Analysis and Design Considerations of an Electric Vehicle Powertrain regarding Energy Efficiency and Magnetic Field Exposure

En esta tesis se analiza el sistema de tracción de un vehículo eléctrico de batería desde el punto de vista de la eficiencia energética y de la exposición a campos magnéticos por parte de los pasajeros (radiación electromagnética). Este estudio incluye tanto el sistema de almacenamiento de energía como la máquina eléctrica, junto con la electrónica de potencia y los sistemas de control asociados a ambos. Los análisis y los resultados presentados en este texto están basados en modelos matemáticos, simulaciones por ordenador y ensayos experimentales a escala de laboratorio. La investigación llevada a cabo durante esta tesis tuvo siempre un marcado enfoque industrial, a pesar de estar desarrollada en un entorno de considerable carácter universitario. Las líneas de investigación acometidas tuvieron como destinatario final al diseñador y al fabricante del vehículo, a pesar de lo cual algunos de los resultados obtenidos son preliminares y/o excesivamente académicos para resultar de interés industrial. En el ámbito de la eficiencia energética, esta tesis estudia sistemas híbridos de almacenamiento de energía basados en una combinación de baterías de litio y supercondensadores. Este tipo de sistemas son analizados desde el punto de vista de la eficiencia mediante modelos matemáticos y simulaciones, cuantificando el impacto de ésta en otros parámetros tales como el envejecimiento de las baterías. Respecto a la máquina eléctrica, el estudio se ha centrado en máquinas síncronas de imanes permanentes. El análisis de la eficiencia considera tanto el diseño de la máquina como la estrategia de control, dejando parcialmente de lado el inversor y la técnica de modulación (que son incluidos en el estudio como fuentes adicionales de pérdidas, pero no como potenciales fuentes de optimización de la eficiencia). En este sentido, tanto la topología del inversor (trifásico, basado en IGBTs) como la técnica de modulación (control de corriente en banda de histéresis) se establecen desde el principio. El segundo aspecto estudiado en esta tesis es la exposición a campos magnéticos por parte de los pasajeros. Este tema se enfoca desde un punto de vista predictivo, y no desde un punto de vista de diagnóstico, puesto que se ha desarrollado una metodología para estimar el campo magnético generado por los dispositivos de potencia de un vehículo eléctrico. Esta metodología ha sido validada mediante ensayos de laboratorio. Otros aspectos importantes de esta contribución, además de la metodología en sí misma, son las consecuencias que se derivan de ella (por ejemplo, recomendaciones de diseño) y la comprensión del problema proporcionada por esta. Las principales contribuciones de esta tesis se listan a continuación: una recopilación de modelos de pérdidas correspondientes a la mayoría de dispositivos de potencia presentes en un vehículo eléctrico de batería, una metodología para analizar el funcionamiento de un sistema híbrido de almacenamiento de energía para aplicaciones de tracción, una explicación de cómo ponderar energéticamente los puntos de operación par-velocidad de un vehículo eléctrico (de utilidad para evaluar el rendimiento de una máquina eléctrica, por ejemplo), una propuesta de incluir un convertidor DC-DC en el sistema de tracción para minimizar las pérdidas globales del accionamiento (a pesar de las nuevas pérdidas introducidas por el propio DC-DC), una breve comparación entre dos tipos distintos de algoritmos de minimización de pérdidas para máquinas síncronas de imanes permanentes, una metodología predictiva para estimar la exposición a campos magnéticos por parte de los pasajeros de un vehículo eléctrico (debida a los equipos de potencia), y finalmente algunas conclusiones y recomendaciones de diseño respecto a dicha exposición a campos magnéticos. ABSTRACT This dissertation analyzes the powertrain of a battery electric vehicle, focusing on energy efficiency and passenger exposure to electromagnetic fields (electromagnetic radiation). This study comprises the energy storage system as well as the electric machine, along with their associated power electronics and control systems. The analysis and conclusions presented in this dissertation are based on mathematical models, computer simulations and laboratory scale tests. The research performed during this thesis was intended to be of industrial nature, despite being developed in a university. In this sense, the work described in this document was carried out thinking of both the designer and the manufacturer of the vehicle. However, some of the results obtained lack industrial readiness, and therefore they remain utterly academic. Regarding energy efficiency, hybrid energy storage systems consisting in lithium batteries, supercapacitors and up to two DC-DC power converters are considered. These kind of systems are analyzed by means of mathematical models and simulations from the energy efficiency point of view, quantifying its impact on other relevant aspects such as battery aging. Concerning the electric machine, permanent magnet synchronous machines are studied in this work. The energy efficiency analysis comprises the machine design and the control strategy, while the inverter and its modulation technique are taken into account but only as sources of further power losses, and not as potential sources for further efficiency optimization. In this sense, both the inverter topology (3-phase IGBT-based inverter) and the switching technique (hysteresis current control) are fixed from the beginning. The second aspect studied in this work is passenger exposure to magnetic fields. This topic is approached from the prediction point of view, rather than from the diagnosis point of view. In other words, a methodology to estimate the magnetic field generated by the power devices of an electric vehicle is proposed and analyzed in this dissertation. This methodology has been validated by laboratory tests. The most important aspects of this contribution, apart from the methodology itself, are the consequences (for instance, design guidelines) and the understanding of the magnetic radiation issue provided by it. The main contributions of this dissertation are listed next: a compilation of loss models for most of the power devices found in a battery electric vehicle powertrain, a simulation-based methodology to analyze hybrid energy storage performance in traction applications, an explanation of how to assign energy-based weights to different operating points in traction drives (useful when assessing electrical machine performance, for instance), a proposal to include one DC-DC converter in electric powertrains to minimize overall power losses in the system (despite the new losses added by the DC-DC), a brief comparison between two kinds of loss-minimization algorithms for permanent magnet synchronous machines in terms of adaptability and energy efficiency, a predictive methodology to estimate passenger magnetic field exposure due to power devices in an electric vehicle, and finally some useful conclusions and design guidelines concerning magnetic field exposure.

