Electric Motors In Vehicle Applications

C. Peter Cho and Ralph H. Johnston

Advancing Technology Group
Delco Remy International
2902 Enterprise Dr., Anderson, IN 460 13, USA

Abstrad -This paper presents the electric motor applications

During the last two decades in response to the need for
in the modern vehicles. Automotive industry trend and three
different motor technologies are also presented. In this paper automotive electrification coupled with the development of
an advanced integrated starter-alternator-damper (ISAD) low-cost, high-performance electronics, with an
system is discussed. The new starter-alternator combinatioti accompanying improvement in permpent magnetic
provides a more efficient and higher output platform, which materials, the automobile electricallelectronicsmarket has
will provide the vehicle designer unique ways to reengineer rapidly expanded. In addition to increased numbers of
many functions under the hood. Virtually any accessory, electricallelectronics devices installed on automobiles,
which is presently belt driven, may be converted to an each year there are 45 million additional automobiles on
electrically powered counterpart with the ready availability
of more electrical power from the larger alternator
the street. Figure 1 shows the world vehicle sales
component of the system. High voltage svstem issues are also comparison and forecast. It has been predicted that the
discussed in this paper. world vehicle sales will be 50% higher in 2010 than in
1990. Figure 2 shows the number of automobile electric
I. INTRODUCTION motor aDplications and Dower generation capability.
Electrification of the automobile was the challenge at the
beginning of the 20* century. At the turn of the century,
there were more electric automobiles than gasoline I World Vehicle hla
(volume in millions)
80
Swm:MIRA-
M~~~~

powered automobiles in the U.S. In 1912 Charles

Kettering introduced the frst electrical system for use on a
60
car (about 200W) making possible electric starting and
lights. As we enter the 21" century, the same
40
electrification challenge resurfaces as a result of the need
to reduce emissions and dependency on foreign oil. Our 2
20
kW platforms must be replaced with 20 kW or even 50 kW
platforms on which many electrically generated functions
0
will be enabled - some of which will be conceived in the 1960 1970 1980 1990 2000 2010
future. The current mechanical powertrain will be
augmented by rotating electric machines commutated by Figure 1. World Vehicle Sales Comparison and Forecast
sophisticated power electronic controllers providing
electrical power for more bfficient systems such as electric
power steering, electric passenger compartment heaters,
electric coolant pumps, electrically active suspension,
electric brakes, auxiliary power unit options, and much 100 I IwbtorrpaCa dk
Powa [Link]. I
more. 80
&
As discussed above, there are two reasons why the 960
automotive industry must convert to the use of high power
840
density, high efficiency, and affordable electromagnetic
devices for use in electrically powered automobiles. First, 20
emissions must be reduced to reduce air and water
0
pollution, as well as global warming. Second, dependency m 1 9 u 1 9 4 5 1 9 6 5 1 9 8 5 u x H
on foreign oil must be reduced for both national security
and cost considerations. Concurrent with the need to
reduce emissions and dependency on foreign oil supplies,
Figure 2. Number of Electric Motors in a Vehicle
customers for automobiles are demanding improvements
in safety, comfort, and quality of drive that can be Each vehicle currently has approximately 20-50
provided by increased electrical power generation electromagnetic devices. Electric motors have also begun
capability for electrical systems. to play an important role along with energy storage for
fbture type vehicles such as the hybrid electric vehicle

0-7803-5296-3/99/$10.00

I93
(HEV) and electric vehicie (EV). The market for most widely used in vehicle because of its high starting
electromagnetic devices and electric motors is expected to torque for initial acceleration, high power density and high
reach $100 billion by year 2005, more than’double the efficiency.
1995 figure. The vehicle electricaVelectronics market is Modem electric motor advances have resulted from
growing about 20 % annually. Even though the price of deve!opments and refinements in magnetic materials,
most electricaVelectronics devices continues to decrease, integrated circuits, power electronic switching devices,
their percentage of total vehicle cost is predicted to rise computer modeling and simulation, and manufacturing
steadily from about 20% to 25% by 2010. technology, rather than by fundamental changes in
The following list is a partial summary of current electric operating and control principles. The dramatic
motor applications and near term future products under improvements in permanent magnet materials and power
development. electronic devices over the last two decades have led to the
Power train: starter motor, alternator, electric engine development of brushless permanent magnet motors that
cooling, air cmditioning compressor drive, idle speed offer significant improvements in power density,
control, engine throttle control, transmission shifter, effkieccy, and noisehibration reduction, as well as
electrically variable transmission, engine coolant pump reduced radiated noise and no electrical sparks.
motor, electrical valve, and ECR actuators
Chassis: electric power steering system, ABS systemp 1 rnJDUGTION MOTORS
*

