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Performance Analysis of Electric Motors Using Vibration Measurement

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• Vehicle Technologies Office
• About the Vehicle Technologies Office
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The Vehicle Technologies Office (VTO) is supporting research and development (R&D) to improve  motors in hybrid and plug-in electric vehicles, with a particular focus on reducing the use of rare earth materials currently used for permanent magnet-based motors.

In an electric drive system, an electric motor converts the stored electrical energy in a battery to mechanical energy. Electric motors consist of a rotor (the moving part of the motor) and a stator (the stationary part of the motor). A permanent magnet motor includes a rotor containing a series of magnets and a current-carrying stator (typically taking the form of an iron ring), separated by an air gap. There are three types of electric motors that can be used in hybrid or plug-in electric vehicle traction drive systems.

• Internal permanent magnet (IPM) motors have high power density and maintain high efficiency over a high percentage of their operating range. Almost all hybrid and plug-in electric vehicles use rare earth permanent magnets in their traction motors. Because of the high costs of magnets and rotor fabrication, these motors are relatively expensive. Other challenges to using IPM motors include the limited availability and high cost of rare earth magnetic materials. Despite the challenges, the automotive industry anticipates continuing to use IPM motors in the majority of electric drive vehicles over the next decade.
• Induction motors have high starting torque and offer high reliability. However, their power density and overall efficiency are lower than that of IPM motors. They are widely available and common in various industries today, including some production vehicles. Because this motor technology is mature, it is unlikely research could achieve additional improvements in efficiency, cost, weight, and volume for competitive future electric vehicles.
• Switched reluctance motors offer a lower cost option that can be easy to manufacture. They also have a rugged structure that can tolerate high temperatures and speeds. However, they produce more noise and vibration than comparable motor designs, which is a major challenge for use in vehicles. Also, switched reluctance motors are less efficient than other motor types, and require additional sensors and complex motor controllers that increase the overall cost of the electric drive system.

VTO Electric Motor R&D

VTO's primary goal is to decrease electric motors' cost, volume, and weight while maintaining or increasing performance, efficiency, and reliability. To meet 2022 cost targets, research must reduce the cost of the motor by 50%.

To achieve these goals, VTO and its partners are examining many research avenues:

• The Beyond Rare Earth Magnets (BREM) R&D project led by Ames Laboratory is investigating lower-cost permanent magnets and magnetic materials. This effort is closely coordinated with the Critical Materials Institute also led by Ames Laboratory .
• Oak Ridge National Laboratory and industry projects are pursuing reduced rare-earth magnet motors, non-permanent magnet motor designs, and innovative motor materials and designs.
• The National Renewable Energy Laboratory is focusing research on improving electric motor thermal management, performance and reliability.

Identification of failure modes in interior permanent magnet synchronous motor under accelerated life test based on dual sensor architecture

• Original Article
• Published: 12 April 2024

Cite this article

• Sikgyeong Choi 1 ,
• Jaewook Oh 1 ,
• Juho Lee 1 ,
• Woyeong Kwon 1 ,
• Jeonghae Lee 1 ,
• Inhyeok Hwang 1 ,
• Jongbum Park 2 &
• Namsu Kim   ORCID: orcid.org/0000-0002-9341-4995 1  

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Recently, the permanent magnet synchronous motors (PMSMs) are considered to be one of the best options for electrical motor due to their high power density and efficiency for various applications including industrial robot and smart mobility. However, the safety and reliability of the PMSM have not been verified sufficiently when compared to the conventional induction motor. The failure of electric motor can lead to catastrophic failure of entire system, so it is important to detect potential failure modes or signs in advance. In this paper, an accelerated life test was carried out to induce and investigate the failure modes of PMSM and various signals were monitored to detect the types of failure modes during the test. The shaft of the motor was radially loaded to accelerate the failure of PMSM. The phase current, temperature, displacement of the shaft, and vibration were monitored to estimate the health state of the motor. As a result, the bearing and the shaft were the most vulnerable components under radially loaded condition. Also, it is proved that the different failure modes can be successfully detected and classified by monitoring the phase current and vibration signal.

