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The study aims to show the influence of selected mechanical parameters of the rotor on the maximum speed and parameters of the electric motor.

A simplified mechanical analysis of the rotor of the electric motor was conducted, determining the safety factor of the motor. An analysis of the impact of key rotor parameters (significant from the mechanical strength perspective) on the electromagnetic parameters and the safety factor of the selected high-speed electric motor was carried out. The influence of changes in the rotor’s geometrical dimensions (centrifugal force) on the electromagnetic parameters of the electric motor was shown.

The study shows the impact of changes in selected rotor parameters on electromagnetic parameters and the safety factor of a high-speed electric motor (at its required operating point of 45,000 rpm). The dependence of the safety factor as a function of the maximum motor speed was determined for the proposed rotor modifications.

The proposed modifications can be used in larger drive systems. They have practically no impact on increasing the value of the motor’s moment of inertia (they do not degrade the dynamics of the motor’s operation).

It was proposed to use a new design coefficient which is in relation to the motor’s safety coefficient. It has been shown that a minimal modification of the motor rotor allows to increase its maximum speed by several dozen per cent (while maintaining the safety factor). It has also been shown that when operating at maximum speed within the safe range, the change in the geometrical dimensions of the rotor hardly influences the change in the value of the centrifugal force.

The purpose of this study is to propose an extended reliability method for an industrial motor drive by integrating the physics of failure (PoF).

Industrial motor drive systems (IMDS) are currently expected to perform beyond the desired operating conditions to meet the demand. The PoF of the subsystem affects its reliability under such harsh operating circumstances. It is crucial to estimate reliability by integrating PoF, which helps in understanding its impact and to develop a fault-tolerant design, particularly in such an integrated drive system. An integrated PoF extended reliability method for industrial drive system is proposed to address this issue. In research, the numerical failure rate of each component of industrial drive is obtained first with the help of the MIL-HDBK-217 military handbook. Furthermore, the mathematically deduced proposed approach is modeled in the GoldSim Monte Carlo reliability workbench.

From the results, for a 15% rise in integrated PoF, the reliability and availability of the entire IMDS dropped by 23%, resulting in an impact on mean time to failure (MTTF).

The integrated PoF of the motor and motor controller affects industrial drive reliability, which falls to 0.18 with the least MTTF (2.27 years); whose overall reliability of industrial drive drops to 0.06 if it is additionally integrated with communication protocol.

Electric motor heating during biomass recovery and its handling on conveyor is a serious concern for the motor performance. Thus, the purpose of this paper is to design and develop a hardware prototype of master–slave electric motors based biomass conveyor system to use the motors under normal operating conditions without overheating.

The hardware prototype of the system used master–slave electric motors for embedded controller operated robotic arm to automatically replace conveyor motors by one another. A mixed signal based embedded controller (C8051F226DK), fully compliant with IEEE 1149.1 specifications, was used to operate the entire system. A precise temperature measurement of motor with the help of negative temperature coefficient sensor was possible due to the utilization of industry standard temperature controller (N76E003AT20). Also, a pulse width modulation based speed control was achieved for master–slave motors of biomass conveyor.

As compared to conventional energy based mains supply, the system is self-sufficient to extract more energy from solar supply with an energy increase of 11.38%. With respect to conventional energy based \ of 47.31%, solar energy based higher energy saving of 52.69% was reported. Also, the work achieved higher temperature reduction of 34.26% of the motor as compared to previous cooling options.

The proposed technique is free from air, liquid and phase-changing material based cooling materials. As a consequence, the work prevents the wastage of these materials and does not cause the risk of health hazards. Also, the motors are used with their original dimensions without facing any leakage problems.

The purpose of this article is to treat the nonlinear optimal control problem in EV traction systems which are based on 5-phase induction motors. Five-phase permanent magnet synchronous motors and five-phase asynchronous induction motors (IMs) are among the types of multiphase motors one can consider for the traction system of electric vehicles (EVs). By distributing the required power in a large number of phases, the power load of each individual phase is reduced. The cumulative rates of power in multiphase machines can be raised without stressing the connected converters. Multiphase motors are also fault tolerant because such machines remain functional even if failures affect certain phases.

