International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)

ISSN: 0976-1353 Volume 24 Issue 6 – APRIL 2017 (SPECIAL ISSUE)

Design and Optimization of mild hybrid BLDC

based starter generator for two wheeler
Venkateshwaran B1, Pushparajesh V2, Kamalakannan D3
1
Dept of EEE, Power Electronics and Drives, Kongu Engineering College, Perundurai
2
Assistant Professor (Sr Gr), Dept of EEE, Kongu Engineering College, Perundurai
3
Assistant Manager, Advanced Engineering, Lucas TVS, Padi.
1
venkateshbav@gmail.com, 2rajesh@kongu.ac.in, 3kamalakannan.engg@lucastvs.co.in

Abstract-This project on the design ofIntegrated
Starter Generator (ISG) for two wheeler, aims at developing an
ISG design that meets the requirements of both the existing
starter motor and magneto in the two wheeler. The ISG to be
developed was proposed to be a Brushless DC (BLDC) machine
similar in shape to that of the magneto with outer rotor
configuration but differing in a few dimensions, occupying the
place of the magneto in the vehicle. In the existing magneto, the
main loads are the head lamps and the battery charging unit.
The ISG would initially help to crank the engine while starting
and would serve as a generator while running. Hence only one
machine would be needed in the place of two. Promising
designs were simulated using MAGNET (a Finite element
electromagnetic analysis tool) to verify the performance. While
simulating in Magnet, static 2D simulations were performed
initially and later, to get finer results, transient simulations
were performed as transient simulations are time consuming
compared to static 2D simulations.
coupled with the engine crank shaft without any gear. Hence
in an ISG, gear noise would be eliminated with quick and
smooth start, facilitating implementation of Start Stop
System (i.e. automatic shutdown of engine when it idles
beyond a pre-defined time at traffic junctions and quick
engine start when signal is ready by throttle actuation with
necessary safety features). With this feature fuel
consumption is reduced, thereby improving overall vehicle
efficiency and also reducing the emissions. In this paper, the
design parameters, analysis of a machine in transient, flux
weakening operation is discussed for two configurations
(IPG with air and steel) and the corresponding graphs are
plotted.
II. REQUIREMENTS OF INTEGRATED STARTER
GENERATOR

Keywords –2 Dimensional (2D);Brushless DC Machine
(BLDC);Interpolar gap(IPG); Integrated Starter Generator
(ISG); Permanent Magnet Synchronous Motor (PMSM);
I. INTRODUCTION
A. Objective
Designing a BLDC motor that fulfills the
requirements of both starter and magneto in two wheeler.
B. Introduction
The Brushless DC (BLDC) motor is the ideal
choicefor applications that require high reliability, high
efficiency, and high power-to-volume ratio [1]. Generally
speaking, a BLDC motor is considered to be a high
performance motor that is capable of providing large
amounts of torque over a vast speed range. In conventional
starter motors, gear noise is very prominent. As the ISG
would occupy the place of the magneto, it would be directly
1. The existing starter motor (DC motor) had
cranked the engine with sufficient torque in
coupling the starter motor pinion with engine
crank shaft via geararrangements.
2. The ISG is different from the existing starter
motor. As the ISG would directly couple to the
engine crank shaft, it need to produce more
torque than starter motor to crank theengine.
3. Thus the new design had to produce a maximum
torque which is sufficient to crank the engine
with relevant speed without any
demagnetizationoccursin themagnets.
4. The existing magneto supplied a lamp load of
50W and a battery charge load of 30W.A design
had to be fixed such that it met the requirements
of both motoring and generating mode. The
performance parameters of both the starter motor
and magneto were benchmarked to arrive at the
design ofISG.

