High Performance Motor Controller for Switched Reluctance Motor

Client Requirements:

  • High Power Density

  • High Efficiency

  • Reduction of Noise and Vibration

  • Extreme Environmental Tolerances

  • Integrated Liquid Cooling System

  • Modularity and Scalability   

  • CAN/Ethernet Compatibility

  • Cross-Platform Functionality (IM, PMSM, SRM)


Project Summary:

The goal of the project is to produce a high power density high efficiency motor controller with liquid-cooling for a 3-phase switched reluctance machine (SRM) in EV/HEV applications. The controller shall reduce the vibration and audible noise of the drivetrain system across the entire torque-speed range in 4-quadrant operation by excess of 50%. The controller is designed for extreme and harsh environmental conditions including -50C to 125C ambient temperature, MIL-STD-810G shock and vibration, and MIL-STD-461F EMI/EMC.

Continuous Solutions has designed, built, and tested a 100kW controller (TRL6) to meet all the project requirements. By implementing our proprietary torque ripple mitigation (TRM) algorithm to the controller, the noise and vibration of the entire drivetrain have been significantly reduced. TRM is a closed-loop, real-time optimization algorithm  to mitigate torque ripple harmonics by manipulating the excitation profile based on continuous vibration feedback and analysis. This technology is scalable to various power levels and to multiple types of electric machines.