A Study on Design Methodologies for Compact Electric Machines Used in Electrified Mobile Hydraulics

Authors

  • Parth Tawarawala Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA
  • Shanmukh Sarode Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA
  • Hassan Assaf Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA
  • Andrea Vacca Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA
  • Lizhi Shang Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA
  • Scott D. Sudhoff Elmore Family School of Electrical and Computer Engineering, Purdue University, West Lafayette, Indiana, USA

DOI:

https://doi.org/10.13052/ijfp1439-9776.2534

Keywords:

Electrification, operational sizing, Electric Machine Optimization, Off-road Vehicles, cooling technology, ePump

Abstract

Electric Machines (EMs) have gained increasing importance in the mobile hydraulic industry as prime movers for hydraulic actuation systems. Therefore, their design and sizing are important aspects for any system layout architecture. The on-road vehicle industry has exploited EM versatility by proposing different sizes for various applications. However, off-road vehicles cannot borrow designs from on-road applications directly due to their unique challenges pertaining to drive cycle dynamics and limited space availability. Furthermore, considerations of the thermal limitations of EM and their cooling must also be studied to devise an effective methodology for designing prime movers suitable for mobile hydraulic applications.

This paper proposes EM operational sizing strategies based on corner point operation, flux weakening and transient operation that can downsize EMs by carefully selecting sizing points from the operating domain. These strategies can leverage the operational capabilities of EMs and involve trade-offs in terms of EM compactness and efficiency. Therefore, based on a specific requirement, a given strategy can have certain benefits explored in this paper. The paper also examines two other downsizing methods based on switching the ePump architecture to variable displacement pump operation and improving the cooling performance. The paper considers a 5-ton mini excavator’s arm actuator as a reference application. The resulting EMs are compared in terms of size and efficiency to study the effectiveness of each operational sizing strategy. This paper uses a well-established genetic algorithm-based multi-objective algorithm to design a Permanent Magnet Synchronous Machine (PMSM) for each sizing strategy. The effect of cooling technology is considered in terms of limiting winding current density for the EMs, and the impact of cooling technology on the size and efficiency of the EM is also demonstrated. Finally, the effectiveness of the proposed operational sizing strategies in downsizing EMs is combined with, and compared to other methods like variable displacement operation and aggressive cooling to identify the best ways to obtain the most compact EMs for any hydraulic application.

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Author Biographies

Parth Tawarawala, Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA

Parth Tawarawala received his bachelor’s degree (B. Tech) in Mechanical Engineering from Indian Institute of Technology (IIT) Bombay, India in 2022. He is currently a PhD student in Mechanical Engineering and a graduate research assistant at the Maha Fluid Power Research Center, Purdue University. His research areas include design and modelling of hydrostatic pumps, electrohydraulic system design and electrification.

Shanmukh Sarode, Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA

Shanmukh Sarode received his bachelor’s degree (B. Tech) in Mechanical Engineering from Sardar Vallabhbhai National Institute of Technology, Surat, India in 2017, the MS in Mechanical Engineering in 2021, and a PhD in Mechanical Engineering from Purdue University in 2023, respectively. He is currently working as an Engineer at Parker Hannifin Corporation at the Motion Technology Center, Cleveland, OH, USA. His research areas include modelling of hydrostatic and hydrodynamic pumps, electrohydraulic system design, and electrification.

Hassan Assaf, Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA

Hassan Assaf received the bachelor’s and master’s degree in Mechatronic Engineering from Polytechnic University of Turin, and a PhD in Agricultural and Biological Engineering from Purdue University in 2023, respectively. He is currently working as a Senior Systems Engineer at Caterpillar Inc., Peoria, IL, USA. His research areas include electrohydraulic actuation design, fluid power education, and fluid power systems.

Andrea Vacca, Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA

Andrea Vacca is the Maha Fluid Power Faculty Chair and a Professor at Purdue University. He currently leads the Maha Fluid Power Research Center which was established in 2004 by the late Prof. Monika Ivantysynova. Dr. Vacca completed his studies in Italy (Ph.D. from the University of Florence in 2005), and he joined Purdue University in 2010 after being an Assistant Professor at the University of Parma (Italy). Fluid power technology has been Dr. Vacca’s major research interest since 2002. Dr. Vacca authored the textbook “Hydraulic Fluid Power” by Wiley and more than 150 technical papers, most of them published in international journals or referred conferences. He is chair of Fluid Power Systems and Technology Division (FPST) of the American Society of Mechanical Engineers (ASME), and a former chair of the Fluid Power Division of the Society of Automotive Engineers (SAE). Dr. Vacca is also one of the Directors of the Global Fluid Power Society (GFPS). Furthermore, he is also the Editor in Chief of the International Journal of Fluid Power. Dr. Vacca also received the 2019 J. Bramah medal of the Institution of the Mechanical Engineers (IMechE).

Lizhi Shang, Maha Fluid Power Research Centre, Purdue University, West Lafayette, Indiana, USA

Lizhi Shang earned his Ph.D. from Purdue University in 2018 with the guidance of his Ph.D. advisor, the late Dr. Monika Ivantysynova. His dissertation focuses on the scaling of the axial piston machine lubricating interfaces. Dr. Shang joined Purdue University as an assistant professor in 2020. Since then, he has led a research group at the Maha fluid power research center studying designing and modelling hydrostatic pumps and motors, hydrodynamic pumps and turbines, fluid power systems, and advanced computational and experimental tribological analysis. His research aims to improve the energy efficiency, reliability, and controllability of fluid power systems by conducting interdisciplinary research on both component and system levels and exploring and expanding fluid power’s use and fluid power technology in new applications.

Scott D. Sudhoff, Elmore Family School of Electrical and Computer Engineering, Purdue University, West Lafayette, Indiana, USA

Scott D. Sudhoff (Fellow, IEEE) received the B.S. (Hons.), M.S., and Ph.D. degrees in electrical engineering from Purdue University, West Lafayette, IN, USA, in 1988, 1989, and 1991, respectively. From 1991 to 1993, he worked as a Consultant at P. C. Krause and Associates in aerospace power and actuation systems. From 1993 to 1997, he was also a Faculty Member with the University of Missouri–Rolla. In 1997, he joined as a Faculty Member with Purdue University, where he is currently the Michael and Katherine Birck Professor of electrical and computer engineering. His research interests include electric machinery, power electronics, marine and aerospace power systems, applied control, evolutionary computing, and genetic algorithms and their application to power electronic converters and electric machine design. He has published over 200 papers in these areas, including six prize papers. He served as the Editor-in-Chief for IEEE Transactions on Energy Conversion and IEEE Power and Energy Technology System.

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Published

2024-10-05

How to Cite

Tawarawala, P. ., Sarode, S. ., Assaf, H. ., Vacca, A. ., Shang, L. ., & Sudhoff, S. D. . (2024). A Study on Design Methodologies for Compact Electric Machines Used in Electrified Mobile Hydraulics. International Journal of Fluid Power, 25(03), 375–412. https://doi.org/10.13052/ijfp1439-9776.2534

Issue

2024: Vol 25 Iss 3

Section

SICFP23