electro-hydraulic power steering, brake-by-wire Alternating current (AC) induction motors are ?he most
actuators, active suspension actuator, and 2-4 wheel common of all types of electric motors manufactured for
drive actuator the general use in household applications, industrial drives,
Body: wiladshietd wipers, window lifts, seat adjuster, and electric propulsion. These motors are rugged,
seat vibrators, sunroof actuators, sliding door closers, relatively inexpensive, and require very little maintenance.
doorlock mechanisms, headlamp .idjuster, mirror They r a g e in size from a few watts to about 15,000 hp.
adjusters, steering column adjusher, HVAC blower, The induction motors have certain lnherent disadvantages:
cruise CQDfrOi, headlight wiper motors, power antenna, speed which is not easily contro!lad, law lagging power
headlight doors, trunk closer, and autc3-1eveEing system. factors wnen lightly loaded, and starting current which is
FigurE: 3 shows a pictorial view of these electric motoi

E J s a W x r L
applications in a vehicle. usually three to sever. times full-loaded current.
The stator is composed of laminations of high-grade steel
with slotted inner surface to accommodate the current
In this rection, the three mos! cnmnicn e!eLtric motor carrying wires. The stator lamination and windings are
technologies and associated power clectronic devices with essentially the same as those used for the brushless
control circuits for vehicle applicatbns are discussed. The permanent magnet motor. There are two COIIUIIQ~I rotor
three motors are the (1) pelmanen1 magnet (omshed rind constructiolis ii induction motors. The squirrel-cage rotor
brushless type) motors, (2) induction motors, and (3) is built with a very small air gap and equipped with ball
switched reluctsnce motors. Among those three motor bearings rather than sleeve beariiigs. The second type of
configurations, the yenrment m q p e t notor type is the rotor construction is the wound rotor. Regardless of the
rotor construction employed, the rotor currents in an Nevertheless, there are six gene61 characteristics that
induction motor are induced by the stator's changing, or detract from wider application in the automotive industry:
rather, rotating magnetic field. This induction action is the 1) friction between the brushes and the commutator, 2)
central operating principle of AC induction motors. brushes and commutators require maintenance, 3) losses
due to current being supplied to the armature through the
An AC induction motor, when driven from a battery
brushes and commutator, 4) brushes and commutators are
source by an appropriate inverter, has external open and produce sparking, 5 ) cooling of a DC motor is
characteristics that are well suited to vehicle propulsion difficult, and 6 ) switching of large currents is required for
and other applications. Unlike brushless permanent control of DC motors.
magnet motors that must have rotor position sensors to be
operated from inverters, rotor position feedback is not Brushless motors are becoming stronger candidates over
needed for inverter drive of induction motors. It is useful traditional brush type motors for the following reasons:
however, to have feedback of rotor speed when an higher efficiency, higher power density, better heat
induction motor is to be operated from an inverter because, dissipation, and increased motor life. In addition,
although it is not required for operation, feedback of rotor brushless motors experience no losses due to brush friction
speed provides the means to have closed-loop control o f and they deliver higher torque compared to a brush type
induction motor speed and slip. motor o f equal size and weight.
Induction motors have relatively low manufacturing cost
and are mechanically rugged because they can be built
without slip rings, brushes, or commutators. Consequently
much attention has been given to induction motors for
future automotive applications in the areas of vehicle
propulsion, engine starting, braking, electricity generating,
speed reversal, speed change, etc. In spite of many
interests in vehicle applications, the costs of the power
-
electronic components are still relatively high.
Furthermore, in many automotive applications it is either
not possible or not desirable to use a mechanical sensor for
Figure 4. Delco Remy Brush Permanent Magnet Starter
speed or angle, etc. This means, a simple and affordable Mot05
control system, using only the voltage and the current of
the induction motor as measured quantities, is necessary. Figure 5 shows a schematic diagram o l i? brusf~less
permanent magnet system.
2. PERMANENT MAGNET MOTORS
Advancements in high-energy permanent magnet materials
and magnet manufacturing technologies have enabled the
manufacturing of hi@%power density and high efficiency
permanent magnet rnotors at reduced cost. The availability
of fast switching high power semiconductor devices with
low on-state voltage drop such as MGSFETs and IGBTs,
as well as high speed microprocessors/digital signal
processors have eonkibuted to advancements in permanent
magnet electric motors. Current trends to reduce the
production cost of permanent magnet motors and
semiconductors we continuing. As discussed in the
following paragraphs, permanent magnei motors consist of
two types: brush and brushless. Figure 4 shows a Delco
Remy International starter motor annature with brushes.
Bnash type permanent magnet motors are used almost Figure 5, Graphical Wepresentbtion of SE Brushless,
exchsiveiy for current automotive applications. Permanent Magnet Motor
The brush permanent magnet motors have four general 3 . SWKTCHED RELUCTANCE MOTORS
characteristics that cause them to be usehl for vehicle
applications: 1) desirable torque versus speed, 2) simple Recently, there has . been increased interest in switched
contrql of torque and speed, 3) high electromagnetic power I eluctmce motor technology due to the high performance,
density, and 4) inverters are not required. fault tolerance operation, simplicity of construction, and
increased cost-effectiveness as cornpared to rare earth

