Not all inverters are the same...
A discussion on why inverter selection can have a greater bearing on
electrical powertrain performance than is immediately obvious.
In the search for ever increasing levels of
efficiency, traditional internal combustion
engines are experiencing high levels of
innovation focused on downsizing and forced
induction. Whilst this does not appear to have
a parallel with the ever increasing levels of
powertrain electrification, a focus on system
performance, ie conceiving the battery,
inverter & electric machine together, can have
an equally dramatic effect on weight, size,
performance, and of course, cost.
A traditional route to conceiving an
electrified powertrain will tend to specify the
system components in the order of electric
machine, battery, and finally the inverter.
In this sequence, the most complex unit,
responsible for optimising bi-directional
energy flow between battery and electric
machine as well as integration with safety
critical vehicle operating systems, is given the
lowest priority, possibly because of the belief
that an inverter is an inverter. The author
would argue that inverter selection should
be given greater consideration at the time
of specifying the battery and motor, as the
inverter will have an equally significant impact
on whether or not the systems performance
and cost targets are achieved.
Zytek is a company experienced in the
parallel development of electric machines,
power electronics and batteries, specifically
engineered for both mainstream and
motorsport sectors of the automotive market.
As a consequence Zytek are uniquely placed
to understand the key parameters that are
required to be considered in the development
of a successful HV electrical system, with
the inverter as the key enabler to unlock
system potential.
Prior to the commencement of either an
inverter selection, or the development of a
new bespoke product designed specifically
for an application, basic primary parameters
need to be understood: input voltage range
(ie battery DC voltage), output voltage range
(matched to the requirements of the electric
machine), output power & current, drive
cycle (to ensure thermal performance can
be maintained), working temperature range
and coolant details (thermal capacity & flow
rates). Following this, secondary information
will be required: maximum electrical
frequency (used to select the optimum PWM
frequency to control switching losses) and
further battery characteristics (to optimise
DC link capacitance to reduce DC ripple
current losses). Even at this high level, it
has become immediately apparent that the
standard information presented on a data
sheet or sales flyer is not adequate to convey
the necessary information to compare
inverter products.
But having selected or designed an inverter
capable of operating using all of the above
data (and much more!), only using very
advanced, state of the art, machine control
techniques can the optimum performance be
realised. Given a nameplate inverter electrical
rating, it is a common misconception that all
similarly rated inverters will drive electrical
machines to produce the same power/torque
output. Zytek use a proprietary AC controller,
using space vector modulation with advanced
discontinuous and over-commutation
techniques, all implemented on a system by
system basis. At no point is any table lookup
of torque vs machine current used, as this
technique cannot be used for top end, high
performance systems capable of extracting the
maximum torque/amp (and hence minimised
system loss). Live, closed-loop models of
both inverter and machine loss are run in the
inverter, enabling operating efficiencies of
>97% to be realised, along with high levels
of delivered torque accuracy (typically <1%
torque error when applied to salient machines,
where torque is not proportional to any
measurable physical variable).
Finally, from a safety aspect, many vehicle
level implementations now require inverters
to meet ISO26262 ASIL level D, necessitating
dualisation of current sensing within the
inverter using different sensing techniques, and
the ability to continue to function even in the
case of a complete loss of 12V KL15 & KL30
ignition signals.
Having been daunted by all of the above, rest
assured that inverters are available capable of
achieving all of the above and more, they just
need to be thought of as less of a pure current
switching device, but more of as the primary
system enabler, but most importantly, as the
primary choice when conceiving you vehicle
electrification requirements.
It is a common
misconception that all
similarly rated inverters will
drive electrical machines
to produce the same
power/torque output
Zytek Automotive Limited
Lancaster Road
Fradley Business Park Fradley
Lichfield, Staffs WS13 8RY, UK
Tel: +44 ( 0 )1543 412 789
Fax: +44 ( 0 )1543 412 799
Email: enquiries @ zytek.co.uk
zytekautomotive.co.uk