Alternative Energy

for Vehicles
Electric Motors, Controller and Electronics
 TITLE

Specifications and
Introduction to Motor story components
Electric Motors

Battery connection Traction control motor Cooling systems

INTRODUCTION
Electric Motor In Daily life
Electric Motor Inventor
MOTOR
STORY
Electric motor
type of motor
1. DC motors
Brushed DC Motor
Brushless DC Motor (BLDC)

2. AC motors
Induction Motor (Asynchronous Motor)
Synchronous Motor
Permanent Magnet Synchronous Motor (PMSM)
Reluctance Motor
Hysteresis Motor
How electric motor work

F = BIL
F ; The force experienced by the conductor (N)
B ; The magnetic flux density (T)
I ; The current flowing through the conductor (A)
L ; The length of the conductor(m)
Conceptual
How Brushed DC motor work

Reality
Use conductor to generated
magnatics field and create
force.
How conductor magnetics field
Electromagnetic coil
How conductor magnetics field
Electromagnetic coil
Brushed DC motor
Brushed DC motor
Construction
Brushed DC motor
Brushed DC motor

Application
Brushed DC motor

Cons : Commutator damage from friction

Electric motor
type of motor
1. DC motors
Brushed DC Motor
Brushless DC Motor (BLDC)

2. AC motors
Induction Motor (Asynchronous Motor)
Synchronous Motor
Permanent Magnet Synchronous Motor (PMSM)
Reluctance Motor
Hysteresis Motor
Brushless DC Motor(BLDC)
Brushed and Brushless comparison

Difference : Brushless motor didn’t have contact between

stator and rotor.
Electric motor
type of motor
1. DC motors
Brushed DC Motor
Brushless DC Motor (BLDC)

2. AC motors
Induction Motor (Asynchronous Motor)
Synchronous Motor
Permanent Magnet Synchronous Motor (PMSM)
Reluctance Motor
Hysteresis Motor
 Presentation
3-Phase
Induction Motor
 Component
Stator - Made by Silicon
- Dept 0.025 in.
- Coating with Varnish

Rotor - Made by Silicon

- Polyester
Rotating magnetic field of Stator
An electric current is passed through the stator to create a rotating magnetic field around
the stator.
Current ?

A rotating magnetic field cuts through the copper coils wrapped around the rotor.
This will induce an EMF to occur in the coil.
The EMF that occurs will cause an electric current in the coil.
Rotating magnetic field of Rotor
When current flows through the coil, it will cause The magnetic field rotates at the Rotor.
The speed of the magnetic field rotates at the Rotor is called Rotor Speed.
 Rotation of Rotor ?

When the rotating magnetic field at the Stator and Rotor interact with each other, it will
cause the rotor to rotate according to the speed of the rotating magnetic field at the Rotor.
 Faraday's Law states

“If there is a change in magnetic

flux through a coil of conductor,
There will be an induced
electromotive force occurring in
coil of conductor”

Michael Faraday
Slip ?

The difference between Synchonous Speed ​and Rotor Speed ​is called Slip.
Squirrel Cage Rotor
Wound Rotor
How
PMSM
work ?
Permanent Magnet Synchronous Motor (PMSM)

The operating principle of a PMSM at synchronous speed

Permanent Magnet Synchronous Motor (PMSM)

45° angle of rotor produce maximum torque

Back EMF (Electromotive Force)
 Types of PMSM

There are two types of Permanent Magnet Synchronous Motor (PMSM) : Surface Permanent Magnet
Synchronous Motor (SPMSM) and Interior Permanent Magnet Synchronous Motor (IPMSM)
Surface Permanent Magnet Synchronous Motor

SPMSM (Surface Permanent Magnet Synchronous Motor)

Interior Permanent Magnet Synchronous Motor

IPMSM (Interior Permanent Magnet Synchronous Motor)

Internal Permanent Magnet Synchronous Reluctance Motor

IPMSynRM (Internal Permanent Magnet Synchronous Reluctance Motor)

 Synchronous Reluctance Motor

High Reluctance State Low Reluctance State

MANUFACTURING
Electric Motor Design

Design analysis : Engineers begin by analyzing

the specific requirements of the motor, such as
power output, torque, speed.