A novel nonlinear optimal control approach has been developed for five-phase IMs. The dynamic model of the five-phase IM undergoes approximate linearization using Taylor series expansion and the computation of the associated Jacobian matrices. The linearization takes place at each sampling instance. For the linearized model of the motor, an H-infinity feedback controller is designed. This controller achieves the solution of the optimal control problem under model uncertainty and disturbances.

To select the feedback gains of the nonlinear optimal (H-infinity) controller, an algebraic Riccati equation has to be solved repetitively at each time-step of the control method. The global stability properties of the control loop are demonstrated through Lyapunov analysis. Under moderate conditions, the global asymptotic stability properties of the control scheme are proven. The proposed nonlinear optimal control method achieves fast and accurate tracking of reference setpoints under moderate variations of the control inputs.

Comparing to other nonlinear control methods that one could have considered for five-phase IMs, the presented nonlinear optimal (H-infinity) control approach avoids complicated state-space model transformations, is of proven global stability and its use does not require the model of the motor to be brought into a specific state-space form. The nonlinear optimal control method has clear implementation stages and moderate computational effort.

In the transportation sector, there is progressive transition to EVs. The use of five-phase IMs in EVs exhibits specific advantages, by achieving a more balanced distribution of power in the multiple phases of the motor and by providing fault tolerance. The study’s nonlinear optimal control method for five-phase IMs enables high performance for such motors and their efficient use in the traction system of EVs.

Nonlinear optimal control for five-phase IMs supports the deployment of their use in EVs. Therefore, it contributes to the net-zero objective that aims at eliminating the emission of harmful exhaust gases coming from human activities. Most known manufacturers of vehicles have shifted to the production of all-electric cars. The study’s findings can optimize the traction system of EVs thus also contributing to the growth of the EV industry.

The proposed nonlinear optimal control method is novel comparing to past attempts for solving the optimal control problem for nonlinear dynamical systems. It uses a novel approach for selecting the linearization points and a new Riccati equation for computing the feedback gains of the controller. The nonlinear optimal control method is applicable to a wider class of dynamical systems than approaches based on the solution of state-dependent Riccati equations.

Permanent magnet synchronous spherical motors can have wide use in robotics and industrial automation. They enable three-DOF omnidirectional motion of their rotor. They are suitable for several applications, such as actuation in robotics, traction in electric vehicles and use in several automation systems. Unlike conventional synchronous motors, permanent magnet synchronous spherical motors consist of a fixed inner shell, which is the stator, and a rotating outer shell, which is the rotor. Their dynamic model is multivariable and strongly nonlinear. The treatment of the associated control problem is important.

In this paper, the multivariable dynamic model of permanent magnet synchronous spherical motors is analysed, and a nonlinear optimal (H-infinity) control method is developed for it. Differential flatness properties are proven for the spherical motors’ state-space model. Next, the motors’ state-space description undergoes approximate linearization with the use of first-order Taylor series expansion and through the computation of the associated Jacobian matrices. The linearization process takes place at each sampling instance around a time-varying operating point, which is defined by the present value of the motors’ state vector and by the last sampled value of the control input vector. For the approximately linearized model of the permanent magnet synchronous spherical motors, a stabilizing H-infinity feedback controller is designed. To compute the controller’s gains, an algebraic Riccati equation has to be repetitively solved at each time-step of the control algorithm. The global stability properties of the control scheme are proven through Lyapunov analysis. Finally, the performance of the nonlinear optimal control method is compared against a flatness-based control approach implemented in successive loops.

Due to the nonlinear and multivariable structure of the state-space model of spherical motors, the solution of the associated nonlinear control problem is a nontrivial task. In this paper, a novel nonlinear optimal (H-infinity) control approach is proposed for the dynamic model of permanent magnet synchronous spherical motors. The method is based on approximate linearization of the motor’s state-space model with the use of first-order Taylor series expansion and the computation of the associated Jacobian matrices. Furthermore, the paper has introduced a different solution to the nonlinear control problem of the permanent magnet synchronous spherical motor, which is based on flatness-based control implemented in successive loops.

The presented control approaches do not exhibit any limitations, but on the contrary, they have specific advantages. In comparison to global linearization-based control schemes (such as Lie-algebra-based control), they do not make use of complicated changes of state variables (diffeomorphisms) and transformations of the system's state-space description. The computed control inputs are applied directly to the initial nonlinear state-space model of the permanent magnet spherical motor without the intervention of inverse transformations and thus without coming against the risk of singularities.

