D6.3 Prototypes of motor, control and EMF monitoring

Executive Summary

This document describes the work done in the related with the PHMS prototype implementation.

The work is based on the monitoring variables previously defined in the Work Package 4 and begins with the identification and analysis of possible hardware architectures in which the PHMS will be based. This is an important issue as the PHMS is an equipment which includes multiple technologies. This requires the implementation of the different monitoring algorithms so that they share the omputation resources and sensors. Thus an efficient architecture or distribution of functions that also allows a proper interaction between the sensors and hardware is needed. In addition, and since the PHMS System is developed by a multidisciplinary team, organizational issues that could affect the development need to be taken into account when selecting the architecture. A functionally integrated but physically distributed architecture seems to fulfil most of the desired characteristics. In this case a Central PHMS module accompanied by several Satellite PHMS modules will execute the defined functionality.

Since the PHMS relies on a distributed architecture, composed by several hardware modules that communicate between them, a communication protocol is needed. This new protocol, in its bottom layers would be based in CAN protocol, which is considered as an standard in the automotive industry. For the application layer, specific messages have been defined, as it does not exist at the moment a standard application protocol.

Following chapters describe the principles of measurement, hardware details, software implementation and validation of each one of the PHMS modules: the motor monitoring system, the control monitoring system and the measuring device for monitoring the occupants’ magnetic field exposure.

The motor monitoring system measures the variables needed to monitor the condition of motor windings, bearings and magnetic field source.

Regarding the control, its satellite PHMS is described. It is formed by two sensor boards (one to measure the variables associated to the DC-Link capacitor and the other one to measure the variables associated to the inverter) and one microcontroller board which acquires and pre-process the data, performs the failure detection, and sends this information by the CAN bus so that it can be processed in the central PHMS. The sensor boards have been tested and, in the case of the capacitor state monitoring, the data provided by them have been introduced into the algorithm with satisfactory results.

In addition, a guide on how to estimate the exposure in the occupants’ compartment from non-local magnetic field measurements for a specific vehicle is provided in Appendix C .


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Project acronym:

Project name:
 Electrical powertrain Health Monitoring for Increased Safety of FEVs

Project reference:

Start date: 01/06/2012
End date: 28/02/2015

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