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Acknowledgements

This work was supported by Korea Research Institute for defense Technology planning and advancement(KRIT)—Grant funded by Defense Acquisition Program Administration (DAPA) (KRIT-CT-22-081, Weapon System CBM+ Research Center). This paper was supported by Konkuk University Researcher Fund in 2022”

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Sikgyeong Choi, Jaewook Oh, Juho Lee, Woyeong Kwon, Jeonghae Lee, Inhyeok Hwang & Namsu Kim

Intelligent Robotics Research Center, Korea Electronics Technology Institute (KETI), Bucheon, Republic of Korea

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Choi, S., Oh, J., Lee, J. et al. Identification of failure modes in interior permanent magnet synchronous motor under accelerated life test based on dual sensor architecture. J. Power Electron. (2024). https://doi.org/10.1007/s43236-024-00810-8

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Received : 10 August 2023

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Accepted : 20 March 2024

Published : 12 April 2024

DOI : https://doi.org/10.1007/s43236-024-00810-8

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Russia pins hopes on electric future as carmakers continue exodus

By Automotive Logistics 2022-10-31T17:18:00+00:00

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Russia is hoping to salvage its automotive sector by pumping billions in investment into electric vehicle (EV) production, rather than trying to rescue production of combustion-engine vehicles at the car plants left redundant by western carmakers who are leaving the country en masse .

State-owned carmakers have struggled to source the volume of components needed to continue production from countries such as China or Turkey, or through parallel import schemes, as sanctions continue to bite.

Mercedes-Benz said it was selling its industrial and financial services subsidiaries to Avtodom, a Russian auto dealership chain

Last week Mercedes-Benz and Ford became the latest carmakers to announce they were ending their business connections in Russia, joining a growing number of automotive companies exiting the country since Russia invaded Ukraine.

Mercedes-Benz announced it was selling its industrial and financial services subsidiaries to Avtodom, a Russian auto dealership chain. Ford also said it had finalised the exit of its previously suspended operations in Russia through the sale of its 49% share in the Sollers-Ford joint venture. Both carmakers suspended production back in March this year after Russia’s invasion of its neighbour.

In September, Toyota and Nissan also ended their relationships with the Russian market, selling their stakes in local branches.

A source in the Russian automotive industry, who wished to remain anonymous, said Russian authorities were turning to EV production after realising there is no way domestic producers of internal-combustion engine (ICE) vehicles can breathe life back into the increasing number of shuttered automotive plants.

“The Industry and Trade Ministry estimated that establishing EV production is easier than localising conventional vehicle assembly,” said the source. “It takes fewer components and this market is less competitive so far.”

The source added that despite having some rationale behind it, the plan is based on populism and “doomed for failure”. In 2021 Russian consumers bought 2,200 EVs. 

Rosatom and Avotor Despite that negative prediction there have been a raft of formidable production announcements of late.

On October 14, Russian state-owned company Rosatom said it had started construction on Russia’s first plant for the production of lithium-ion batteries. The investment in the facility is reported to be close to 26 billion roubles ($450m).

The battery plant will begin with installed annual capacity for 50,000 batteries, with the potential to ramp up output to between 120,000-130,000 units per year.

Albert Karimov, Russia’s deputy minister for trade and industry, said that Kaliningrad-based Avtotor is seen as the key customer for the Rosatom plant.

In September 2022, Avtotor announced plans to invest 32 billion roubles ($550m) in establishing infrastructure for EV production in Russia, including building several electric engine factories. The company plans to convert some production capacities to release the first EVs in 2023. 

The announcement followed Avtotor being forced to suspend the assembly of BMW vehicles when the German carmaker pulled out of the Russian market in March. In September, it was also forced to stop contract production of Hyundai and Kia vehicles when it ran out of assembly kits and automotive components, the supply of which had stopped a few months earlier. 