The motion control problem of spherical motors is nontrivial because of the complicated nonlinear and multivariable dynamics of these electric machines. So far, there have been several attempts to apply nonlinear feedback control to permanent magnet-synchronous spherical motors. However, due to the model’s complexity, few results exist about the associated nonlinear optimal control problem. The proposed nonlinear control methods for permanent magnet synchronous spherical motors make more efficient, precise and reliable the use of such motors in robotics, electric traction and several automation systems.

The treated research topic is central for robotic and industrial automation. Permanent magnet synchronous spherical motors are suitable for several applications, such as actuation in robotics, traction in electric vehicles and use in several automation systems. The solution of the control problem for the nonlinear dynamic model of permanent magnet synchronous spherical motors has many industrial applications and therefore contributes to economic growth and development.

The proposed nonlinear optimal control method is novel compared to past attempts to solve the optimal control problem for nonlinear dynamical systems. Unlike past approaches, in the new nonlinear optimal control method, linearization is performed around a temporary operating point, which is defined by the present value of the system's state vector and by the last sampled value of the control inputs vector and not at points that belong to the desirable trajectory (setpoints). Besides, the Riccati equation which is used for computing the feedback gains of the controller is new, and so is the global stability proof for this control method. Compared to nonlinear model predictive control, which is a popular approach for treating the optimal control problem in industry, the new nonlinear optimal (H-infinity) control scheme is of proven global stability, and the convergence of its iterative search for the optimum does not depend on initial conditions and trials with multiple sets of controller parameters. It is also noteworthy that the nonlinear optimal control method is applicable to a wider class of dynamical systems than approaches based on the solution of state dependent Riccati equations (SDRE). The SDRE approaches can be applied only to dynamical systems which can be transformed into the linear parameter varying form. Besides, the nonlinear optimal control method performs better than nonlinear optimal control schemes, which use approximation of the solution of the Hamilton–Jacobi–Bellman equation by Galerkin series expansions. Furthermore, the second control method proposed in this paper, which is flatness-based control in successive loops, is also novel and demonstrates substantial contribution to nonlinear control for robotics and industrial automation.

The purpose of this paper is to exploit the optimal performances of each magnetic material in terms of low iron losses and high saturation flux density to improve the efficiency and the power density of the selected motor.

This paper presents a study to improve the power density and efficiency of e-motors for electric traction applications with high operating speed. The studied machine is a yokeless-stator axial flux permanent magnet synchronous motor with a dual rotor. The methodology consists in using different magnetic materials for an optimal design of the stator and rotor magnetic circuits to improve the motor performance. The candidate magnetic materials, adapted to the constraints of e-mobility, are made of thin laminations of Si-Fe nonoriented grain electrical steel, Si-Fe grain-oriented electrical steel (GOES) and iron-cobalt Permendur electrical steel (Co-Fe).

The mixed GOES-Co-Fe structure allows to reach 10 kW/kg in rated power density and a high efficiency in city driving conditions. This structure allows to make the powertrain less energy consuming in the battery electric vehicles and to reduce CO₂ emissions in hybrid electric vehicles.

The originality of this study lies in the improvement of both power density and efficiency of the electric motor in automotive application by using different magnetic materials through a multiobjective optimization.

The case study has been prepared for management students/business executives to understand electric vehicle (EV) business, business environment, industry competition and strategic planning and strategy implementation.

The size of the Indian passenger vehicle market was valued at US$32.70bn in 2021; it was projected to touch US$54.84bn by 2027 with a Compound Annual Growth Rate (CAGR) of more than 9% during the period 2022–2027. The passenger vehicle industry, a part of the overall automotive industry, was expected to grow at a rapid pace, as the Indian economy was rising at the fastest rate. However, the Government of India (GoI) had put a condition on the growth scenario by mandating that 100% of vehicles produced would be EVs by 2030. Tata Motors (TaMo), a domestic player in the market, had been facing a challenging competitive environment. Although it had been incurring losses, it had successfully ventured into the EV business. TaMo had taken advantage of the first mover by creating an electric mobility business vertical to enable the company to deliver on its aspiration of providing innovative and competitive e-mobility solutions. TaMo leadership had been putting efforts to scale up the electric mobility business, thus, contributing to GoI’s plan for electric mobility. Shailesh Chandra, president of electric mobility business, had a big task in hand. He had to scale up EV production and sales despite insufficient infrastructure for charging and shortages of electronic components for manufacturing.

