Permanent Magnet Generators with Three-phase

Half-wave Voltage Regulator in Hybrid Vehicles

Shi Liwei, Zhang Xueyi
Dept. of Automobile Engeering
Shandong University of Technology
Zibo, Shandong, China
shiliwei@sdut.edu.cn

AbstractPermanent magnet generators used in hybrid vehicles connects with the internal combustion engine (ICE) using a
primarily provide the equipments in the hybrid cars with the DC belt.
power and charge the batteries. The generator rotor is composed
of the rotor core and the multi-block Nd-Fe-B permanent magnet WHEEL
fixed on the rotor core. The polar of the adjacent Nd-Fe-B
permanent magnet is opposite, in another words, N polarity and STARTOR
BATTERY

S polarity are arrayed alternately. When this rotor rotating, ENGINE AMT
magnetic field rotates with it, the armature coil cuts magnetic-
curve, and produces electromotive force. The three-phase half-
MOTOR
wave controlled commutation voltage regulator is designed,
which can both regulate the voltage and the current and output
GENERATOR
direct current at the stable voltage. The less power consumption
and high-efficiency power generator solve the problems to realize
the voltage stability, which generated by the hybrid vehicles
permanent-magnet generator at wide speed and wide load.

Keywords- hybrid vehicles; permanent magnet; generator;

voltage regulator
I. INTRODUCTION
Growing environmental and economic concerns have
driven recent efforts to produce more fuel efficient and lower
emissions vehicles.
Hybrid Electric Vehicles(HEVs) are automobiles which
have both electric drivetrains and fuel-consuming
powerplants.HEVs provide some of the most promising
designs with the capability of meeting the future goals. It can
offer a further chance to reduce fuel consumption and
emissions. Low fuel consumptions, low emissions and high
performance are characteristics of hybrid electric
vehicles(HEV). HEVs attract more and more enthusiasm for
development from the vehicle manufactures. Hybrid driving
systems can be well applied in combat vehicles. With hybrid
driving system, high power can be acquired with a smaller
engine and less fuel consumption than with engine alone.
Better mobility and wider combat range can be achieved. With
the motor driving alone mode, a quite approach to enemy can
be acquired.
Figure.1 shows one structure of drive assembly of a hybrid
electric vehicles. There are 3 lectrical machines, generator,
startor and the main motor (M), in the figure. The starter is a
standby one. The M, which is called main motor, It connects
with the wheels through the final gear. The Generator, as a
subject of this paper, is an permanent magnet generator which
Figure 1. Series HEV Schematic
Presently, alternator with silicon rectifier is prevailing on
automobiles, the magnetic field of this set is generated by
excitation winding in rotor, so the winding consumes more
energy and is destructible, and there must be a battery to offer
its excitation current, which improve the automobiles cost.
One kind of the alternator has carbon brush and slip ring, the
brush is damageable and its lifespan is short. The other
alternating current generator is blushless, but it thickens the air
gap and its flux leakage is increased. So it is very weighty and
costly1-3. Therefore, it is quite necessary to design and
manufacture a new kind of generator named Nd-Fe-B
permanent magnet generator with three-phase half- bridge
controlled rectifier and electronic regulator.
II. DESIGN OF PRIMARY PARAMETER
A. Output power, rotate speed and regulated voltage
The generator produces direct current for starter and
electric facilities on hybrid vehicle. The designed output power
is 2kW and the rotate speed of the generator is 4000r/min;
Using 14 group battery, the output voltage of the generator is
that 14h14f0.5V196f7V.
B. Design of primary parameter of the generator

This research is sponsored by the SDNSFC(Grant No. Z07F06).

978-1-4244-2487-0/09/$25.00 2009 IEEE

 The sketch map of the Nd-Fe-B permanent magnet Lm the length of the rotor, Lm = m Dm .
generator set in hybrid vehicle is illustrated in Figure 2.
2) Calculation of the Number of Windings
According to the electromagnetism principium formula,
the number of loop circle can be represented by:
E0
N= (2)
4k B fk w0
Where
E0 --electromotive force of generator as empty load;
k w winding factor, k w =0.92;
0 Effective magnetic flux through stator winding.
pn
f =
60
 p number of pole pairs,the permanent magnet
Figure 2. Nd-Fe-B permanent-magnet generator structure generator is designed for 12 poles, p =6;
1.rear cover 2. bearing 3. rotor iron core 4. shaft 5. pole shoes 6.Nd- nrotate speed,r/min;
Fe-B permanent magnets 7. stator iron core 8. shell 9. winding
10.front cover 11 axis 12. pulley . 3) Design of the stator structure
1) Design of primary parameter of the rotor Silicon steel plates with pear-shaped groove steel the stator.
Every silicon steel plate is insulated with each other. Armature
Vm
The rotor diameter: Dm = 1.123 windings are the high-intensity enameled wires5,6. Stator
K m m is showed in Figure 2.

