Sizing the Drive
system
Sizing the propulsion motor
• The basic steps for sizing a propulsion motor:
1. Set the specifications : The speed and power and torque figures to propel the
vehicle or machine, as well as any other performance criteria that are important for the
application.
Torque (T) = Power (P) / Angular velocity (ω)
2. Select an appropriate motor: After calculating the required torque, you can select a
motor that is capable of providing the necessary torque and speed. You will need to
consider factors such as the motor's maximum torque and speed, efficiency, and weight.
3. Check Safety factors: When sizing a motor, it's important to consider safety factors to
ensure that the motor is not overloaded during operation. This includes taking into
account any variations in torque or speed that may occur during use, as well as any
other factors that may affect the motor's performance.
4. Test the motor: Once you have selected a motor, it's important to test it to ensure
that it meets the performance requirements of the system. This includes testing the
motor under various operating conditions to ensure that it is capable of providing the
necessary torque and speed.
Sizing of Electric Motor in EVs
• Physical size of EV depends mostly on torque specification.
• Torque is determined by amount of Flux the iron can carry and amount of current the conductors
can carry.
• Two Fundamental Sizing constraints-Electric loading and Magnetic loading.
• Max. Current density of conductors-
• 2A/ for continuous operation , 6A/ for 3 min, 20A/ for 30 sec
• Max Magnetic loading- 0.8 Tesla. k- Prop. constant
• First approximation of size of EM : A- Ampere Turns per circumferential length
B-Magnetic Flux density
L, D-Length and dia. of rotor
• Detailed analysis and Modeling methods (FEM)
Note: This slide is just for information, not important for exam.
• Speed torque curve- Constant torque and constant power region.
• Capability curve defines the operating bounds(peak Torque and power) of the drive.
Matching the EM and ICE in Hybrids
• Matching the electric machine and the internal combustion engine (ICE) depends on several factors:
1. Power output: The electric machine should be able to provide enough power to complement the
power output of the ICE. The power output of the ICE can be estimated from its displacement, number
of cylinders, and maximum RPM. The power output of the electric machine depends on its voltage,
current, and efficiency.
M/G torque and power is customized by the electric fraction, EF, defined as the ratio of M/G peak
power to total peak power. For hybrid propulsion systems, this fraction ranges from 0.1< EF < 0.4.
2. Speed of motor-generator M/G : maximum input speed at transmission is restricted to <12000 rpm
from the engine side and on the transmission side by the proper gear selection.
3 Speed Torque curve: The electric machine should provide torque at low RPMs to assist the ICE during
acceleration. The torque curve of the electric machine should complement the torque curve of the ICE
to provide a smooth and seamless driving experience.
4. Available space, weight and budget: The electric machine and ICE should be sized appropriately to fit
within the available space and weight budget of the vehicle. The size and weight of the electric
machine and ICE depend on their power output, cooling requirements, and other factors.
5 Fuel efficiency: The electric machine should be able to provide enough power to reduce the load on
the ICE during cruising and low-load conditions. This can help to improve the fuel efficiency.
Constant Power Speed
Ratio (CPSR)
• At the low-speed region the
motor has a constant torque.
• The maximum speed at
which a motor generates a
constant (maximum) torque
is known as base speed.
• In the high-speed region the
motor has a constant
(maximum) power.
• The highest speed at which
Constant power Speed ratio, x,
the motor generates constant
maximum power is known as defined as the ratio of maximum
maximum speed. speed to the base speed during
constant power operation.
Speed ratio & Speed–torque profile of a 60 kW electric
motor
Tractive effort and power versus vehicle speed with
different Motors
Sizing the power electronics
• Sizing the power for electronics involves calculating the amount of electrical power that the electronic device
or circuit requires to operate effectively and safely.
• To size the power for electronics, the following factors to be considered:
1. Voltage: Determine the voltage required by the device or circuit. This may be specified in the device's
datasheet or in the circuit design.
2. Current: Determine the current required by the device or circuit. This may also be specified in the
datasheet or in the circuit design.
3. Power rating: Calculate the power rating required by the device or circuit by multiplying the voltage and
current. For example, if the voltage required is 12V and the current required is 1A, the power rating
required is 12W.
4. Safety margin: Add a safety margin to the calculated power rating to ensure that the device or circuit
operates reliably and safely. The amount of safety margin to add depends on the specific application and
the level of risk involved.
5. Power supply: Choose a power supply that can provide the required voltage and current with the
appropriate safety margin. The power supply should also be able to handle any fluctuations in voltage or
current that may occur during operation.
