Motor Drive Design for a Battery Electric Vehicle (BEV)

This poster describes a novel BEV motor drive which accommodates fluctuations found in normal driving conditions.A BEV is in testing phase at the University of Arkansas -Fort Smith (UAFS) using a Baldor H2 1 drive and a 5-speed transmission.This H2 drive is designed for conveyor belts and air handling applications.The H2 drive disables when speed/torque demands abruptly change due to acceleration, hill climbing, and shifting gears.These abrupt increases in load current and rapid decreases in speed disable the H2 drive for 90 s.The process of designing/constructing a drive to replace the H2 started Fall 2012; this drive will operate with a 380 V bus voltage while supplying 160 A for 20 s and 220 A for 3 s.Currently, a 1 st generation BEV motor drive has been successfully tested with a 100 V bus.Tests conducted at a 380 V bus voltage have shown limited success; unexpected heating has occurred, leading to thermal runaway.Plans have been made to address this issue with a new 380 to 18 V DC/DC converter needed for IGBT drivers and adding liquid cooling.This project built a bridge between local business and UAFS in motor development and specialized powertrain parts as ABB Baldor has donated an H2 drive and designed/built a customized BEV motor.ADKO and REEM/RUUD have also contributed machine shop services.It has connected students with practicing engineers to share knowledge/experience.