Silicon Mobility with Cascadia Motion Shows Up to 4.6% Improvements in Motor and Inverter Efficiency with Advanced Control

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HVIC 2.1 card with OLEA® FPCU T222 mounted on a PM100 inverter

“The results of this work indicate a convincing improvement in motor and inverter efficiency. This makes an IGBT based inverter more competitive compared to an SiC inverter – without the added cost. says Larry Rinehart, director of advanced engineering, Cascadia Motion.

Silicon mobility, a provider of digital control solutions for EV / HEV electrified powertrain, shows 2% to 4.6% efficiency improvements of inverter and electric motor, compared to SVPWM control technique industry standard, using its smarter control.

At the 34th International Electric Vehicle Symposium – EVS34 -, Silicon Mobility in cooperation with Cascadia Motion presented its latest research and development results. In one academic document presented at one of the EVS34 conference sessions, Silicon Mobility demonstrates the use of Optimized Pulse Pattern Modulation (OPP) to increase the efficiency of inverter and permanent magnet synchronous motor (PMSM) by reducing switching losses in the inverter as well as copper and iron losses in the electric motor.

The OPP algorithm was implemented using Silicon Mobility’s high performance OLEA® T222 field programmable control unit, dedicated to advanced and secure real-time control of power conversion in the powertrain. electric. The efficiency of the resulting system was measured on a high voltage bench using a Cascadia Motion PM100 IGBT Based Inverter and a BorgWarner Production electric motor HVH250. System efficiency is compared to industry standard SVPWM modulation using comparable Field Oriented Control (FOC) at 8 operating points representing actual driving loads. As a result, the combined losses of the motor and inverter systems were reduced from 2% to 4.6% using the OPP depending on the operating conditions of the motor.

Advanced software in an advanced integrated circuit

The range of an EV is strongly affected by the efficiency of its powertrain. The energy stored in the battery must be converted into vehicle motion while losing as little energy as possible (resulting in waste heat) in the inverter and motor. While many developments aim to improve the battery as a primary energy storage and use more efficient broadband power devices, Silicon Mobility is focusing on further efficiency optimizations using solutions of advanced control with innovative integrated circuit and software.

Today, Silicon Mobility is capable, thanks to advanced control algorithms using the power of OLEA® FPCU chip, to greatly reduce energy loss and consequently improve the efficiency of the electric inverter / motor of electric powertrains.

The heart of the highly innovative patented solution lies in the dedicated architecture of the OLEA® FPCU (Field Programmable Control Unit), which enables superior control performance for the electric powertrain. Using programmable hardware acceleration for time-critical control loops, depending on engine operating conditions, the OLEA® FPCU can apply different types of modulation techniques to provide the optimum modulation for the target set point. In addition to Space Vector PWM (SVPWM), the FPCU supports flexible implementation of generic angle-based pulse control (APC) modulations. One example is Optimized Pulse Models (OPP), a modulation technique that relies on a set of precisely applied switching (pulse) models that are pre-calculated offline to optimize the behavior of the motor and drive system. Its main objective is to shape the harmonic signature of the control current in order to reduce iron and copper losses depending on the operating conditions of the motor.

The published article explains and illustrates in detail how APC modulation correctly performs OPP, how a multi-criteria pattern generation tool with scoring and constraints was developed, details of the measurement protocol and results.

Result: Up to 4.6% improvement in efficiency

  • The actual driving points selected are less than 50Nm in the low efficiency region of the map.
  • All the measurements were carried out in a closed loop at the same average temperature for the inverter and the electric motor.
  • The efficiency of the system is increased from 2% to 4.6% on these points.
  • Electric motor and inverter loss reduction ranges from 87W to 1230W.
  • 3 types of patterns provided the best results (Ri2, Ripple & THD).

“Any improvement in the efficiency of the propulsion system (motor + inverter) is good, because the improvement in the efficiency of the motor and the inverter allows a lower cooling system demand and a better range of the vehicle. Says Larry Rinehart, director of advanced engineering, Cascadia Motion. “The results of this work indicate a convincing improvement in motor and inverter efficiency. This makes an IGBT based inverter more competitive compared to an SiC inverter – without the added cost.

“OPP modulation supports the same objectives as the adjacent work on new power transistor technologies (GaN, SiC), advanced inverter system architecture (multi-stage, multi-level) and advanced strategies torque, current and magnetic flux control as a model Predictive control or AI-based control, ”said Khaled Douzane, vice president of products at Silicon Mobility. “They all aim to produce better fuel efficiency for the EV / HEV transmission. And since the physical approaches to improving efficiency are different, their practical benefits from each will mainly add up. “

Available immediately

To date, OLEA® FPCU is the only automotive-qualified system-on-a-chip powerful enough to perform such a demanding algorithm, while ensuring ASIL D ISO 26262 level of security.

APC technology with OPP is available in INVERTER APP OLEA® HE control for OLEA® FPCU and is available for some customers.

About Silicon Mobility

Silicon Mobility is a technology leader inventor of the FPCU semiconductor architecture for ultra-fast and extremely secure real-time control. Silicon Mobility is accelerating all electric mobility transitions in the cleanest, safest, most secure and smart way. The company designs, develops and sells flexible, real-time, secure and open semiconductor solutions for the automotive industry, used to increase energy efficiency and reduce pollutant emissions while ensuring passenger safety.

Silicon Mobility’s products control electric motors, batteries, and energy management systems in hybrid and electric vehicles. By using Silicon Mobility technologies, manufacturers improve the efficiency, reduce the size, weight and cost of electric motors, and increase battery runtime and durability. Its technologies and products accelerate the electrification of the car’s powertrain for OEMs. Silicon Mobility is headquartered in Sophia-Antipolis, France, with a global presence in Germany, Silicon Valley, California, China and Japan. For more information visit: http://www.silicon-mobility.com

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