5
 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 24 Issue 6 – APRIL 2017 (SPECIAL ISSUE)

III. SIMULATION OF ISG FOR MOTORING MODE

OPERATION

A 16 pole 18 slots BLDC motor with inter polar gap

(IPG) with air (see Fig 1b) and steel (see Fig 1c) in yoke has
been selected to achieve the requirements of an ISG
(Integrated Starter Generator). The purpose of introducing
an IPG with steel in yoke is to achieve a high speed during
fieldweakening.
The model implementation was designed using the
MAGNET (Infolytica corporation) software[2]. The first
stepof the design process is to draw the motor dimensions
withspecified diameter using AUTOCAD or MAGNET
itself. If the 2D model is drawn by AUTOCAD, the dxf file
format is imported into the magnet. After that material
related to particular parameter is assigned. Here for stator
core and yoke, silicon steel (M36 26Ga) and (M33035A)
respectively are used and NdFeB magnet is used. Concentric
winding is employed for themotor[4].
Fig 2 Finite Element Mesh
A. Staticanalysis:
The static model for BLDC was designed to check
the current flow and flux in the different coils by varying the
position of rotor. By the prediction of no load analysis the
line voltages and phase voltage are derived.
B. No loadanalysis:
For no load analysis, the rotor is rotated about 45
deg mechanical angle i.e it corresponds to one full electrical
cycle and this model consists of moving parts Yoke, Rotor
airgap and the magnets. Flux linkage with the conduction of
120 deg is shown in fig 3 and the flux lines counter plot is
shown in fig 4.

Fig 1(a) Solid model of BLDC motor

Fig 3 No load Flux linkage plot
IPG with
air

Fig 1(b) Inter Polar Gap with Air

IPG with
steel

Fig 1(c)Inter Polar Gap with Steel

In the finite element method of analysis, the model is

divided into a mesh ofelements. Fig 4 No Load Flux Lines of BLDC motor

6
 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 24 Issue 6 – APRIL 2017 (SPECIAL ISSUE)

C. Loadanalysis:

This analysis is mainly verified for the motor to

check the desired torque characteristics. From the line
voltage in no load analysis, any two phases are excited and
the torque Vs current characteristics are obtained. Here the
Y and B phases gets excited with positive and negative
current respectively to certain angle and R phase with zero
current. The flux density plot of stator and rotor when
passing operating current is shown in figure 5 and 6(a,b)
respectively.

Fig 6(b) Flux Density Plot of Rotor with IPG-Steel

D. Demagnetization:

When machines are subjected to external magnetic

fields and/or temperature changes, the magnetic properties
of permanent magnets may change, leading to
demagnetization, which may affect the performance of such
machines[2]. It is therefore very important to take this
phenomenon into account when designing suchmachines.

Demagnetization of an ISG starts at 140o C since

theHc (coercivity) value of the magnet exceeds the iHc
Fig 5 Flux Density Plot of stator value.

Magnet get
Demagnetized

Fig 6(a) Flux Density Plot of Rotor with IPG-Air Fig 7 Demagnetization Effect

E. Transientanalysis:

Transient analysis is also carried out for two

designs in the BLDC motoring mode to exactly predict the
performance of the motor by applying necessary velocity to
the machine. It is usually carried out to predict the results of
current for various speeds and to identify the losses
associated with the machine. The results of transient analysis
are shown in Table 1 and DC and RMS currents for is shown
in Fig9.

7
 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 24 Issue 6 – APRIL 2017 (SPECIAL ISSUE)

IV. SIMULATION OF ISG FOR GENERATING

MODEOPERATION

Once the engine is cranked by an ISG, the same

machine can acts as a generator to produce a required
amount of power for auxiliary requirements. This is
achieved by implementing a diode bridge rectifier setup and
voltage regulator for batterycharging.

Fig 8 Simulation Circuit Diagram for motoring mode

Fig 10 Simulation Circuit Diagram for generating mode

Table 2 Transient Analysis Results for Generator Mode

SPEED (RPM) OUTPUT POWER

(W)
5000 100
IPG WITH 6000 150
STEEL 7000 400
7500 450
Fig 9 DC Current and RMS Current plot 5000 80
5500 95
IPG WITH AIR
6500 150
Table 1 Transient Analysis Results for motoringmode 7000 350