195
permanent magnet motors. There are four reasons for reluctance motor is the different number of poles on the
supporting the switched reluctance motor technology: stator and the rotor. The windings of diametrically
opposite stator poles are connected in a series to form the
e Economical, and powerhl computational computers electric phases of the motor. For each electric phase, a
with associated software, power electronic circuit with one or two electronic
0 High frequency power electronic devices such as switches is necessary for the control of unidirectional
MOSFETs and IGBTs at low cost, current flowing during appropriate intervals for the torque
0 Increased understanding of the switched reluctance production. Exciting the stator coils in sequence produces
technology, and the torque in the motor. This requires an inverter (i.e. a set
e Integrated design of motor and electronics capability. of electronic switches such as MOSFETs or IGBTs) that
Despite increased use, further work is necessary to drives the motor from the battery’s DC voltage supply.
improve torque ripple, noise, and other system design Switched reluctance motors have several features that
problems. Switched reluctance motors have demonstrated make then the best choice for a range of automotive
performance comparable to induction motors and applications. These include: high efficiency over a wide
permanent magnet motors in terms of specific torque, range of torque and speed, high torque capabilities at low
power, operational speeds, and overall system efficiency. operational speeds, simple and rugged rotor construction,
In addition, switched reluctance motors also have the fault tolerant, four-quadrant operation, and suitable for
potential of operating in severe environmental conditions, extreme environmental conditions.
being simple to manufactute at low cost, and having
excellent fault tolerance characteristics. 111. INTEGRATED
STARTENALTERNATOR DAMPER
SYSTEM
The new starter-alternator combination provides a more
efficient and higher output platform, which will enable the
vehicle designers unique ways to reengineer many
functions under the hood. Virtually any accessory, which
is presently belt driven, may be converted to an electrically
powered countelpart with the ready availability of more
electrical energy from the larger alternator component of
the system. Hydraulic power steering units, belt driven air
conditioning compressors, and various fluid pumps and
their components could be replaced with more efficient
electric motor-driven systems powered by the ISAD.
In recent years the demands for more electrical power, as
well reduced fuel consumption and emissions are
increasing pressures to develop alternative technologies to
meet the needs of the future. There are some methods of
reducing fuel consumption and emissions that could use 3
to 4 times more power, but current high volume alternators
cannot be modified to deliver this amount of power. The
Figure 6. Schematic Cross-section of a Switched Reluctance ISAD system is a candidate technology to provide the
Motor with Drive Circuits necessary paradigm shift to meet these future needs.
The construction of a switched reluctance motor is shown Starting motor advantages of the new ISAD system
schematically in Figure 6. Typically, a switched include a quiet start feature that with eliminate the gears
reluctance motor has salient poles (i.e. poles having a well and whine of the traditional starter. This system will be
defined, protruding, geometric shape) on the rotor and also able to increase the starting speed and also supports the
on the stator, hence the name ‘doubly-salient’ motor. Only acceleration phase. Fewer parts will increase system
the stator has current-carrying conductors. The laminated reliability. The ISAD system includes all functions of the
rotor is made up of salient poles and the core, without any engine starter motor and alternator in one electric system
windings or permanent magnets. The stator and rotor installed between the engine and gearbox without
cores are laminated to reduce eddy currents, and the coils significantly increasing the weight and size of the vehicle.
are wound around each stator pole, see Figure 6. This
construction feature makes the rotor very rugged and easy The machine can be an induction, permanent magnet, or
to manufacture. One important feature of the switched switch reluctance configuration with its rotor mounted