Selection of design parameters : Important

parameters such as stator and rotor size, magnetic
flux density.
Electric Motor Parts
Stator Core Lamination

Silicon Sheet
Stator Core Lamination : The main material used in the production of the stator is silicon steel, a
low-magnetic steel that reduces energy loss from eddy currents.
Pros of using lamination

Stator Core Lamination

• Reduced energy loss

• Reduced heat
• Increased durability
Stator Core Lamination

Stator Core and Rotor Lamination

Production starts with cutting the steel sheets into small thin layers (lamination) and stacking them
together to form a cylinder or other specific shape.
Why is winding Configuration important?

Create a magnetic field

Determine efficiency
Customize performance
Type Of Winding

Distributed Concentrated
Winding Winding
Distributed Winding

Distributed winding is the process of winding the coils in multiple slots around the stator, which
results in a more uniform distribution of the magnetic field to multiple locations around the stator.
Concentrated Winding

Concentric winding involves winding multiple turns of a coil in a single slot or adjacent slots in the stator. The coils
are positioned where the magnetic field is most concentrated in the motor core, creating a clear but limited
distribution of the magnetic field.
Varnish Process
วาร์นิช (varnish)

The varnish used to coat electric motors is usually made from a material called an insulator, which is specially designed to
withstand the harsh conditions inside the motor, such as high heat, humidity, and various chemicals.
Stator Manufacturing
ROTOR

The rotor is the rotating part of an electric motor that produces torque by rotating in the magnetic field generated by the
stator. It is divided into two main types : the squirrel cage rotor structure and the permanent magnet rotor structure.
ROTOR
Rotor Lamination

The rotor core part is made by cutting silicon steel sheets into thin pieces, similar to making a stator,
and then stacked to obtain the required thickness.
Squirrel Cage Rotor

The squirrel cage rotor manufacturing system is different in the casting of the conductor by the squirrel cage rotor.
Permanent Magnet Rotor

Permanent magnet rotor manufacturing system in the conductive part with permanent magnet installation
Motor Housing Manufacturing

Motor housing serve to protect the internal motor components, such as the rotor, stator, and drive unit, from
external environmental conditions such as moisture, dust, and shock. Motor housing also serve as a supporting
structure for the motor components and assist in heat dissipation.
Motor assembly and quality control

The stator and rotor are assembled using highly

automated processes such as installing bearings
and connecting the drive system.

Motors are tested under conditions that simulate real use

to measure their durability against continuous operation.
This testing also includes analysis of heat generation and
heat dissipation in
Motor control system

https://my.ku.th/

How the motor is

controlled
For BLDC and PMSM Motor.
 Control syst Overview

System Components

Main Components in control system:

Controller Inverter Battery Motor

manage speed and torque DC to AC conversion for
Optimizes regenerative driving mode
braking AC to DC conversion for
Safety and Protection regenerative braking
Manages power flow
 Control syst Overview

Simplify system operation

How an Electric Vehicle Accelerate

1 2 3

Controller Inverter Motor

Recieve input from acceleration convert DC current from battery Starts turning, and the vehicle
paddle position using position to AC current for motor base on moves forward.
sensor. controller command.
 Control syst Overview

Simplify system operation

How an Electric Vehicle Decelerate

1 2 3

Controller Motor Inverter

Detect if acceleration paddle is Act as an alternator to invert convert AC current from motor
released. kinetic energy to electrical to DC current to recharge
power. battery
 control stst Overview Commutation

how dc current convert to ac current

Why BLDC and AC need

controller
In electric vehicles, the operation of BLDC and AC motors is quite similar, as
both require AC current input. Current commutation is crucial for operating
the motor and is managed by the collaboration of the controller and inverter.

