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To improve the endurance mileage of electric vehicles (EVs), it is important to decrease the energy consumption of the Permanent Magnet Synchronous Motor (PMSM) drive system. This paper proposes a novel loss optimization control strategy named system efficiency improvement control which can optimize both inverter and motor losses. A nonlinear power converter loss model is built to fit the nonlinear characteristics of power devices. This paper uses double Fourier integral analysis to analytically calculate the fundamental and harmonic components of motor current by which the fundamental motor loss and harmonic motor loss can be accurately analyzed. From these loss models, a whole-frequency-domain system loss model is derived and presented. Based on the system loss model, the system efficiency improvement control method applies the genetic algorithm to adjust the motor current and PWM frequency together to optimize the inverter and motor losses by which the system efficiency can be significantly improved without seriously influence on the system stability over the whole operation range of EVs. The optimal effects of system efficiency is verified by the experimental results in both Si-IGBT-based PMSM system and SiC-MOSFET-based system.

High-efficiency permanent-magnet synchronous machine (PMSM) drive systems need not only optimally designed motors but also efficiency-oriented control strategies. However, the existing control strategies only focus on partial loss optimization. This paper proposes a novel analytic loss model of PMSM in either sine-wave pulse-width modulation (SPWM) or space vector pulse width modulation (SVPWM) which can take into account both the fundamental loss and harmonic loss. The fundamental loss is divided into fundamental copper loss and fundamental iron loss which is estimated by the average flux density in the stator tooth and yoke. In addition, the harmonic loss is obtained from the Bertotti iron loss formula by the harmonic voltages of the three-phase inverter in either SPWM or SVPWM which are calculated by double Fourier integral analysis. Based on the analytic loss model, this paper proposes a maximum efficiency per torque (MEPT) control strategy which can minimize the electromagnetic loss of PMSM in the whole operation range. As the loss model of PMSM is too complicated to obtain the analytical solution of optimal loss, a golden section method is applied to achieve the optimal operation point accurately, which can make PMSM work at maximum efficiency. The optimized results between SPWM and SVPWM show that the MEPT in SVPWM has a better effect on the optimization performance. Both the theory analysis and experiment results show that the MEPT control can significantly improve the efficiency performance of the PMSM in each operation condition with a satisfied dynamic performance.

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