In 2021, Avtotor produced 177,000 finished vehicles, 13% up from the previous year. Investing in vehicle production to get anywhere near that figure now is seen as a strategic task on a national scale, according to Alexander Sokolov, general director of Avtotor.

AvtoTor is investing to reconfigure its assembly plants to make electric vehicles

Sokolov said securing independent vehicle production was a critical undertaking in the current political environment. “From this point of view, developing EVs and the production of our own components is of the utmost importance,” he said.

Evolute and Moskvitch Motor-Invest has also launched production of EVs under the Evolute brand in the western Lipetsk region of Russia. By the end of the year, Motor-Invest plans to deliver the iJoy crossover and the iVan minivan for sale. In total, by the end of the year, the company intends to produce 2,000 EVs and to grow that in the new year.

In addition, Moscow City plans to launch EV production under the old Soviet brand Moskvitch, alongside ICE production , at the former Renault plant in Moscow, which was nationalised in May when Renault cut ties with the plant and sold all of its shares to Moscow City. Plans to make ICE vehicles there under that brand appear to have failed. 

Dmitry Pronin, the new general director of the plant, disclosed that in 2023 it would manufacture 50,000 vehicles, including 10,000 EVs. In 2024, these figures are set to grow to 100,000 and 20,000, respectively.

Binary market Despite these plans, the Russian news outlet Avtovzglyad , citing several market analysts, recently reported that Russian automotive plants are likely to crumble, as national demand slumps to 600,000 vehicles from 1.6m in 2021. In 2023, sales are projected to bounce back slightly to 650,000 units.

Assuming that all foreign carmakers, except the Chinese-owned brands, will eventually sever their ties with Russia, as many as ten ownerless vehicle plants will remain in the country. According to the analysts cited by Avtovzglyad , those plants could only hope to compete for production of 150,000 units a year, and “no sane businessman, even from friendly China, would invest in localising any production in Russia under these circumstances.”

“For some time, all these factories will stand idle and even turn into warehouses, or they will be stupidly plundered and we will only be left with [Russian carmakers] Avtovaz and UAZ,” said Avtovzglyad .

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Cooler transformers could help electric grid

Stampede2 simulations model transformer hot-spot temperature reductions.

Most people do not give the U.S. electric grid a second thought -- we flip a switch and the lights come on. Behind the scenes are thousands of power plants and utilities linked by millions of miles of transmission lines. And to make raw electricity useful, grid transformers convert high voltage to lower voltage that millions of households can plug into.

Transformers are aging and approaching an average of being 30 to 40 years old. Plus, they face more stress than ever before brought on by factors such as renewable energy and by extreme weather events such as hurricanes, heat waves, and winter storms. Case in point -- the 2021 event in Texas that left millions powerless.

That is when University of Texas at Austin (UT Austin) researchers decided to look inside grid transformers to see if they could make them better. Grid transformers are filled with copper windings, other metallic components, and cellulose-based electrical insulation like kraft paper. The cellulose insulation is a great electrical insulator essential in the process of 'stepping down' voltage, but it also traps heat, which can lead to overheating.

"We've researched a new class of nanomaterials where we take conventional cellulose-based paper and dope it with high thermal conductivity nanometer and micrometer-sized particles," said Vaibhav Bahadur, an associate professor in the Cockrell School of Engineering, UT Austin. Bahadur is the corresponding author of a study that modeled the impact of high thermal conductivity paper on the performance and life of grid transformers published March 2024 in Cell Press journal Heliyon . This is the first study that predicts the extent to which tuning the thermal conductivity of paper can enhance transformer life.

Simulations on the Stampede2 supercomputer of the Texas Advanced Computing Center (TACC) helped Bahadur and his collaborators engineer solutions to overheat of grid transformers -- a critical component of the electric grid.

Collaborators at the University of Maryland and the USDA Forest Products Laboratory fabricated the high thermal conductivity paper using nanoparticles of boron nitride. Bahadur's lab built a 3D model of the transformer to mimic an actual grid transformer taken apart and studied by study co-author Robert Hebner, also in the Cockrell School of Engineering.

