Switched Reluctance Drives Ltd

East Park House

Otley Road
Harrogate
North Yorkshire
HG3 1PR
United Kingdom
Our Ref : gbwh/2819
General Enquiries: +44 (0)1423 845200
Fax: +44 (0)1423 845201

(1) Introduction SR Drive System

An SR Drive System comprises a brushless, magnet-free dc (SR) motor and a
power converter with signal processing unit. The system operates from a dc power
source and provides a directly controlled torque output. The SR motor operates
entirely on reluctance torque consisting of a doubly salient structure with single
excitation on the stator.
The generic output characteristics are very similar to those of a conventional dc
motor but without the electrical and mechanical constraints imposed by a
commutator and brushes. Operating as a motor or a brake in either direction of
rotation it provides full 4-quadrant operation and can also operate as a stand alone
generator to provide dc electrical power from a mechanical source.
A simple diagram of an SR Drive system.

Mechanical
energy

Power
Supply
Mains
Battery
Generator
etc

Power
Conversion

SR Machine

User
Interface
Torque/Speed

Signal Processing

Bi-directional electromechanical
energy conversion

Electronic control
package

(2) Torque/Speed Characteristics

Most traction applications require an electrical drive system to replicate the
capability of a conventional mechanical transmission system which will provide a
high torque at standstill and low speeds followed by a region of constant power
output over a wide speed range. An SR Drive System excels in its ability to
provide these characteristics.

Reg. Office: East Park House, Otley Road, Harrogate, HG3 1PR, UK Reg No. 1517273 England Vat No GB 3431397 66 000
www.srdrives.co.uk

A typical SR Drive traction motor torque speed characteristic.

High torque
at low speed

1.2
1

Torque

Wide const HP
speed range

0.8
0.6

High max
speed

0.4

High system efficiency

over wide range of
Torque & Speed

0.2
0
0

Speed

10

12

Motoring quadrant only other quadrants symmetrical (may need more

high speed braking)

Constant power speed ranges in excess of 10:1 are common and in some special
cases for off road traction systems the range has been extended to 17:1.
SR Drive systems will also provide full symmetrical performance in the braking
quadrant with smooth torque control over the operating range and a smooth
transition from motoring to braking and vice versa.
(3) System Efficiency
An energy efficient drive system is an essential factor in electric or hybrid vehicle
applications. SR Drive systems provide high efficiency and, most importantly, it is
maintained over a large part of the operating torque speed plane. As with all
electrical systems efficiency will vary with size the larger powers exhibiting higher
efficiencies. The following diagrams give 3D plots of two examples and in both
cases the efficiency includes both motor and controller measured as a system.

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Small Traction Drive Efficiency

Motor & Controller
Efficiency

100.0%
90.0%
80.0%
70.0%
60.0%
50.0%
40.0%
30.0%
20.0%
10.0%
0.0%

15
12
9
Torque

6
3

0-170 Nm

10

12

90.0%-100.0%
80.0%-90.0%
70.0%-80.0%
60.0%-70.0%
50.0%-60.0%
40.0%-50.0%
30.0%-40.0%
20.0%-30.0%
10.0%-20.0%
0.0%-10.0%

14

Speed 0 7000 rev/min

90kW Industrial Drive

Measured System Efficiency (motor & controller)
95
93
91
89
87
System
85
efficiency
83
81
79
77
75
15

93-95
91-93
89-91
87-89
85-87

12

6
Torque
0 1800 Nm

00

12

15

83-85
81-83
79-81
77-79
75-77

Speed 0 1500rev/min
No data below 300 rev/min

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It is worth noting that the SR Drive system does not suffer from any cogging (deenergised) or low load electromagnetic drag which helps maintain efficiency at low
loads.
(4) SR Motor Size, Shape and Cooling
The size of any electrical machine is determined largely by its thermally
continuous torque rating. The SR machine provides an excellent specific torque
output due to a combination of electromagnetic energy conversion efficiency and
ease of cooling. In general it will provide a more compact solution than a
conventional induction motor.
The SR machine employs a cold rotor thus nearly all the heat losses generated
are in its stator which makes thermal management simple to implement. In
particular cooling by means of an external liquid is very effective for traction and
hybrid vehicle applications. A water ethylene glycol mix is commonly used and in
some applications is shared with the engine coolant circuit.
The diagram below illustrates a typical small traction motor for automotive or
similar applications.
The motor can provide 100Nm of continuous torque and provides a constant
power of 25kW continuous over a speed range from 1800rev/min to 11000rev/min.
Motor dimensions are 220 mm diameter x 210 mm length (approx).

SR machines can also be made with a wide range of aspect ratios from short
pancake shaped machines to long and thin designs which often allows an
application specific design to be adapted to fit a given space volume which is
important for many automotive applications.

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Integrated SR machine
(1200 Nm) on 16L Diesel
Engine
The above picture shows a compact large diameter SR machine directly mounted
on the crankshaft of a large Diesel engine to perform hybrid duties in the vehicle
application.
(5) SR Motor Robustness
The construction of the SR machine makes it particularly robust both electrically
and mechanically making it ideal for the challenging environment imposed by most
traction applications. This rugged construction leads to unrivalled reliability in
operation.
The key features promoting ruggedness and reliability are summarised in the
diagram below.

Switched Reluctance Motor = Reliability

No Phase Overlap

High dv/dt Opposition.

` Low Capacitance to
frame reduces RFI

Cool Rotor
Mechanically
Robust
Cool Bearings
Simple Rotor Construction:
` No Rotor Bars
` No Commutator
` No Windings
` No Magnets

Short Winding Overhang

` Reduced Temperature
` Improved Coil Rigidity
Simple Thermal Management

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(6) Controller and Silicon Utilisation

The electronic power converter system for the SR motor utilises standard
electronic components as may be found in a typical frequency inverter. However
the circuit configuration and energy conversion process required by the motor
provides for very effective utilisation of the power silicon which is the major cost
driver. This is particularly true for traction applications requiring a wide constant
power range.
A typical control module is shown below rated at 70kW and liquid cooled

(7) System Electromagnetic Compatibility (EMC)

EMC is an important issue for any electronically controlled drive system and is
often a major cost driver for the total traction system. A Switched Reluctance
System will exhibit some level of electromagnetic interference but several factors
contribute to make this a more easily managed issue. The low switching
frequencies employed combined with low leakage capacitance in the machine and
some second order effects tend to minimise the cost of necessary filtering required
to meet certification levels.
(8) Sensorless Operation
Current is applied to the motor phases by the power converter; it is essentially
switched on and off (i.e. commutated) in synchronism with the rotors angular
position.
The necessary rotor position information is most commonly obtained using a
simple coarse (e.g. 8 or 12 pulses per rev) encoder affixed to the motor shaft. This
method has been successfully employed for over two decades in many thousands
of SR Drive systems with an exceptional record for reliability. If, however,
environmental conditions are such that use of an encoder is a disadvantage rotor
position information can also be obtained by using a set of algorithms proprietary
to SR Drives which operate on currents and voltages at the motor terminals. This
technique has been validated in several environmentally sensitive application
areas including electric traction.
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(9) Fault Tolerance & Fail to Safe

The SR system is made up of a group of essentially independent electrical circuits
both in the motor and power electronics. This feature enables the system to exhibit
a unique level of fault tolerance since in many cases a fault can be isolated in a
particular circuit whilst the others remain fully active. This allows the drive system
to continue operating albeit at reduced output giving a limp home capability.
In addition the fault modes that do exist are very benign providing an inherent fail
to safe feature without having to add additional protection systems to handle fault
conditions.

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