control methods:
Trapezoidal (Six-step)
Sinusoidal Occur in Inverter
Field oriented control (FOC)
 control stst Overview Commutation

how dc current convert to ac current

BLDC operation:

Adjust speed of vehicle by adjust frequency

Adjust torque by increase current
 control stst Overview Commutation

how dc current convert to ac current

Trapezoidal control:
Advantages
Constant magnetic
flux
Simplest
Cheapest

Disadvantages
Torque Ripple

*** 2 teminal is excite (opposite polarity) ***

and 1 remain is neutral
control stst Overview Commutation

how dc current convert to ac current

Trapezoidal: 1 2 3

N N

3
S N
S S

4 5 6

S
S

N N N S

1 2 3 4 5 6
control stst Overview Commutation

how dc current convert to ac current

Sinusoidal control:
Advantages
Variable magnetic
flux
Smoother operation
Low torque ripple

Disadvantages
Complexity
Switching loss
control stst Overview Commutation

how dc current convert to ac current

Sinusoidal control:

PWM technique is applied in sinusoidal control which generate smoother current

curve compared to trapezoidal control
 control stst Overview Commutation

how dc current convert to ac current

Field oriented control:

Advantages
Lowest noise
Smoothest operation
Maximum motor efficiency

Disadvantages
Computation complexity
Switching loss
Coding experience needed
 control stst Overview Commutation

how dc current convert to ac current

Field oriented control:

What is FOC
FOC is motor control method that allows more precise control of motor torque and speed by
controlling the stator currents in such a way that the motor’s magnetic field is aligned with the rotor’s
magnetic field
 control stst Overview Commutation

how dc current convert to ac current

Matching control metod:

Why do we need sensors?

- Knowing rotor positions is very crucial for more effective motor control and more optimal torque for an
output. By using sensor is like a feedback for control system which these sensors will provide rotor position for
the system.
control stst Overview Commutation Sensor

Sensor

Hall Sensor
control stst Overview Commutation Sensor

Sensor

Resolver Sensor
The Resolver Sensor measures angular
position using rotor windings to send an AC
signal to the stator windings, converting the
voltage into positional data. It is ideal for
electric vehicles and automated systems
requiring high precision and vibration
resistance.
control stst Overview Commutation Sensor

Sensor

Resolver Sensor
control stst Overview Commutation Sensor

Sensor

Resolver Sensor
0

270 90

180
control stst Overview Commutation Sensor

Sensor

Optical Encoder
The Encoder Sensor converts the rotor’s rotation into
digital signals by counting pulses from a patterned
disk. As the disk rotates, it passes through a light
sensor, generating signals that can be calculated into
the position. This sensor is commonly used in electric
vehicles due to its high accuracy.
control stst Overview Commutation Sensor

Sensor

Optical Encoder

EX;

Optical Encoder generates 1000 pulses per 360-

degree rotation, counting the pulses indicates the
rotor’s position. If 250 pulses are counted, the rotor
has rotated 90 degrees.
 control stst Overview Commutation Sensor

Sensor vs Sensorless

Sensor vs Sensorless

NO SENSOR

Advantages: Disadvantages: Advantages: Disadvantages:

High Accuracy High Cost Reduced Cost Lower Accuracy
Immediate Response Complex Installation Simpler Design Slower Response
 control stst Overview Mortor controlling

how dc current convert to ac current

Motor controlling overview

Regenerative Braking
Regenerative braking is a technology used in electric and
hybrid vehicles that allows them to recover energy during
braking. Instead of wasting the kinetic energy as heat (as in
conventional braking systems), regenerative braking
converts that energy back into electrical energy, which can
then be stored in the vehicle's battery for later use.

