Dr. Senyi Liu (IEEE Member) received the B.Eng. and M.Eng. in vehicle engineering from Tongji University, Shanghai, China, in 2015 and 2018. He received Ph.D. degree from City University of Hong Kong (CityU) in 2021. Currently, he is research professor in Tongji University. His main research interests include advanced control of motor drive systems, electric servo system, and wireless power transmission.

The primary objective of this tutorial is to provide comprehensive technological routes with implementation approaches for achieving high-overload capability in electric motors and drives. This topic is motivated by the growing demand for heavy-duty electric motor drives in wide areas like transportation electrification. The importance of developing high-overload motor drives (HOMDs) has been raised. The final aim is to equip attendees with a thorough understanding of the state-of-the-art in HOMD development and help them tackle real problems or challenges in promoting high-overload motors and drives products.

Novelties and technical innovations of this tutorial are highlighted as follows. (i) Innovative motor topologies and winding designs that can expand the torque-speed output range beyond standard rated conditions. (ii) Novel electrical and magnetic materials, such as high-energy-density permanent magnets and high-saturation core materials, that enable HOMDs to withstand heavier loading. (iii) Robust mechanical structures and fault-tolerant control techniques that support higher rotational speeds and overload conditions. (iv) Efficient cooling schemes and advanced thermal management strategies that are crucial for sustaining the thermal conditions of HOMs under extreme operating conditions.

Topics that this tutorial will cover in detail include: (i) Introduction to HOMDs; (ii) Instructions of four recategorized routes to achieve HOMDs with principle and mechanism explanations; (iii) Design of novel electric drives with corresponding control strategies to enhance operational overloading capability; (iv) Case studies and design examples illustrating the implementation of these technologies.