The case study has been prepared for management students/business executives for strategic management class. It is recommended that the case study is distributed in advance so that the students can prepare well in advance for classroom discussions. Groups will be created to delve into details for a specific question. While one group will make their presentation, the other groups will question the solution provided and give suggestions.

Teaching notes are available for educators only.

CSS 11: Strategy.

This study aims to extend the driving range by on-board charging with use of photovoltaic (PV) source, avoiding the dependency on the grid supply and energy storage system in addition to that reduce the conversion complexity influenced on converter section of electric vehicle (EV) system.

This paper proposed a PV fed integrated converter topology called integrated single-input multi-output (I-SIMO) converter with enriched error tolerant fuzzy logic controller (EET-FLC) based control technique to regulate the speed of brushless direct current motor drive. I-SIMO converter provides both direct current (DC) and alternating current (AC) outputs from a single DC input source depending on the operation mode. It comprises two modes of operation, act as DC–DC converter in vehicle standby mode and DC–AC converter in vehicles driving mode.

The use of PV panels in the vehicle helps to reduce dependence of grid supply as well as vehicle’s batteries. The proposed topology has to remove the multiple power conversion stages in EV system, reduce components count and provide dual outputs for enhancement of performance of EV system.

The proposed topology leads to reduction of switching losses and stresses across the components of the converter and provides reduction in system complexity and overall expenditure. So, it enhances the converter reliability and also improves the efficiency. The converter provides ripple-free output voltage under dynamic load condition. The performance of EET-FLC is studied by taking various performance measures such as rise time, peak time, settling time and peak overshoot and compared with conventional control designs.

Voltage source inverter-fed permanent magnet synchronous motors (VSI-PMSMs) are widely used in industrial actuation and mechatronic systems in water pumping stations, as well as in the traction of transportation systems (such as electric vehicles and electric trains or ships with electric propulsion). The dynamic model of VSI-PMSMs is multivariable and exhibits complicated nonlinear dynamics. The inverters’ currents, which are generated through a pulsewidth modulation process, are used to control the stator currents of the PMSM, which in turn control the rotational speed of this electric machine. So far, several nonlinear control schemes for VSI-PMSMs have been developed, having as primary objectives the precise tracking of setpoints by the system’s state variables and robustness to parametric changes or external perturbations. However, little has been done for the solution of the associated nonlinear optimal control problem. The purpose of this study/paper is to provide a novel nonlinear optimal control method for VSI-fed three-phase PMSMs.

The present article proposes a nonlinear optimal control approach for VSI-PMSMs. The nonlinear dynamic model of VSI-PMSMs undergoes approximate linearization around a temporary operating point, which is recomputed at each iteration of the control method. This temporary operating point is defined by the present value of the voltage source inverter-fed PMSM state vector and by the last sampled value of the motor’s control input vector. The linearization relies on Taylor series expansion and the calculation of the system’s Jacobian matrices. For the approximately linearized model of the voltage source inverter-fed PMSM, an H-infinity feedback controller is designed. For the computation of the controller’s feedback gains, an algebraic Riccati equation is iteratively solved at each time-step of the control method. The global asymptotic stability properties of the control method are proven through Lyapunov analysis. Finally, to implement state estimation-based control for this system, the H-infinity Kalman filter is proposed as a state observer. The proposed control method achieves fast and accurate tracking of the reference setpoints of the VSI-fed PMSM under moderate variations of the control inputs.

The proposed H-infinity controller provides the solution to the optimal control problem for the VSI-PMSM system under model uncertainty and external perturbations. Actually, this controller represents a min–max differential game taking place between the control inputs, which try to minimize a cost function that contains a quadratic term of the state vector’s tracking error, the model uncertainty, and exogenous disturbance terms, which try to maximize this cost function. To select the feedback gains of the stabilizing feedback controller, an algebraic Riccati equation is repetitively solved at each time-step of the control algorithm. To analyze the stability properties of the control scheme, the Lyapunov method is used. It is proven that the VSI-PMSM loop has the H-infinity tracking performance property, which signifies robustness against model uncertainty and disturbances. Moreover, under moderate conditions, the global asymptotic stability properties of this control scheme are proven. The proposed control method achieves fast tracking of reference setpoints by the VSI-PMSM state variables, while keeping also moderate the variations of the control inputs. The latter property indicates that energy consumption by the VSI-PMSM control loop can be minimized.

