GENERAL DESCRIPTION

[0001] The present disclosure related generally to the field of drive systems for an electric vehicle. Specifically, a switched reluctance motor (SRM) drive system for an electric vehicle.

[0002] In a SRM drive system, the high speed limit for the motor is determined by multiple factors, such as dc bus voltage, motor characteristics and control strategy. Normally, providing the motor with a wider speed range is desirable. For electric vehicle applications, it may be desirable to provide the motor with a higher top speed and/or higher torque.

[0003] Current electric vehicles operate with SRMs due to their simple, low cost, high efficiency and robustness. The power is delivered to the windings in the stator rather than the rotor. SRMs are capable of producing high torque at low speeds, making them favorable for propulsive motors in electric vehicles. The torque produced by the SRM is due to its tendency of its rotor to move to a position where the inductance of the excited windings is maximized. By turning the current on at the phases in a predetermined sequence, the stator poles attract the rotor poles in a cyclical manner. The current is switched off in windings immediately before the attracted rotor poles rotate past the corresponding rotor. The current switching sequence allows the motor to produce torque. The SRM allows great advantages of inherent fault tolerance and high reliability due to independent circuits for each phase of the SRM. In current SRM drive systems, the high speed limit is determined by multiple factors, such as DC-BUS voltage, motor characteristics, and motor control profiles. It is desired to include a motor with a wide speed range. Specifically, a higher top speed and/or torque is desired for electric vehicle applications.

[0004] Accordingly, an object of the present disclosure is to provide a new and inventive circuit for the windings of the motor to allow higher speeds and/or torque. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The features, aspects, and advantages of the present invention will become apparent from the following description, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.

[0006] Figure 1A is an electric vehicle with an SRM.

[0007] Figure IB is an electric vehicle with an exemplary drivetrain and with an SRM. [0008] Figure 2 a circuit diagram for single phase of a conventional SRM.

[0009] Figure 3 is a current waveform for the SRM in a low speed and high speed range. [0010] Figure 4 is an exemplary SRM motor.

[0011] Figure 5 is an embodiment of the switchable winding circuit for a single phase of the SRM.

[0012] Figure 6 is another embodiment of the switchable winding circuit for a single phase of the SRM.

[0013] Figure 7 is another embodiment of the switchable winding circuit for a single phase of the SRM.

[0014] Figure 8 is another embodiment of the switchable winding circuit for a single phase of the SRM.

DETAILED DESCRIPTION

[0015] As disclosed herein, a switchable winding for a propulsion motor for an electric vehicle is provided. Specifically, the propulsion motor is a SRM. The inverter circuit for a phase of an SRM includes diametrically opposite windings which are selectively switched on (i.e., carrying current), allowing the rotor to rotate towards a minimum reluctance

configuration. A DC power source is provided to supply power to the motor via the windings. The DC power source in an electric vehicle may be the main battery of the electric vehicle. [0016] According to one embodiment of the disclose, an SRM includes an inverter circuit for one phase of the SRM. The windings of the inverter circuit may be selectively supplied current. Different switch arrangements may be provided to allow greater control of the inverter windings compared to conventional SRM inverter circuits. This innovative arrangement allows the motor to operate at higher torque and speed.

[0017] Fig. 1 A shows an exemplary electric vehicle 1 configured to be driven by a propulsion motor(s). The propulsion motor is powered by a main battery (not shown). The motor may be an SRM that drives the wheels of the electric vehicle 1. The SRM of the vehicle may be a 3 phase SRM with a 6/4 configuration, (i.e. 6 stators and 4 rotors, see Fig. 4), however other multiphase configurations such as 6/6, 8/6, 12/8, single phase configurations such as 6/6, or any other configuration allowing magnetic reluctance to produce torque via the motor, windings, and main battery.

[0018] FIG. IB shows an electric vehicle 1 with the drivetrain 100, the exemplary vehicle includes an internal combustion engine 10, a generator 11, and SRM 14/14’. The internal combustion engine 10 drives the generator 11 to produce electrical power for a battery 12 and the motors 14/14’. A generator inverter 16 for the generator 11 may also be provided. A gearbox 13 is provided to provide the required drive ratio for the vehicle. Power to the motor is communicated via inverters 15 / 15’, which transforms DC power provided to the AC power required by the SRM 14 /14’. The inverters 15 / 15’ may include multiple phases corresponding to each phase of the motors 14/14’.

[0019] Fig. 2 shows a conventional inverter circuit for one phase of the SRM. Current conventional inverter circuits do not provide additional switching to the phase windings W _A 2 and WA2 _\ Typical wave forms for SRMs at low speed (LS) and high speed (HS) is shown in Fig. 3. At low speeds the current is controlled via pulse-width modulation and high speeds a one pulse control is used. The inverter shown in Fig. 2 includes two transistors Qi / Q2, two power diodes Di / D2, a capacitor, and a DC supply VDC. The inverter transforms the DC supply into AC to be utilized for the motor.

[0020] Fig. 4 illustrates the exemplary motor 14 / 14’ as a 3-phase 6/4 SRM with windings W _A / W _A’ of a single phase A are shown to be diametrically opposite. The rotor 22 is radially inwards relative to the surrounding stator 21. Additional phases B and C may include their own windings W _B / W _B’ and Wc / Wc _’ which are also diametrically opposite from each other. An angular position sensor (not shown) for the rotor may also be provided to aid in the control of the motor.

