRO EV Research | Dr. Howard C. Lova-

A SpecicaBon for a Small 4 Wheel Drive EV

Assume 4 wheel motors, peak total power 48 kW constant over
30 km/h - 120 km/h, 175/65 R14 tyres
High peak torque - 420 Nm up to 273 rpm
Low mass - e.g. 15 kg ! 28 Nm/kg
Small volume - e.g. OD 340 mm, length 75 mm ! 62 kNm/m3
High eciency - e.g. 90%, ideally enabling air cooling
Robust to vibraMons
Low cost minimum NdFeB use
Flux weakening e.g. 4:1, but safe in the event of a fault

4 | CSIRO EV Research | Dr. Howard C. Lova-

Bicycle In-Wheel Motors

Direct Drive

Geared

www.value-e-bikes.com.au
5 | CSIRO EV Research | Dr. Howard C. Lova-

In-Wheel Hybrid e-CVT

Planetary gear e-CVT like a Prius
A design for a bicycle:
ConMnuous rider power 200 W
ConMnuous electric power 200 W
110 270 rpm
Hub OD 190 mm
Hub axial length 75 mm

Details:
Wa-erson P.A., 11th InternaMonal
Conference on Electrical Machines
and Systems, ICEMS 2008, Wuhan

NexxtDrive patents similar

6 | CSIRO EV Research | Dr. Howard C. Lova-

Solar Car In-Wheel Motors

Aurora Solar Car

Direct Drive In-Wheel Motor

In conjuncMon with University of Technology Sydney, Newcastle University (UK),
and Aurora
7 | CSIRO EV Research | Dr. Howard C. Lova-

Marand/CSIRO - Halbach Magnet Motor

Tyre

Magnet
Blocks

Copper
Winding

Winding
Magnet
Ring

Axial ux

Axle

!
z

8 | CSIRO EV Research | Dr. Howard C. Lova-

Marand/CSIRO - Halbach Magnet Motor

Axial ux
Halbach magnet array
40 pole
ConMnuous power 5 kW
Eciency 98%
Motor OD 360 mm
Motor axial length 43 mm
Motor mass 6 kg
Used by Aurora in World Solar
Challenges, including 1st in 1999

9 | CSIRO EV Research | Dr. Howard C. Lova-

Marand/CSIRO Surface Magnet Motor

Axial ux
Magnets on surface of steel
plate
40 pole
ConMnuous power 4 kW
Eciency 97%
Motor OD 355 mm
Motor axial length 45 mm
Motor mass 10 kg
Used by 2nd, 3rd, and 4th cars in
World Solar Challenge 2009

10 | CSIRO EV Research | Dr. Howard C. Lova-

h-p://innovaMon2012.com.au/wp-content/
uploads/2012/04/Marcel-Kamp.pdf

Mitsuba In-Wheel Motor

Radial ux
Surface magnet
32 pole
ConMnuous power 5 kW
Eciency 97%
Motor OD 260 mm
Motor axial length 60 mm
Used by Tokai University, in
winning World Solar
Challenge 2009, 2011

11 | CSIRO EV Research | Dr. Howard C. Lova-

Prototype In-Wheel EV Motors

General Motors
axial ux, two-sided
surface magnets
500 Nm peak

Rahman et al., IEEE Trans. Industry

Applica3ons 42, 1185-1192, 2006;
and US Patent 7,262,536

12 | CSIRO EV Research | Dr. Howard C. Lova-

Mitsubishi MIEV
radial ux, external rotor,
embedded magnets,
600 Nm peak

Wikipedia

13 | CSIRO EV Research | Dr. Howard C. Lova-

TM4
radial ux, external rotor,
surface magnets,
670 Nm peak, 40 kg

Protean Electric Protean Drive PD18

Radial ux, surface magnets
Peak torque 800 Nm
ConMnuous torque 500 Nm,
liquid cooled
Motor OD 420 mm
Motor axial length 115 mm
Hence peak 50 kNm/m3
Total motor mass 31 kg
(including inverter?)
Tests suggest unsprung mass
not so criMcal
ProducMon 2014, Liyang, China

14 | CSIRO EV Research | Dr. Howard C. Lova-

Surface PM Motor
Pros (parMcularly Halbach,
Iron-less)
Smallest
Lightest
Most ecient

15 | CSIRO EV Research | Dr. Howard C. Lova-

Cons
Motor cost (lots of magnets)
Electronics cost (no eld
weakening)

ogging torque
t
amplitu
ude.

[W]

(5)