The proposed nonlinear optimal control method for the VSI-PMSM system exhibits several advantages: Comparing to global linearization-based control methods, such as Lie algebra-based control or differential flatness theory-based control, the nonlinear optimal control scheme avoids complicated state variable transformations (diffeomorphisms). Besides, its control inputs are applied directly to the initial nonlinear model of the VSI-PMSM system, and thus inverse transformations and the related singularity problems are also avoided. Compared with backstepping control, the nonlinear optimal control scheme does not require the state-space description of the controlled system to be found in the triangular (backstepping integral) form. Compared with sliding-mode control, there is no need to define in an often intuitive manner the sliding surfaces of the controlled system. Finally, compared with local model-based control, the article’s nonlinear optimal control method avoids linearization around multiple operating points and does not need the solution of multiple Riccati equations or LMIs. As a result of this, the nonlinear optimal control method requires less computational effort.

Voltage source inverter-fed permanent magnet synchronous motors (VSI-PMSMs) are widely used in industrial actuation and mechatronic systems in water pumping stations, as well as in the traction of transportation systems (such as electric vehicles and electric trains or ships with electric propulsion), The solution of the associated nonlinear control problem enables reliable and precise functioning of VSI-fd PMSMs. This in turn has a positive impact in all related industrial applications and in tasks of electric traction and propulsion where VSI-fed PMSMs are used. It is particularly important for electric transportation systems and for the wide use of electric vehicles as expected by green policies which aim at deploying electromotion and at achieving the Net Zero objective.

Unlike past approaches, in the new nonlinear optimal control method, linearization is performed around a temporary operating point, which is defined by the present value of the system’s state vector and by the last sampled value of the control input vector and not at points that belong to the desirable trajectory (setpoints). Besides, the Riccati equation, which is used for computing the feedback gains of the controller, is new, as is the global stability proof for this control method. Comparing with nonlinear model predictive control, which is a popular approach for treating the optimal control problem in industry, the new nonlinear optimal (H-infinity) control scheme is of proven global stability, and the convergence of its iterative search for the optimum does not depend on initial conditions and trials with multiple sets of controller parameters. It is also noteworthy that the nonlinear optimal control method is applicable to a wider class of dynamical systems than approaches based on the solution of state-dependent Riccati equations (SDRE). The SDRE approaches can be applied only to dynamical systems that can be transformed to the linear parameter varying form. Besides, the nonlinear optimal control method performs better than nonlinear optimal control schemes which use approximation of the solution of the Hamilton–Jacobi–Bellman equation by Galerkin series expansions.

The purpose of this study is to calculate the normal force of a two degree of freedom direct drive induction motor considering coupling effects based on an analytical model. Compared with the traditional single degree of freedom motor, normal force characteristics of two-degree-of-freedom direct drive induction motor (2DOFDDIM) is affected by coupling effect when the machine is in a helical motion. To theoretically explain the influence mechanism of coupling effect, this paper conducts a quantitative analysis of the influence of coupling effect on normal force based on the established analytical model of normal force considering coupling effect.

Firstly, the normal forces generated by 2DOFDDIM in linear motion, rotary motion and helical motion are investigated and compared to prove the effect of the coupling effect on the normal force. During this study, several coupling factors are established to modify the calculation equations of the normal force. Then, based on the multilayer theoretical method and Maxwell stress method, a novel normal force calculation model of 2DOFDDIM is established taking the coupling effect into account, which can easily calculate the normal force of 2DOFDDIM under different motions conditions. Finally, the calculation results are verified by the results of 3D finite element model, which proves the correctness of the established calculating model.

The coupling effect produced by the helical motion of 2DOFDDIM affects the normal force.

In this paper, the analytical model of the normal force of 2DOFDDIM considering the coupling effect is established, which provides a fast calculation for the design of the motor.