Electric vehicle – future development , technology and energy ...cd1.edb.hkedcity.net/.../NSS/Energy02_Dec08/ElectricVehicle_PartII.pdf · • When solar energy is not sufficient,

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Power Electronics Research Centre

..Power the futurehttp://perc.polyu.edu.hk

The Hong Kong Polytechnic University

Electric vehicle future development , technology and

energy efficiency

Prof. Eric Cheng




Largest Power Electronics Group in the region

30 Research Personnel 14 Academic staff $10 M consultancy project in 2007 $20M R&D funding in 2007 Produces 45 Journal papers and

60 Conference papers in 2007 Supporting research for

automotive: DC power conversion, Battery technology, Electrical system, Lighting, Motor technology,, Actuation, Green energy

The team is familiar in the region for EV design

Equipment and research for electric vehicle

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We have good facilities and large research laboratories. This includes the motor drive lab, EMI lab, power conversion lab.




We have facilities latest equipment in EMI and EMC. We have a new laboratory in EMC measurement with a number of GHz high frequency equipment.

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We have good facilities and large research laboratories. This includes the motor drive lab, EMI lab, power conversion lab.




Laboratories

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EV R&D :


New Magnetic components Power supplies Adaptors/Fast battery charger Low cost motor drives & actuation system Planar motion system Battery management system

Dept. of EE


EV Platform technology

High power battery charger

Battery diagnosis system

High power traction (propulsion) drive

Regenerative braking Fully soft-switching for

all DC distribution DC conversion

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Dept. of EE


Cutting edge technology in EV

Plastic magnetic for power conversion in car

Fast battery charger Linear motion control for

car actuation SR motor design DC power line wire harness

Fully electronic ABS and

steering Green power- fuel cell



New Development and project


AFS Adaptive lighting system Apply to front lighting with

HID lamp control and actuation system

2 industrial partners Technology: high dynamic

motion control, dimming control, advanced optics

In-wheel motor design Use SR motors for motor

deign Fully 4-wheel drive 2 industrial partners ITF funding of HK$4.1 M

Dimming control

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Dept. of EE


Electric Vehicle Platform

Develop an EV platform research for Hong Kong

Collaborate with Many industries

Design for Battery Charger Motor, Drive All electronics

Dept. of EE


Electric Vehicle (Opening in Convention Center)

Capability to develop EV from 2kW to 20kW

Real prototype EV has designed:

MyCarTM 2kW, 3kW, 6kW

- SmartTM 20kW Golf cart 3kW, 4kW

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Dept. of EE


Electric Vehicle (security car) Technology includes: Battery management Battery charger Electrical system design Vehicle lighting Motor design Motor drive System control Vehicle safety Site test at Diamond Coast

International Kart circuit

Dept. of EE


EV show case

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Dept. of EE


Golf Cart developmentDesign for motor drive

Battery system

All electric control

Dept. of EE


EV show caseMyCar

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Dept. of EE


EV show caseMercedes Benz -Smart

Dept. of EE


EV show case

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Dept. of EE


EV show case 2-wheels

Dept. of EE


EV Battery charger technology

High power battery charger using soft-switching

Power level from 800W to 5kW

Slow and quick charging

High power density

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Dept. of EE


EV Battery charger technology

Battery charging characteristics

Three stage of charging: Constant current Constant voltage Pulse charging

Constant current control voltage

Dept. of EE


High power and fast charger Provide high current

for charging Shorten the

charging time Provide fast and

slow charging

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Dept. of EE


Disadvantage of fast charging The battery has a pre-

defined charging current

For Lead-acid, the charging is 0.1C

It takes 8-10 hours for charging

Fats charging reduces the life time, say 300 cycles to 50 cycles

Low power

High power

Dept. of EE


Disadvantage of fast charging Conditional monitoring is necessary Battery are formed by a matrix

connection Series and parallel Each cell may have different

temperature and voltage Over temperature, over voltage and

current will damage and lead to explore

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Dept. of EE


Li-ion battery Li-ion: Lithium Iron phosphate LiFeP04

Saver under over charge condition Other Li-ion: Lithium Cobalt Oxide LiMn2O4,

Lithium Manganese Oxide LiCoO2 Cannot be used for over charging or short-circuit

Dept. of EE


Battery management systems

Conditional monitoring batteries

Balance of battery State of charge State of health

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Dept. of EE


Electronic lighting

Dept. of EE


Lighting technology in EV HID (High intensity

Discharge) LED

BallastBallast Tail lampTail lamp

Headlamp prototypeHeadlamp prototype Lid designLid design HeadlampHeadlamp

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Dept. of EE


EV Platform technology

2 4 6 8 10

2

4

6

8

10

X Axis Title

Y A

xis

Title

0.5000

1.000

1.500

2.000

2.500

3.000

3.500

4.000

4.500

Free forming techniques Car lighting


.Power the futurehttp://perc.polyu.edu.hk

HID lighting circuitfeaturesHigh voltage33kV striking3-stages

Hong Kong Polytechnic University

C

C

0

1

2

C6

D2 D3

S21

2

S4

1

2

C3

D1S1

1

2 C0

S3

1

2

C2

V1

R3

Flybackconverter

.