Development and improvement of protection-system algorithms for ground-fault detection and location in synchronous machines

Uno de los defectos más frecuentes en los generadores síncronos son los defectos a tierra tanto en el devanado estatórico, como de excitación. Se produce un defecto cuando el aislamiento eléctrico entre las partes activas de cualquiera de estos devanados y tierra se reduce considerablemente o desaparece. La detección de los defectos a tierra en ambos devanados es un tema ampliamente estudiado a nivel industrial. Tras la detección y confirmación de la existencia del defecto, dicha falta debe ser localizada a lo largo del devanado para su reparación, para lo que habitualmente el rotor debe ser extraído del estator. Esta operación resulta especialmente compleja y cara. Además, el hecho de limitar la corriente de defecto en ambos devanados provoca que el defecto no sea localizable visualmente, pues apenas existe daño en el generador. Por ello, se deben aplicar técnicas muy laboriosas para localizar exactamente el defecto y poder así reparar el devanado. De cara a reducir el tiempo de reparación, y con ello el tiempo en que el generador esta fuera de servicio, cualquier información por parte del relé de protección acerca de la localización del defecto resultaría de gran utilidad. El principal objetivo de esta tesis doctoral ha sido el desarrollo de nuevos algoritmos que permitan la estimación de la localización de los defectos a tierra tanto en el devanado rotórico como estatórico de máquinas síncronas. Respecto al devanado de excitación, se ha presentado un nuevo método de localización de defectos a tierra para generadores con excitación estática. Este método permite incluso distinguir si el defecto se ha producido en el devanado de excitación, o en cualquiera de los componentes del sistema de excitación, esto es, transformador de excitación, conductores de alimentación del rectificador controlado, etc. En caso de defecto a tierra en del devanado rotórico, este método proporciona una estimación de su localización. Sin embargo, para poder obtener la localización del defecto, se precisa conocer el valor de resistencia de defecto. Por ello, en este trabajo se presenta además un nuevo método para la estimación de este parámetro de forma precisa. Finalmente, se presenta un nuevo método de detección de defectos a tierra, basado en el criterio direccional, que complementa el método de localización, permitiendo tener en cuenta la influencia de las capacidades a tierra del sistema. Estas capacidades resultan determinantes a la hora de localizar el defecto de forma adecuada. En relación con el devanado estatórico, en esta tesis doctoral se presenta un nuevo algoritmo de localización de defectos a tierra para generadores que dispongan de la protección de faltas a tierra basada en la inyección de baja frecuencia. Se ha propuesto un método general, que tiene en cuenta todos los parámetros del sistema, así como una versión simplificada del método para generadores con capacidades a tierra muy reducida, que podría resultar de fácil implementación en relés de protección comercial. Los algoritmos y métodos presentados se han validado mediante ensayos experimentales en un generador de laboratorio de 5 kVA, así como en un generador comercial de 106 MVA con resultados satisfactorios y prometedores. ABSTRACT One of the most common faults in synchronous generators is the ground fault in both the stator winding and the excitation winding. In case of fault, the insulation level between the active part of any of these windings and ground lowers considerably, or even disappears. The detection of ground faults in both windings is a very researched topic. The fault current is typically limited intentionally to a reduced level. This allows to detect easily the ground faults, and therefore to avoid damage in the generator. After the detection and confirmation of the existence of a ground fault, it should be located along the winding in order to repair of the machine. Then, the rotor has to be extracted, which is a very complex and expensive operation. Moreover, the fact of limiting the fault current makes that the insulation failure is not visually detectable, because there is no visible damage in the generator. Therefore, some laborious techniques have to apply to locate accurately the fault. In order to reduce the repair time, and therefore the time that the generator is out of service, any information about the approximate location of the fault would be very useful. The main objective of this doctoral thesis has been the development of new algorithms and methods to estimate the location of ground faults in the stator and in the rotor winding of synchronous generators. Regarding the excitation winding, a new location method of ground faults in excitation winding of synchronous machines with static excitation has been presented. This method allows even to detect if the fault is at the excitation winding, or in any other component of the excitation system: controlled rectifier, excitation transformer, etc. In case of ground fault in the rotor winding, this method provides an estimation of the fault location. However, in order to calculate the location, the value of fault resistance is necessary. Therefore, a new fault-resistance estimation algorithm is presented in this text. Finally, a new fault detection algorithm based on directional criterion is described to complement the fault location method. This algorithm takes into account the influence of the capacitance-to-ground of the system, which has a remarkable impact in the accuracy of the fault location. Regarding the stator winding, a new fault-location algorithm has been presented for stator winding of synchronous generators. This algorithm is applicable to generators with ground-fault protection based in low-frequency injection. A general algorithm, which takes every parameter of the system into account, has been presented. Moreover, a simplified version of the algorithm has been proposed for generators with especially low value of capacitance to ground. This simplified algorithm might be easily implementable in protective relays. The proposed methods and algorithms have been tested in a 5 kVA laboratory generator, as well as in a 106 MVA synchronous generator with satisfactory and promising results.