Where Vm the volume of Permanent Magnetic The width of the stator groove bs 0 : In conditions of
Materials, which can be calculated in the short-circuit triangle guaranteeing inlay lines and machining convenience, the small
method[4]: figure will be chose.
PN 0 C F k
2
k The width of the stator tooth bt
Vm = i 10 2 (m 3 ) (1)
3.54k B fB H k i 1
B Lef t
Where bt =
PNapparent power of generator when its power K Fe Bt 2 LS
factor equal to zero, namely cos =0, W; cos

0 magnetic leakage coefficient; where Lef The axial length of the air gap;

C F coefficient of magnetometive force; D1

t pole pitch, (m), t = ;
k a coefficient of longitudinal axial armature Zs
reaction; k B waveform factor,when magnetic field in air
gap obeys the sinusoidal functions, k B =1.11;
f frequency;
has

D2

B magnetic induction on zero load; bs2

H short circuit magnetic field strength;

hs2

bs1

hs1

ki short circuit current multiple. bs0

D1

K m Magnet filling coefficient, K m =0.60.8;

m Rotor slenderness ratio,
a) stator piece b) pear-shaped groove
L 1
m = m = (0.61.6) , Figure 3. the stator piece
Dm p
p number of pole pairs; D1 inner stator diameter, (m);
 Z s the number of stator slot; N t N s d 2
Groove full rate: Sf =
2( As Ai )
K Fe the folding pressure coefficient of the stator
piece, K Fe =0.920.95; where N t the numbers of parallel lines;

Bt 2 Saturated magnetic flux density of the silicon steel d the diameter of the lines.
plate, Bt 2 =1.5T1.8T;
d2
LS stator Core thickness.
The height of the stator yoke has

h1
h2
0
has =

h3
2 K Fe Bas LS

h5 h4
where Bas the magnetic flux density of stator
b0

h6
yoke, Bas =1.5T.
d1
Groove full rate Sf
According to the output current value and wire current Figure 4. Stator Slot Topology
density of the generator, the appropriate wire and insulating
III. PRINCIPLE OF THE THREE-PHASE HALF-WAVE
standards are selected and the trough area As will be assured CONTROLLED COMMUTATION VOLTAGE REGULATOR
initially:
The three-phase half-wave controlled commutation voltage
bs1 + bs 2 b 2 regulator consists of benchmark circuit, the sampling circuit,
As = hs 2 + s 2 trigger circuit and rectifier circuit7,8. The welded PCB is
2 8 fixed inside the aluminium die-casting shell, and then molded
bs1 the width of stator slot in narrower side, with unsaturated colophony. The regular is dustproof, moisture
proof, shake proof and shock resisting. So it adapts well to the
( D1 + 2 bs 0 tan ) Z s bt worse surroundings. The three-phase half-wave controlled
b s1 = ;
Z s tan commutation voltage regulator circuit diagram shown in figure
3.
hs1 the height of the stator groove wedge ,

+
B D F
1 C1 T1
hs1 = 1 + (bs1 bs 0 ) tan ;
R1
T2 Dw 2
2 A R3
C2 JF1 JF2 JF3

R5 C E G
Dw1 D1
bs 2 the width of stator slot in wider side, D2 Ud R
R4
( D2 2has ) Z s bt R6 D3

bs 2 = ;
Zs + R2 D4
SCR1
R7 D5
SCR2

hs 2 the height of the Trapezoidal stator groove, D6

SCR3

-
1
hs 2 = ( D2 D1 bs 2 ) hs1 has ;
2
Figure 5. the three-phase half-wave controlled rectification voltage
The area of the insulating layer of groove: stabilizer circuit