"The experimental part of the study was critical in testing whether to invest in improving the transformer installation," Hebner said. "We had a transformer donated to The Center for Electromechanics, which was powered by UT Austin's one megawatt micro grid. We could connect it and run the temperatures up and down, and we could measure how the transformer behaved. The model and the measurements meshed very well," Hebner said.

"Our results indicate that if the thermal conductivity is increased by a few times using the engineered paper, the hotspot temperature inside a transformer can be reduced by between 5 to 10 °C," he added. "In most conditions that should be enough to double or triple the life of the transformer."

The Bahadur Research Group was awarded allocations on TACC's Stampede2 supercomputer, a National Science Foundation-funded computational workhorse for UT Austin researchers and thousands of other researchers in the U.S. open science community.

"This model was simulated using TACC resources to predict the thermal performance," Bahadur said. "We modeled the thermal conductivity as a varying parameter, and we figured out the extent of improvement needed in thermal conductivity to see a meaningful temperature reduction."

The main computational challenge was the shear immensity of modeling the details inside an actual transformer.

"To accurately estimate temperatures, we used a fine-sized mesh based on finite element methods and modeled the conduction through the diffusion heat transfer equation -- the computational costs are high in doing so," Bahadur said. "The main reason we used Stampede2 was to get simulations done in a matter of minutes/hours and not wait for days to get our results."

Next, the researchers will test a small-scale transformer prototype and add the thermal conducting paper to study how it behaves in an operating environment with fluctuating loads.

This research has the possibility to find applications in the real world, where new transformers could be made with improved nano and micro particle enhanced thermal insulating paper. Old transformers could be retrofitted with the new paper during routine refurbishment.

"We started not as a transformer project, but as a semiconductor project. This research aims to take a lot of the electronic devices that we have and make them operate better by operating cooler and more efficiently," Hebner added.

• Electricity
• Energy Technology
• Spintronics
• Nanotechnology
• Inorganic Chemistry
• Thermodynamics
• Distributed generation
• Engineering
• Battery electric vehicle
• Electric power
• Solar power
• Three-phase electric power

Story Source:

Materials provided by University of Texas at Austin . Original written by Jorge Salazar. Note: Content may be edited for style and length.

Journal Reference :

• S. Bilyaz, A. Bhati, M. Hamalian, K. Maynor, T. Soori, A. Gattozzi, C. Penney, D. Weeks, Y. Xu, L. Hu, J.Y. Zhu, J.K. Nelson, R. Hebner, V. Bahadur. Modeling the impact of high thermal conductivity paper on the performance and life of power transformers . Heliyon , 2024; 10 (6): e27783 DOI: 10.1016/j.heliyon.2024.e27783

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Fatal Traffic Risks With a Total Solar Eclipse in the US

• 1 Department of Medicine, University of Toronto, Toronto, Ontario, Canada
• 2 Evaluative Clinical Science Platform, Sunnybrook Research Institute, Toronto, Ontario, Canada
• 3 Institute for Clinical Evaluative Sciences, Toronto, Ontario, Canada
• 4 Division of General Internal Medicine, Sunnybrook Health Sciences Centre, Toronto, Ontario, Canada
• 5 Center for Leading Injury Prevention Practice Education & Research, Toronto, Ontario, Canada
• 6 Department of Medicine, University of British Columbia, Vancouver, British Columbia, Canada
• 7 Centre for Clinical Epidemiology & Evaluation, University of British Columbia, Vancouver, British Columbia, Canada

A total solar eclipse occurs when the moon temporarily obscures the sun and casts a dark shadow across the earth. This astronomical spectacle has been described for more than 3 millennia and can be predicted with high precision. Eclipse-related solar retinopathy (vision loss from staring at the sun) is an established medical complication; however, other medical outcomes have received little attention. 1

Read More About

Redelmeier DA , Staples JA. Fatal Traffic Risks With a Total Solar Eclipse in the US. JAMA Intern Med. Published online March 25, 2024. doi:10.1001/jamainternmed.2023.5234

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