[0021] Fig. 5 illustrates an exemplary inverter circuit of an SRM of an electric vehicle. As shown, windings WAS and WAS’ are provided with a selective serial / parallel configuration. Windings WAS and WAS’ may be switched into series via the Kss switch. The serial switch Kss allows the windings WAS and WAS’ to be configured in a series connection. Thus, the windings WAS and WAS’ are connected along a single path, so that the same current flows through both switches. Switches KLS and KLS’ are also provided to allow windings WAS and WAS’ to be configured in a parallel connection. As a result, the windings WAS and WAS’ are along different paths such that current is split so that the same voltage flows through both switches. When the motor operates at low speed the circuit operates in the serial

configuration, Kss is closed (i.e. current allowed to pass) and KLS and KLS’ is open (i.e. current not allowed to pass). The serial configuration allows the motor to operate at maximum torque. As the motor speed is increased the motor switches to the parallel configuration at a predetermined motor RPM value. The predetermined value may be Maximum Rotations per Second (MAXRPS) of the motor in the present inductance rating or any value under MAXRPS to form the desired profile for the SRM behavior at different speeds. The SRM behavior may include desired torque or power curves tailored to different vehicles or objectives required for the SRM. During the parallel configuration, the parallel switches K _LS and K _LS’ are closed and the serial switch Kss opens. In the parallel configuration, the winding inductance of the SRM becomes 25% of the serial configuration. The lower inductance allows the inverter to drive the motor to higher speeds. Maximum speed of the motor or Maximum Rotations per Second MAXRPS is related to the dc bus voltage, and inductance characteristics. [0022] The serial switch Kss is required to have a current rating to be the same as the inverter output current rating while the parallel switches KLS and KL.V are required to have current rating half of the inverter output current rating. In this parallel / series configuration, the windings WA and WB are required to be identical in its number of turns. The switches Kss,

KLS and KLS’ may be unidirectional.

[0023] Fig. 6 illustrates another embodiment where windings W _A6 and W _A6’ may be different windings of different turn ratios. In the exemplary inverter circuit of an SRM shown in Fig. 6, a serial switch K _L6 and bypass switch K _H6 are provided. The serial switch K _L6 is located in series connection with WA6 and WA6\ The bypass switch KH6 is located on a circuit line parallel to WA6\ A high speed mode may also be provided. KL6 and KH6 are disposed such that, in the high speed mode, the opening of switch K _L6 while maintaining K _L6 closed allows current to pass through winding WA6 but not through WA6’. The configuration shown in Fig. 6 reduces the motor winding’s inductance and back-EMF (the electromotive force caused by self-induction of a phase) which allows for higher speeds when the motor reaches a predetermined motor RPM value. The predetermined value may be Maximum Rotations per Second (MAXRPS) of the motor in the present inductance rating or any value under MAXRPS to form the desired profile for the SRM behavior at different speeds. The SRM behavior may include desired torque or power curves tailored to different vehicles or objectives required for the SRM. Also, the configuration shown in Fig. 6 allows winding W _A6’ to be of any number turn desired, The greater the number of turns in a coil, the greater the inductance. For example, the motor’s behavior may be tuned by changing the turn ratio of W _A6’ as needed.

[0024] Fig. 7 illustrates another embodiment utilizing one uni-directional power switch K _H 7 and a power diode D _A 7. Power diode D _A 7 is in series connection to the windings W _A 7 and WA7 _’ . Power switch KH7 is parallel to the winding WA7 _’ and power diode DA7. The configuration shown in Fig. 7, allows the inverter to provide a low speed range and a high speed range. A silicon controlled rectifier (SCR) may be utilized for the uni-directional power switch but other switches based on semi-conductors may also be considered. At the low speed range, switch KH7 is open. As the motor speeds up, switch KH7 may close to bypass winding W _A 7 _’ to reduce winding inductance and back-EMF to enable the motor to rotate at higher speeds. The winding cut-off ratio f may be between 0 and 1. The winding cut-off ratio is defined as the ratio of the second winding turns TWAT to the total winding turns of the phase (TWA7 + TWAT). Thus

[0025] Fig. 8 illustrates another embodiment utilizing multiple speed ranges to allow refinement of control of the SRM. The provision of multiple speed ranges allows the SRM to have a higher top speed due to having greater range of control of the inductance in the motor. The circuit may have any number of N switches KN with corresponding N number of supplementary windings XN and in addition to primary winding WAS. One diode DAS is also needed to allow current to flow in one direction. The current ratings of each switch KN may be determined by the maximum current running through at the speed range the switch KN corresponds to. Adding additional windings and corresponding switches allows finer tuning of the motor behavior at different speeds.

[0026] The SRM described in the embodiments above may include multiple inverter circuits described in any of the embodiments that control different phases of the SRM. The same phase may be disposed in different stators of a stator/rotor stack, that is a stacked stator may be used with any embodiment described above. With different stators, torque generated should be balanced to ensure the rotor rotates efficiently without any damage due to torque differentials along the shaft at any modes.

[0027] As utilized herein, the terms“approximately,”“about,”“substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims. [0028] It should be noted that the term“exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0029] The terms“coupled,”“connected,” and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

[0030] References herein to the positions of elements (e.g.,“top,”“bottom,”“above,” “below,” etc.) are merely used to describe the orientation of various elements in the figures.

It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0031] It is important to note that the construction and arrangement of the inverter circuit for an SRM as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.