b
Ai = C i 2hs 2 + bs1 + s 2 R1,R2,R3,R4,R5,R6,R7resistance; Rload;C1,C2capacitance;
2 D1,D2,D3,D4,D5,D6diode; Dw1,Dw2stabilivolt;T1,T2triode;
SCR1,SCR2,SCR3silicon controlled rectifier; JF1,JF2,JF3three-phase
permanent alternator with the same three Armature windings;
where Ci the thickness of the insulating layer of Point A is the node of R1, R2 and R3;
groove; B is the beginning of the JF1 and C is the Empennage;
D is the beginning of the JF2 and E is the Empennage;
F is the beginning of the JF3 and G is the Empennage.
 We can change the voltage at A by adjusting the resistance energy (BH)max=224 KJ/m224~256KJ/m3. The test results of
of R1, accordingly, the target value U 0 =14V of the adjuster is this new type generator from low rotary speed to high speed
attainable. are shown in table 1.

The same three Armature windings of three-phase TABLE I.
permanent alternator are JF1, JF2 and JF3, their phase
difference are 120e. The B,D and F, the beginnings of JF1,
JF2 and JF3 , are fixed to one point in the shape of Y, which
is the anode of the regulator. The anodes of silicon controlled
rectifiers, SCR1, SCR2 and SCR3, are used as the cathodes of
the regulators.
From Table I, as the rotate speed range from 2000r/min to
When the generator is in the low speed, the output voltage 4800r/min, the output voltage stays between 189.2V and
is lower than the target value U0. The voltages of the emitter of 199.3V; the data achieves the design requirements.
the triode T1 and point A are lower than the breakdown
voltage of stabilivolt Dw1.So the triode T1 is shut. Because
that both the stabilivolt and the capacitance are provided the
anode voltage to the triode, the voltage provided by the emitter
and the base is larger than 0.7V. So T2 is on. The collector
current is through resistance R7 and D4 , D5 , D6 respectively
to supply the trigger currents for the gates of the silicon
controlled rectifier SCR1 , SCR2 and SCR3 .So the silicon
controlled rectifiers are on and output the DC.
With the rise of the rotate speed, the output voltage U d is
ascending, the voltage between the emitter of T1 and point A is
also ascending, when U d is exceed the target value U0, the
voltage between the emitter of T1 and point A is high enough
to break through diode Dw1, thus T1 is turned on. Then the
voltage between the emitter and base electrode of T2 is
0.2V~0.3V, less than 0.7V, triode T2 is cut-off and it can not
offer the silicon controls with circuit, so the silicon control
retains on until there is no positive voltage on it. With the
decline of the output voltage, the voltage between the emitter
of T1 and point A is reduced too. [1]
When the output voltage U d become lower than the target
[2]
value U 0 , the triode T1 is off and T2 is on. At this time, the
silicon-controlled rectifier is on too and the three-phase half- [3]
wave controlled rectifier circuit is back to work. When U d is
[4]
increased again and exceeds U 0 , DW 1 is breakdown again. So
[5]
T1 is on and T2 is off again. Such repeated, T1 and T2 are on
or off by turn. Shifting phase, cutting wave and rectifier assure [6]
the generator output the steady current, and they provide the
equipments in the hybrid cars with the DC power supply and
charge the batteries. [7]
[8]
IV. PERFORMANCE TEST
Nd-Fe-B permanent-magnet generator used in hybrid
[9]
vehicles has a rotor of 16 star poles with pole shoes, the rated
voltage is 196V and the nominal power is 20kW, nominal
speed is 4000r/min. The magnetic material is NTP30H9,
its remnant magnetism density Br=1.12T, coercive force
Hc=790KA/m, and the maximum product of the magnetic
THE TEST RESULTS OF THE GENERATOR OUTPUT VOLTAGE V
model output voltage output voltage output voltage
No. in 2000r/min in 4000r/min in 4800r/min
1 189.2 195.2 195.6
2 191.4 198.8 199.3
3 190.5 196.6 197.5
V. CONCLUSIONS
The Conclusion can be drawn as follows:
As the rotate speed varies from 2000r/min to
4800r/min, the output voltage stays between 12.16V
and 14.33V, and performance of stabilizing the voltage
is well.
The three-phase half-wave controlled commutation
voltage regulator owns both regulate the voltage and
the current and output direct current at the stable
voltage. The less power consumption and high-
efficiency power generator solve the problems to
realize the voltage stability, which generated by the
hybrid vehicles permanent-magnet generator at wide
speed and wide load.
The Nd-Fe-B permanent magnet rotor has no
excitation windings, which can save energy on the
windings. Without the slip ring and carbon brush, so
this set has a reliable performance.
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