.

LampSec

Igniter

.

sparkgap

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LED lighting circuitfeaturesLow voltageMatrix connectionUse integrated sphere for light measurement


Dept. of EE


Car lighting using LEDDesign technology in LED head and tail lighting

Lighting control with superbrightLED and tri-colour control

Replace all existing conventional tail and head light

Refractors

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HID Electronic ballast

Features:High power factorLow cost

ApplicationsHigh intensity lamp ballastMulti tube operation





DC voltage management/ power converter in Car

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Use of power converter in Car Conversion to other voltage:

12V to 16V (Personal computer) 12V to 220V ac (ac power supply) 12V to 24V (conversion between different

systems) 42V to 12V (42V bus to 12V equipment) 48V to 12V (Electric vehicle) 48V to 200V (Electric vehicle



Various Power Converters The Hong Kong Polytechnic University

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Phase-shifted power converters

Vin Vout RLLlkN1:N2

Q3D3 C3Q1D1 C1

Q2D2 C2 Q4D4 C4

Cin Cout

M1

M2

M3

M4

Iin Iout

Converter BridgeInverter Bridge

i(t)

Zero CurrentSwitching

Zero VoltageSwitching

leading leg(left leg)

lagging leg(right leg)




Power ConverterEngineering model

Power density >2W/cm3

Good range

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The techniques we use::High frequency switching Soft-switching High frequency magnetics

Features:High power density High reliability High temperature range




Machines, Drives and Simulation,

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Power factor corrected SR motor

Features:High power factorLow cost components

ApplicationsMotor driveElectric vehicle




Soft-switching SR motor drive

Features:Soft-switchingLow cost Power conditioningUsing switched-capacitor techniques


DC A

Q2D2

Q1

Q4

B

Q3 D3D1Q5

Q6

C

D6D4

iLoad

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Coupling between the windings for SRMSRM

Non-linear modeling for multiphase switched reluctance motors (SRMs)Self-inductance, mutual inductance and coupling coefficient




Modelling for the magnetic characteristics for SRM

Two-dimensional bicubic splineinterpolation is used to describe the magnetic characteristics in switched reluctance motors.

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Environmental Protection





Battery system

The former requires battery storage which provides immediate energy storage .

When solar energy is not sufficient, the charged battery supplies power to the load. The circuit requires sufficient number of battery storages and a good battery charger.

Other energy storages are also available such as hydrogen energy storage, etc.

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Magnetics





Winding loss calculation Multi-layer and multi-strand

generalized modeling. Can be applied to any frequencies & core sizes. High accuracy of the resistance calculation.

Application:Transformer, inductor

Rac against bundle size with various turn pitches 3 layers and 36 strands Rac 336

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Polymer bonded Magnetics

Features:FlexibleLow eddy currentSuitable for high frequencyEasy to make

Applications:Power supplyTransformerInductorCharger





Polymer bonded Magnetics

Ring, U, E and square U cores)

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Low profile magnetics

Features:High powerLow profile

ApplicationsUninterruptible Power supplyPower converters





Development

Low profile converter

SW-Cap Converter PC adaptor LED lighting

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Other Development in PolyU

Low profile converter



Machines


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Transient performance of a three-phase induction motor with the Smith connection

Single-phase operation of three-phase induction motor with the Smith connection.

This project will investigate the transient performance of the motor with the smith winding connection




Finite element for motors

A 2D and 3D finite element program has been developed for the analysis for the motor

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General Losses Estimation of Non-Sinusoidal Supplied Motors Based in Finite Element Technique

to present a generic

method to characterize the iron losses in the laminated cores of motors supplied by non-sinusoidal power sources based on an investigation of the transient behaviours of harmonic fluxes.



