7/31/2023 0 Comments Emc motors![]() ![]() It is not (yet) a general practice to take EMC into consideration when designing an electric motor. The prices of the rare earth materials, although not cheap, have still been kept low enough during recent years, which has enabled the leading position of permanent magnet motors. Axial flux motor, as the one seen in YASA motor, Figure 3 (e)Ĭombined with high torque density and high efficiency, permanent magnet machines dominate the EV electric motor sector.Permanent reluctance motor, as the one seen in Danfoss Visedo, Figure 3 (d).Switched reluctance motor, as the one seen in Ricardo prototype, Figure 3 (c).Induction motor, like the one seen in early models of Tesla Model S, Figure 3 (b).Permanent magnet brushless DC machine, as the one seen in Nissan Leaf, Figure 3 (a).The common motor topologies used in automotive EDUs are listed below: A detailed breakdown of an EDU module is then presented. All the key components are shown and marked. Demystifying EMC-the Breakdown of an EDUįigure 2 demonstrates the electric system of an EDU. To cover the full scale of an EMC design of an EDU in one paper is ambitious, but this paper should give all designers in the field a broad idea of good, cost-effective EMC design, and how to avoid EMC issues that could potentially jeopardize the project delivery plan. Sometimes, an unsolved EMC issue leads to a failed product launch, causing a financial loss of millions of dollars.ĭrawing on know-how in state-of-art electric machines and power system design, combined with experiences in the field of EMC, this article highlights the design challenge of an EDU, outlines crucial design blind spots, and addresses key EMC issues. Any EMC troubleshooting required during the verification testing phase will inevitably make a huge impact on the project delivery plan. ![]() Testing to verify EMC conformance is always expensive and time consuming. This approach avoids or reduces the time and resources spent on finding and fixing EMC issues during the testing phase. One of the most important lessons is to design a system with EMC in mind from the get-go. To demystify the EMC issues that design engineers are facing, this paper focuses on the design aspect of EMC. The unit must also conform to EMC standards, a design process that is often (incorrectly) regarded as ‘black magic’ by designers. Improving the compact design of an EDU will achieve a smaller size, lighter weight, and better thermal performance. One can already foresee the increase to this percentage due to the economy of scale behind electrification. BackgroundĪ survey carried out by the International Energy Agency in 2017 concluded that more than 40% of global electricity production was consumed by electric motors . In order to build up a common understanding, this paper explores the EMC design of the EDU from the angle of electric machines, power electronics, and thermal design. The compromise must be based on understanding. Engineers should all be familiar with the compromise associated with good engineering. ![]() The EMC design of such a complex system requires lots of compromises. This paper focuses on the EMC challenges of EDU design. In addition to the size, cost and performance challenges, automotive design engineers are now facing the ever-challenging thermal and EMC requirements. These specifications include function, mechanical, environmental, electrical, electromagnetic compatibility (EMC), functional safety, and more. For key differentiator components such as the EDU, the battery pack, and software integration, it is often in the OEMs’ own interests to keep the design in house, which gives them an advantage over their competitors.įor automotive applications, all components must be designed to meet OEM’s unique design specifications. The suppliers, when receiving the product specification and requirement, design the bespoke parts for the OEMs. The OEMs often outsource components of a vehicle to Tier-1 suppliers allowing them to focus their resources on vehicle system integration and manufacturing. In this case, the transmission is sandwiched between an electric motor and the power electronics module. ![]() The three-in-one EDU from Bosch is shown in Figure 1 . This is often referred to as the three-in-one unit. The beating heart of an EV is its electric drive unit (EDU), also referred to as powertrain, which consists of an electric motor, a power electronics module, and a transmission. With Tesla leading the market, followed by traditional vehicle original equipment manufacturers (OEMs) such as Volkswagen, PSA, and Toyota, to name just a few, the electrification of the automotive industry has been advancing at a fast pace . The past decade has witnessed both a leap forward in technology and market expansion of the global electric vehicle (EV) industry . ![]()
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