Dynamometer Characterization of Electric Powertrain Components for Accurate Modeling and Control Design of a Dual-Motor All-Wheel-Drive Electric Vehicle

Abstract

United States government data shows AWD EV production increasing over 376 % from 2020 to 2023. The literature highlights energy savings from mixed-type dual EM powertrains and optimization-based energy management strategies (EMS), compared to single-type dual-motors and rule-based control. Other trends include the adoption of silicon carbide (SiC) based inverter devices and 800 V systems. Axial-flux machines have seen increased traction, with implementations in Ferrari’s SF90 Stradale, Lamborghini’s Revuelto, and Mercedes-Benz’s acquisition of YASA Ltd.

These findings motivated the study of dual-motor AWD EV thermally constrained energy management. Using McMaster Automotive Resource Centre’s (MARC’s) facilities, accurate modeling of powertrain components was pursued to contribute realistic results.

Firstly, inverter device materials and voltage ratings were studied in a Chevrolet Bolt EV model. Experimental validation was conducted on 1200 V inverters, powering 160+ kW traction machines. The model’s loss error was mostly within 100 W of measured loss. An empirical loss model revealed the analytical model estimates range within 6 km. This work highlighted the benefits of 800 V DC buses and SiC inverters.

Secondly, experimental characterization of a yokeless and segmented armature (YASA) axial flux machine, by YASA Ltd., was documented. Dynamometer tests covered a wide torque, speed, and DC bus voltage range. The Bolt EV was modeled with the YASA machine, comparing its performance to the stock machine. All data was compiled and published in an online open-source repository.

Lastly, thermally constrained energy management of various control strategies for a dual-motor AWD EV model were compared. Over two drive cycles, an MPC strategy ranked best in selected performance metrics. During a racetrack drive cycle, the MPC strategy kept the thermally limited motor cooler 246 % longer than a rule-based strategy. This work highlighted MPC’s potential in reducing total lifetime thermal wear of a dual-motor powertrain’s thermally limited motor.