ND MMF
F HARMONICSS

Interior Permanent Magnet (IPM) Motors

Where
W
arre the wavefoorms in fig. 1 and fig. 2. Due
D to
stator coils
c
is geneerally
the possibility off operation inn excess of ten
t times the base
by the stator (Bs) liinked
speeed in the field
d weakening region, there will be harm
monic
) with reeluctance (Rair).
com
mponents preseent at frequenccies of severall kilohertz.
Comparison of Concentrated
VericaMon
V Experimental
V.
METHOD
DS AND
RESULLTSof Open Circuit
(4
4) Windings in
[A
A] Distributed
and
Parameters
f an IPM fi
M
achine
with (FE)
I this paper,, time-stepped
d, otransient
inite
element
an IPM Machine for Field In
Concentrated Windings
ncluding
g airgap length
h and
anal
Weakening
ApplicaMons
lysis is used to determinee the machinne parameterss and
Chong, D[1
u-a,
iao, two
Rahman
(UNSW),
and
perfformance charracteristics
8]. XThe
models
comp
pared
ant. Th
herefore
the Qonly
Chong,
Du-a,
uang Dai,
double-laye
heree areThis
84-slo
er, modeled
distributed
dd windings
and
d 18Lova-
(CSIRO)
flux open
airgap isd the
woss
thethe
modeled
measured
sectiont, will
show
the
and
measured open
Rahman and
(UNSW),
and slot,, double-layer
r, concentrated
d windings
as
s shown
in fiig. 3a
of an 800W,
reacti
ion. 18-s
Integral
00W,
14-pole,
slot, l-slot
double-layer circuit parameters
14-pole, 18-s
slot,
double-layer
Lova- (CSIRO)
and 3b
respectivel
ly. (fig. 2).
p. wavefo
forms containiing a
CW-IPM
machine
eakage harm
ow le
monic

us it is a common praactice
mpletely sinusoidal.

F
Fundamental
term
m
Fig. 4. Measured peak cogging torque pointts and FE estimated waveform of
the CW-IPM prototype machine

Fig. 4. Meas
the CW-IPM

In a comparison made with two other UNSW IPM

In a c

(a)
(b)(b)
(b)
(a)
machines
roduced
by
the(a) CW-IPM
machines
[13],
cogging
torque
pr
m
machine
FE model,
2. 800W,
14-pole,
layer CW-IPM
machine (a) FE model,
double layer CW-IPM m
Fig. Fig.
ution18-slot
of a)double
84--slot,
distributed
d windings
b) 18-slot
1
3. Flux
distribu
machines
a much
lower cogging torque
t
as a percentage of machines
(b)
Manufactured
prototype.
25
5
50

CSIRO produced
EV Research | Dfro
r. om
Howard
16 | um
ic spectru
anC. Lova-

conceentrated windingss

rated torque produced (1.54%(peakk

A. Electromotive Force

to peak)

as compared to

a
rated torqu

Interior PM Motors
Pros
Field weakening
Reduced magnet volume

17 | CSIRO EV Research | Dr. Howard C. Lova-

Cons
SMll uses considerable magnet
material
Weight
Volume

Transverse Flux (TF) Motor?

Genesis:

Current
MoMon

18 | CSIRO EV Research | Dr. Howard C. Lova-

Other TFM Patents

Bosch, WO 90/09697

19 | CSIRO EV Research | Dr. Howard C. Lova-

Rolls Royce, US 5,886,449

Daimler-Chrysler Rail
Systems, US 6,236,131

20 | CSIRO EV Research | Dr. Howard C. Lova-

Nissan/Renault,
US 2007/0164628

Servax TFM TorqueChampion

Up to 75 Nm peak

www.servax.com

21 | CSIRO EV Research | Dr. Howard C. Lova-

TFM Example

Weh H., May H., & Shalaby M.,

InternaMonal Conf. on Electrical
Machines, Cambridge USA, 13-15
Aug 1990, 1040-1045

CSIRO EV Research | Dr. Howard C. Lova-

22 | In-Wheel Motors | Peter A. Wa-erson

Parameter

Value

Wanted

continuous torque
(Nm)

400

210

peak torque (Nm)

600

420

active mass (kg)

14

15

active OD (mm)

270

340

active length (mm)

125

75

peak volume torque 84,

density (kNm/m3)
active
parts

62,
over all
volume

peak mass torque

density (Nm/kg)

43,
active
parts

28,
over all
mass

speed, power
factor, inductance

not
stated

TFM
Advantages Disadvantages
High torque density
Many poles and many parts
proporMonal to pole number
Low magnet mass, hence low
material cost
Simple, cheap winding just
one coil per phase
High inductance enabling
ux weakening for constant
power range

23 | CSIRO EV Research | Dr. Howard C. Lova-

to assemble
Less robust to vibraMon
Low rigidity may imply
higher noise
Inductance can be too high
Low eciency

Switched Reluctance (SR) Motor?

Advantages:
Low cost no magnets
Robust
High temperature
Good eld weakening

Disadvantages:
Lower torque density

A typical SR motor

24 | CSIRO EV Research | Dr. Howard C. Lova-

An SR In-Wheel Motor

CSIRO/Latrobe/Swinburne/VPAC/AutoCRC
Axial ux, two airgaps
Goal peak torque 425 Nm
Goal motor mass 25 kg
Under development

Details
Lova- H.C. et al., 37th Annual
Conf. of the IEEE Industrial
Electronics Society, 7-10 Nov.
2011, Melbourne, Australia

25 | CSIRO EV Research | Dr. Howard C. Lova-

(not nal dimensions)

Conclusions
CollaboraMon PossibiliMes (AutoCRC, ARC, Tax IncenMves,
Grants)
Direct-Drive, In-Wheel Motors
Surface PM Motor (cost++)
Interior PM Motor (cost and mass)
Transverse Flux Machine (research)
Switched Reluctance Motor (mass)

26 | CSIRO EV Research | Dr. Howard C. Lova-

Thank you
CSIRO Materials Science and Engineering
Dr. Howard C. Lova-
Team Leader Electrical Machines
t +61 2 9413 7412
m +61 419 971 263
e Howard.Lova-@csiro.au
w www.csiro.au/science/ElectricMachines.html

CSIRO MATERIALS SCIENCE AND ENGINEERING