196
directly to the engine cr&kshaft at the location of the Some devices on the vehicle that are now driven
flywheel. The stator is mounted in the bell housing of mechanically could be driven electrically, since the needed
either the engine or transmission. power will be available. Components such as the air
conditioning compressor, the water pump, and the power
steering system can then be operated only on demand,
instead of remaining a continuous parasitic load on the
engine when they are in the “off” part of their operating
cycle. This will further reduce fuel consumption m d
emissions.
VI. HIGH VOLTAGE SYSTEM ISSUES
Interest in higher voltage for autQmotiveelectrical systems
has been increasing in the past couple of years. The
interest has been driven by the need for increasing
electrical ?ewer required for features and functions that
would improve fuel economy and emissions, as well as
customer comfort.
In 1989 the North American car companies were
Figure 10. 3-D Solid Model of ISAD recognizing the need for higher voltage systems to meet
The higher efficiency ISAD system can reduce fuel their future power needs. An early result of the SAE
consumption and emissions because less fuel is wasted in Committee effort was the publication of an Information
the production of heat in the various parts of the vehicle Report J2232 identifying the maximum voltage (48 volts)
system. The higher voltage, higher power system enables that should be considered from an electrical shock safety
other features to be added to the vehicle which can further perspective.
reduce fuel consumption and emissions by improving the European car companies in 1996 began to be concerned
basic control of the engine. The results of adding these about the future shortage of vehicle electrical power for the
features cannot be estimated quantitatively at this time future. Mercedes led an effort to have MIT establish a
because these features have not yet been developed to Consortium of car companies, suppliers, and other
point where the estimates can be made. stakeholders in vehicle electrical systems. Its goals are to
The engine can be cranked up to its normal idle speed identify the issues, potential solutions to the deal with the
before fueling begins. Because of the heat this high speed issues, and gain broader support in the industry for higher
cranking produces in the combustion chamber the fuel, voltage systems. The European focus is on 12 - 36 volts
when injected, is more readily vaporized improving (14 - 42 volt generator voltages), and this is the focus of
combustion and reducing cold start emissions. Audible the MIT Consortium effort. European car companies
noise normally associated with engine cranking is almost currently have programs targeting 200land 2002 for
eliminated as an added feature of the system. introduction of these 14 - 42 volt systems in passenger
cars.
The power available with this system will be high enough
to operate electromagnetic engine valves. The control There are tangible benefits to the vehicle using higher
flexibility of electromagnetic valves can lower emissions voltage systems. Among them are: current for high power
as well as improve fuel economy and engine performance. loads is reduced in proportion to the increase in voltage.
In the 36-volt system the currents will be reduced by a
The higher power capability could make electrically factor of 3. Overall system efficiency is increased by the
powered exhaust stream after treatment systems more reduction in current, which improves fuel economy and
viable as a means of further reducing emissions. reduces emissions. Wiring systems are reduced in size and
The ability to use electromagnetic engine valves will weight. The size and cost of power semiconductors are
enhance fuel economy as well as emissions. The system reduced at lower currents.
can function as a retarder in which a portion of the kinetic Higher voltage enables the use of new features and
energy of the vehicle can be recovered during coasting and functions that require high power:
braking and stored the battery. The amount of
regenerative braking energy that can be recovered and Starter - Alternator, like ISAD (fuel economy and
used will depend on the storage capacity of the battery emissions improvement). Electric power steering (fuel
system, and this will establish the actual fuel economy economy and emissions improvement). Electric air
improvement. conditioning compressor (fuel economy and emissions
improvement). Electromagnetic engine valve actuation

197
(fuel economy and emissions improvement). Damping of VI. REFERENCES
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the vehicle that are ncw d r i v ~ nmechanical!y coufd be
driven electrically, SUicI: the weded power will be
available by ISAD system. Compoiients such as the air
conditioning compressor, the water pump, a m the power
steering system c x i then bt; operdted only on demand,
instead of retnainiiig a continuous pamsitic load on the
engine when they a e in thi: ’‘off” part of their operating
cycle. This will hither reduce fuel consumption and
emissions. High voltage issues were also discussed.