Related Hardwares
Inverter
Traction motor controller
Traction motor
HV Battery
control stst Overview Mortor controlling

how dc current convert to ac current

control stst Overview Mortor controlling

how dc current convert to ac current

oscilloscope
control stst Overview Mortor controlling

how dc current convert to ac current

control stst Overview Mortor controlling

how dc current convert to ac current

 control stst Overview Mortor controlling

how dc current convert to ac current

WHAT IS INVERTER?

= +

IGBT Mosfet +
Inverter
Transistor
Insulated-gate
bipolar transistor
control stst Overview Mortor controlling

how dc current convert to ac current

control stst Overview Mortor controlling

how dc current convert to ac current

control stst Overview Mortor controlling

how dc current convert to ac current

control stst Overview Mortor controlling

how dc current convert to ac current

 control stst Overview Mortor controlling

how dc current convert to ac current

Motor:
Converts electrical energy into mechanical energy.
Electrical energy is fed into the motor, resulting in the
generation of rotational force or motion.

Stator: The stationary part that generates a magnetic field.

Rotor: The rotating part that produces mechanical motion.

Generator:
Converts mechanical energy into electrical energy.
Mechanical energy (from a turbine, engine, or other sources) is fed into the generator, resulting
in the generation of electrical power.

Stator: The stationary part where the electrical current is induced.

Rotor: The rotating part that moves through the magnetic field.
control stst Overview Mortor controlling

how dc current convert to ac current

Motors and Generators are Reversible: In some

contexts, motors and generators can be interchangeable
depending on their operation. For example, in a
regenerative braking system, an electric motor can
function as a generator to convert kinetic energy back
into electrical energy. However, in typical applications, a
motor is used to drive mechanical loads, while a
generator is used to produce electrical power.
 control stst Overview Mortor controlling

how dc current convert to ac current

WHAT IS INVERTER?

RECTIFIER
A rectifier is an electrical device that converts alternating current (AC)
to direct current (DC). This process is essential for powering DC
devices and charging batteries. Rectifiers can be found in various forms
 control stst Overview Mortor controlling

how dc current convert to ac current

WHAT IS INVERTER?

DC TO DC transformer
A "DC to DC transformer" generally refers to a DC-DC converter, which is
a device that changes the voltage level of direct current (DC) electricity.
Unlike traditional transformers that work with alternating current (AC),
DC-DC converters manipulate DC voltage in various ways.
control stst Overview Mortor controlling

how dc current convert to ac current

an induction motor you supply the input energy to the stator coils when
energized the coils produce a rotating magnetic field the RMF drives the
rotor which creates torque and allows the motor to drive the load in an
induction motor the speed of the rotor is always less than the RMF speed
please note down the direction of current induced in the rotor bars in this
case you can easily see here that the driving force on the rotor is in the
same direction of the rotor rotation
control stst Overview Mortor controlling

how dc current convert to ac current

what if you can reverse this condition meaning if the RMF speed is
lesser than the rotor speed in this case the direction of the induced
current in the rotor bars will flip this also means that the force
acting on the rotor suddenly flips to the opposite direction and
the rotor slows down this is why you feel automatic brakingaction
when you remove your foot fromthe accelerator pedal
control stst Overview Mortor controlling

how dc current convert to ac current

 Front Motor

The front motor is installed on the front axle, usually located in the front engine bay, which was previously used for
combustion engines in conventional vehicles and is used in front-wheel-drive (FWD) systems.
 Rear Motor

The rear motor is typically installed on the rear axle of the vehicle, located under the trunk, and is used in rear-wheel-drive (RWD)
systems, which are suitable for performance-focused driving with improved acceleration and responsiveness.
 Dual Motor

A dual motor setup features one motor on the front axle and another on the rear axle for all-wheel-drive (AWD) systems. This allows for precise
torque distribution to both front and rear wheels based on road conditions or driving situations, enhancing performance in various driving
scenarios.
 In-Wheel Motor

In-wheel motors are installed directly in each wheel of the vehicle, with each wheel having its own motor. This setup is commonly used
in vehicles that require precise torque control at each wheel, often found in all-wheel-drive (AWD) systems.
Cooling Systems
AIR COOLING

Passive air cooling relies on natural airflow to cool the motor without
fans. Heat dissipates through convection, where hot air rises and
cooler air replaces it, aided by features like cooling fins to increase
surface area.