Improved high-speed de-excitation system for brushless synchronous machines tested on a 20 MVA hydro-generator

Synchronous machines with brushless excitation have the disadvantage that the field winding is not accessible for the de-excitation of the machine. This means that, despite the proper operation of the protection system, the slow de-excitation time constant may produce severe damage in the event of an internal short circuit. A high-speed de-excitation system for these machines was developed, and this study presents the continuation of a previously published study. This study presents the design by computer simulation and the results of the first commissioning of this de-excitation system in a commercial 20 MVA hydro-generator. The de-excitation is achieved by inserting resistance in the field circuit, obtaining a dynamic response similar to that achieved in machines with static excitation. In this case, a non-linear discharge resistor was used, making the dynamic response even better.

Field-winding fault detection in synchronous machines with static excitation through frequency response analysis.

Frequency Response Analysis is a well-known technique for the diagnosis of power transformers. Currently, this technique is under research for its application in rotary electrical machines. This paper presents significant results on the application of Frequency Response Analysis to fault detection in field winding of synchronous machines with static excitation. First, the influence of the rotor position on the frequency response is evaluated. Secondly, some relevant test results are shown regarding ground fault and inter-turn fault detection in field windings at standstill condition. The influence of the fault resistance value is also taken into account. This paper also studies the applicability of Frequency Response Analysis in fault detection in field windings while rotating. This represents an important feature because some defects only appear with the machine rated speed. Several laboratory test results show the applicability of this fault detection technique in field windings at full speed with no excitation current.

New Fault-Resistance Estimation Algorithm for Rotor-Winding Ground-Fault Online Location in Synchronous Machines With Static Excitation

New Fault-Resistance Estimation Algorithm for Rotor-Winding Ground-Fault Online Location in Synchronous Machines With Static Excitation

A sensorless virtual slave control scheme for kinematically dissimilar master-slave teleoperation

The use of telerobotic systems is essential for remote handling (RH) operations in radioactive areas of scientific facilities that generate high doses of radiation. Recent developments in remote handling technology has seen a great deal of effort being directed towards the design of modular remote handling control rooms equipped with a standard master arm which will be used to separately control a range of different slave devices. This application thus requires a kinematically dissimilar master-slave control scheme. In order to avoid drag and other effects such as friction or other non-linear and unmodelled slave arm effects of the common position-position architecture in nonbackdrivable slaves, this research has implemented a force-position control scheme. End-effector force is derived from motor torque values which, to avoid the use of radiation intolerant and costly sensing devices, are inferred from motor current measurement. This has been demonstrated on a 1-DOF test-rig with a permanent magnet synchronous motor teleoperated by a Sensable Phantom Omni® haptic master. This has been shown to allow accurate control while realistically conveying dynamic force information back to the operator.