Input Copper Output The circuit diagram in Fig 10 showedthe transient

Speed Efficiency analysis of an ISG in generating mode of operation where
power Loss Power
(RPM) (%) the stator coils get connected to the uncontrolled full bridge
(W) (W) (W)
IPG 480 3000 9.5 320 66 diode rectifier whose output is connected to the battery via
WITH voltagesource.
720 2500 37 530 74
AIR
IPG 475 3500 9.45 370 78 SPEED Vs OUTPUT POWER
WITH
STEEL 725 3100 38 740 88 500
400
Power(W)

300 IPG with

The circuit diagram (Fig 8) shown above is used to 200 steel
carry out the transient analysis. In the circuit, the DC 100
voltage source is connected to the inverter circuit for the IPG with air
trapezoidal commutation of 120degswitching. 0
5000 6000 7000 8000
The result obtained in transient analysis clearly Speed (RPM)
shows that the promised design meets the requirements of
existing starter of the two wheeler.
Fig 11 Generation mode performance curve

8
 International Journal of Emerging Technology in Computer Science & Electronics (IJETCSE)
ISSN: 0976-1353 Volume 24 Issue 6 – APRIL 2017 (SPECIAL ISSUE)
The result shown above in Fig 11 clarifies the
generator performance that meets the requirements of
charging the battery and powering the auxiliary equipment’s
as same as existing magneto.
V. FIELD ORIENTED CONTROL OF AN ISG
During field weakening mode, the machine
operates as a (Permanent Magnet Synchronous Motor)PMSM
and delivering a high speed for different current angle.
In the field weakening range, some of the stator
current, and in some cases, finally all the stator current is
consumed in reducing the stator flux linkage. Consequently,
more stator current is required in the field weakening range
than for the corresponding torque in the constant flux range
[3]. Fig 8 shows the Vectordiagram [5] for the speed above
the rated value.
Fig 12 Vector Diagram of Flux weakening-above the
base speed
The field weakening of an ISG is simulated with
MATHCAD (Internally designed software by Lucas-TVS)
and the performance of Speed Torque characteristics are
obtained for constant torque and constant power region. It is
benchmarked that the design of machine with IPG-Steel is
giving better performance of speed above 10000 RPM
compared to the machine with IPG-Air. So the machine with
IPG-Steel is taken to next proceedinglevel.
VI. RESULTS ANDCONCLUSION
In this paper, the design methodology of Integrated
Starter Generator using BLDC/PMSM motor which meets
the requirements of both motoring and generating mode is
designed and the analysis of dynamic response is evaluated
with MAGNET (Infolytica Corporation) software and
MATHCAD (Lucas-TVS).
VII. ACKNOWLEDGEMENT
I,Venkateshwaran B hereby thank Lucas TVS
Ltd., Chennai & their dynamic engineers for their constant
support and proper guidance to the successful completion of
the project.
VIII.REFERENCE
[1] R. Hendershot, Jr. president, “Design of Brushless Permanent-
Magnet Motors” James Magna Physics Corporation.
[2] www.infolytica.com – Electromagnetic Field
SimulationSoftware.
[3] JuhaPyrhönen “Electrical Drives”, LUT, Department of
ElectricalEngineering pp-9.22-9.24.
[4] Juhapyrhonen, TapaniJokinen, Valeria Hrabovcova, "Design of
rotating electrical machines", John Wiley & sons,Ltd
[5] Shivarajappa, J.Sassikumar, Dr.P. Meena, "Performance
Analysis of Surface Permanent Magnet Synchronous Motor",
IICPE 2014, 6th IEEE India International Coferenceon Power
Electronics, 8-10Dec, NIT KuruKshera,India.
[6] Jung-Moo Seo, Jung-Hwan Kim, Se-Hyun Rhyu, Jun-Hyuk
Choi, and In-Soung Jung, Senior Member, IEEE, “A Study on
Brushless DC Motor for High Torque Density, International
Journal of Mechanical, Aerospace, Industrial, Mechatronic and
Manufacturing Engineering Vol:5, No:10,2011.
[7] Stefan Sjokvist “Demagnetization Studies on Permanent
Magnets” UppsalaUniversitet.