Active air cooling works by using a fan or forced airflow to cool the
motor's components, such as the stator and rotor. This system is
more effective than natural convection and is ideal for motors that
require rapid heat dissipation under heavy loads.
AIR COOLING

Internal air circulation within the motor occurs through blades mounted directly
on the rotor, or in closed motors, using blades on the shaft. This helps to cool
the stator windings, rotor windings, and drive-end bearings. Research focuses
on designing air ducts in the rotor and stator structure to enhance heat transfer
and lower the motor’s operating temperature. Optimizing the geometry of air
ducts can further improve cooling efficiency, making the motor operate more
reliably and reducing thermal loads.
AIR COOLING

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LIQUID COOLING
LIQUID COOLING

The water pump in a liquid cooling system circulates coolant

through pipes connected to components like the electric motor and
battery. The coolant absorbs heat from these parts and transfers it
to the radiator, where the heat is dissipated. Once cooled, the
coolant is pumped back into the system to continue the cycle. This
process helps maintain optimal operating temperatures for the
motor and battery, ensuring efficient performance.

water Pump
LIQUID COOLING
How to water pump work ?

Temperature Sensor ECU water pump

1. Temperature Detection: Temperature sensors and flow sensors detect the coolant’s temperature and flow rate.
2. Data Processing: Sensor data is sent to the ECU (Electronic Control Unit) for processing.
3. Pump Activation: If the temperature exceeds a set threshold, the ECU activates the water pump
4. Coolant Circulation: The water pump circulates coolant through the pipes to areas that require cooling.
5. Continuous Monitoring: The pump continues operating until the temperature drops back to the normal range.
LIQUID COOLING

The Cooling Valve Actuator (CoVA) in a liquid cooling system controls the
flow of coolant by adjusting valves to regulate the amount of coolant directed
to various components, such as the motor and battery. It receives signals
from temperature sensors and adjusts the valve opening to maintain optimal
temperatures. By managing the flow rate based on cooling needs, CoVA
ensures efficient thermal management, preventing overheating while
improving energy efficiency in the system.

Cooling Valve Actuator (CoVA)

LIQUID COOLING

The cooling system of an electric motor using liquid injection into the
internal structure consists of six main points:

1. Housing jacket: Circulates coolant around the motor's housing to

manage heat.
2. Stator cooler: Cools the stator windings.
3. Coolant outlet: Releases heat by circulating the coolant out of the
motor.
4. Cooling system of the shaft: Dissipates heat from the motor shaft.
5. Liquid injection using ring systems: Injects coolant around the
shaft via a ring system.
6. Liquid injection nozzle: Injects coolant into the motor system
through the nozzle.
LIQUID COOLING

Liquid cooling method

1. Coolant enters through the Coolant Entry.
2. It circulates around the Stator and Rotor, absorbing heat generated during operation.
3. The system uses Cooling Jackets to channel the coolant, facilitating heat exchange.
4. Once the coolant absorbs the heat, it flows out through the Coolant Exit.
5. The heated coolant is then directed to a radiator or external cooling system to release the
absorbed heat before re-entering the cycle.

In liquid cooling systems, coolant typically flows around and through

channels in the stator, rotor, and sometimes the shaft. For this particular
system, that coolant passes through or around the rotor (where heat is
concentrated) as well as around the shaft to dissipate heat efficiently.

Drive Shaft and Rotor

LIQUID COOLING

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Tesla Model 3

Radiator
LIQUID COOLING

Porsche Taycan Audi e-tron GT