Plataforma de simulación en Matlab-Simulink de un accionamiento regulado para emular aerogeneradores

En este proyecto se desarrolla un modelo de simulación de un accionamiento controlado que emula el comportamiento de una turbina eólica, el cual se ha llevado a cabo a través del programa para simulación Matlab/Simulink. Su desarrollo se ha estructurado de la siguiente forma: Tras una breve introducción a la energía eólica y a las máquinas eléctricas objeto de estudio en este proyecto, se procede a la caracterización y representación de dichas maquinas dentro de la plataforma de simulación virtual Simulink. Posteriormente se explican posibles estrategias de control de la máquina de inducción, las cuales son aplicadas para la realización de un control de velocidad. Asimismo, se realiza un control vectorial de par de la máquina de inducción de modo que permita un seguimiento efectivo del par de referencia demandado por el usuario, ante distintas condiciones. Finalmente, se añade el modelo de turbina eólica de manera que, definiendo los valores de velocidad de viento, ángulo de paso y velocidad del eje, permite evaluar el par mecánico desarrollado por la turbina. Este modelo se valida comprobando su funcionamiento para diferentes puntos de operación ante diversas condiciones del par de carga. Las condiciones de carga se establecen acoplando al modelo de la turbina, un generador síncrono de imanes permanentes conectado a una carga resistiva. ! II! ABSTRACT In this project, the simulation model of a controlled drive that emulates the behaviour of a wind turbine is developed. It has been carried out through the platform for multidomian simulation called Matlab/Simulink. Its development has been structured as follows: After a brief introduction to the wind energy and the electrical machines studied in this project, these machines are characterized and represented into the virtual simulation platform, Simulink. Subsequently, the possible control strategies for the induction machine are explained and applied in order to carry out a speed control. Additionally, a torque vector control of the induction machine is performed, so as to enable an effective monitoring of the reference torque requested by the user, under different conditions. Finally, the wind turbine model is implemented so as to assess the turbine mechanical torque, after defining the wind speed, the pitch angle and the shaft speed values. This model is validated by testing its functionality for different operating points under various load torques. The load conditions are set up by attaching a permanent magnets synchronous machine, with a resistive load, to the turbine model.

Development of a grid connected micro wind generator. A practical activity for the course on electric generation with wind energy

This paper describes a practical activity, part of the renewable energy course where the students have to build their own complete wind generation system, including blades, PM-generator, power electronics and control. After connecting the system to the electric grid the system has been tested during real wind scenarios. The paper will describe the electric part of the work surface-mounted permanent magnet machine design criteria as well as the power electronics part for the power control and the grid connection. A Kalman filter is used for the voltage phase estimation and current commands obtained in order to control active and reactive power. The connection to the grid has been done and active and reactive power has been measured in the system.

Nuevo "sistema de desexcitación rápida para máquinas síncronas con excitación brushless" (HSBDS) en un generador de 15 MVA

Las máquinas síncronas con excitación indirecta sin escobillas (tipo brushless) presentan el problema de que no es posible acceder al devanado de campo para desexcitar la máquina. Esto provoca que, a pesar de la operación correcta del sistema de protecciones, la lenta constante de tiempo de desexcitación pueda producir graves daños en el caso de un cortocircuito interno. En este documento se presentan las pruebas de un novedoso sistema de desexcitación rápida para este tipo de máquinas en un generador de 15 MVA. La desexcitación se consigue introduciendo una resistencia en el circuito de campo, obteniendo una respuesta dinámica similar a la que se consigue en las máquinas con excitación estática. La principal aportación de este estudio es la adaptación del método a máquinas de tamaño industrial y las diversas pruebas realizadas en un generador de 15 MVA validando el correcto funcionamiento de este sistema. Synchronous machines with brushless excitation have the disadvantage that the field winding is no accessible for the de-excitation. This means that, despite the proper operation of the protection system, the slow de-excitation time constant may produce severe damage in the event of an internal short circuit. In this paper the test in a 15 MVA generator of a novel high-speed de-excitation system for brushless synchronous machines is presented. The de-excitation is achieved by inserting a resistance in the field circuit, obtaining a dynamic response similar to that archived in machines with static excitation. The main novelty of this paper is the use of this method in a industrial size machine. This system has been validated through experimental tests on a 15 MVA generator, with satisfactory results.

New On-Line Excitation-System Ground Fault Location Method Tested in a 106 MVA Synchronous Generator

In this paper, a novel excitation-system ground-fault location method is described and tested in a 106 MVA synchronous machine. In this unit, numerous rotor ground-fault trips took place always about an hour after the synchronization to the network. However, when the field winding insulation was checked after the trips, there was no failure. The data indicated that the faults in the rotor were caused by centrifugal forces and temperature. Unexpectedly, by applying this new method, the failure was located in a cable between the excitation transformer and the automatic voltage regulator. In addition, several intentional ground faults were performed along the field winding with different fault resistance values, in order to test the accuracy of this method to locate defects in rotor windings of large generators. Therefore, this new on-line rotor ground-fault detection algorithm is tested in high-power synchronous generators with satisfactory results.