Power Quality


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It affects the safety operationEquipment in car generate EMI, but also attacked by EMI

Electromagnetic interference (EMI)




Electromagnetic MonitoringTo investigate the effect of background EMI Vehicle is exposed to EMI environment

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EMI and EMC Testings


G-Tem cell EMI analyzer



EMI and EMC EquipmentThe Hong Kong Polytechnic University

High-pot EMI scanner GHz amplifier Near-field probe GHz generator

Spectrum Anal GHz generator Antenna Cable emission sensor

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Large Industrial Projects





Automotive HID and LED lightings $8.8 Million Polymer-bonded magnetic $4 Million IVVC control for motors $0.72 Million In-Wheel motor for vehicle $4.1 Million Next generation electric vehicle $4 Million Integrated Charger and controller $4 Million Automotive electric air-conditioning $2.5 Million Funding source: Guangdong and HK Government,

industry and University

Examples of Large Industrial Projects

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Automotive HID and LED lightings

To develop new generation of HID and LED

5 Industrial Companies support

Collaborate EE and ISE Project $8.8 million Duration 2 years Funding source: Guangdong

and HK Government

Examples of Projects




My Car project To develop new generation

Electric Vehicle A HK and an Italian

company support Project $4 million Duration 2 years Funding source: HK Government

and industry


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IVVC control for inductors motorsIVVC

To develop new generation motor drive using fixed speed

Three companies support Project $0.72 million Duration 1 year Funding source: HK

Government and industry

0

5

10

15

20

25

30

0.1 0.2 0.3 0.4 0.5 0.6

Load Factor

Per

cent

Improved PFEnergy savings





Polymer bonded Magnetics To develop new generation Polymer-

bonded magnetic devices Four companies support Project $4 million Duration 2 years Funding source: HK Government and

industry


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In-wheel motor for vehicle

Based on switched reluctance motors

$4 Million funding To develop new generation

in-wheel motor and the control for automotive


1. Background1. Background

Major Requirements of EVs on Electric Motor Drives

a high instant power and a high power density; a high torque at low speed for starting and climbing, as well as a high power at high speed for cruising; a very wide speed range with constant-power region ;a fast torque response ;a high efficiency over the wide speed range with constant torque and constant power regions ;a high reliability and robustness for various vehicle operating conditions ;a reasonable cost and a fault tolerance




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Traditional Internal Combustion Engine Vehicles (ICEVs)





Electric Vehicles (EVs)




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General Tend of Electric Motor Drives for EVs

In-wheel direct-drive structure




2. Research and Developed 2. Research and Developed WorkWork

2.2 Characterization of SRM Drives for EVs

Construction of SRMs




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Characterization of SRM Drives for EVs

Operating principle of SRMs




2. Research and Developed 2. Research and Developed WorkWork2.2 Characterization of SRM Drives for

EVs

Typical converter topology




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Expected output characteristics






Main performances of developed SRM drive

Rated power: 5 kWNumber of phases: 4Number of stator poles: 8Number of rotor poles: 6Rated DC link voltage: 240 VRated motor speed: 1000 rpm




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Integrated charger and driver for vehicle

To develop new generation integration of battery charger and motor drive using single circuit

Integrate two circuits into a single circuit

Vin Vout RLLlkN1:N2

Q3D3 C3Q1D1 C1

Q2D2 C2 Q4D4 C4

Cin Cout

M1

M2

M3

M4

Iin Iout

Converter BridgeInverter Bridge

i(t)

Zero CurrentSwitching

Zero VoltageSwitching

leading leg(left leg)

lagging leg(right leg)

Integrated charger and motor drives




EMI tests for IndustryFor Railway EMC

EMF for human safety

EMI and EMC for circuit and systems

Annual revenue $4 million

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Conclusion

1st plastic magnetic core for power conversion in the world1st Large EV research group in Hong Kong1st Self developed electric vehicle in Hong Kong1st in-wheel motor using the switched-reluctance technologyLargest power electronics research group in the regionHighest number of research papers in power electronics, machines and drives in the region




ConclusionElectric vehicle is a future technology for motion control and transportationHas been used successful for fixed route transportation , eg Rail, VanReduce energy by more than 80-50%Future technology allows the use of high energy density of battery

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Future:Use ultra-capacitor for energy storageConnect battery vehicle with electrical network for energy storageWind power related vehicleElectric vehicle for aerospace and seasAll electric control

Braking (ABS- Anti-lock braking System)Steering (Power assistive Steering)Direct drive and self (auto driving /pilot)




Conclusion Power Electronics Research Centre (PERC)Fully supported from the industry and government. Research in fundamental study as well as applied researchAims - to help local industry and the region

(PERC) -

Contact: Prof. Eric Cheng, Dept. of EE, HK PolyUTel: +852-27666162, Email: [email protected]

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Thank You

Documents

Electric vehicle – future development , technology and energy ...cd1.edb.hkedcity.net/.../NSS/Energy02_Dec08/ElectricVehicle_PartII.pdf · • When solar energy is not sufficient,