Multiphase PMSM and PMaSynRM flux map model with space harmonics and multiple plane cross harmonic saturation

© 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes,creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.Multiphase Synchronous Machines vary in rotor construction and winding distribution leading to non-sinusoidal inductances along the rotor periphery. Moreover, saturation and cross-saturation effects make the precise modeling a complex task. This paper proposes a general model of multi-phase magnet-excited synchronous machines considering multi-dimensional space modeling and revealing cross-harmonic saturation. The models can predict multiphase motor behavior in any transient state, including startup. They are based on flux maps obtained from static 2D Finite-Element (FE) analysis. FE validations have been performed to confirm authenticity of the dynamic models of multiphase PMaSynRMs. Very close to FE precision is guaranteed while computation time is incomparably lower.Postprint (author's final draft

A Novel 100 kW Power Hardware-in-the-Loop Emulation Test Bench for Permanent Magnet Synchronous Machines with Nonlinear Magnetics

This paper presents a high dynamic power hardware-inthe-loop (PHIL) emulation test bench to mimic arbitrary permanent magnet synchronous machines with nonlinear magnetics. The proposed PHIL test bench is composed of a high performance real-time simulation system to calculate the machine behaviour and a seven level modular multiphase multilevel converter to emulate the power flow of the virtual machine. The PHIL test bench is parametrized for an automotive synchronous machine and controlled by a motor converter using a predictive trajectory dead-beat current controller. Measurements of high dynamic current steps and phase current ripples at the real machine are reproduced precisely at the PHIL test bench. Thus, the validity of the used machine model as well as the excellent performance of the PHIL test bench is proven

Healthy and open phase PMaSynRM model based on virtual reluctance concept

© 2021 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes,creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.The trend in the industrial power electronics electrical drives is to reach high power density and high efficiency in variable load conditions at cost-effective unwasteful designs. Currently, motors with permanent magnets (such as IPMSM and PMaSynRM) are of great interest because of compactness, low losses, and high torque capability. The performance of a drive system can be predicted with a motor electromagnetic authentic nonlinear model. In this paper, a novel, fast, and precise motor model of PMaSynRM based on virtual reluctance (VR) is proposed. It takes into account the cross saturation, winding distribution, space harmonics, slotting effect, and stepped skewing. The virtual reluctances are identified by finite element analysis (FEA) and implemented in the time-stepping simulation. The flux inversion is not required. The proposed concept is useful in the rotating field or phase quantities (for open phase simulation). The model is also discretized for SiL and HiL applications. Finally, the validation in FEA and experimental setup was performed.This work was supported in part by Spanish Ministry of Economy and Competitiveness under TRA2016-80472-R Research Project and Secretaria d’Universitats i Recerca del Departament d’Empresa i Coneixement de la Generalitat de Catalunya under 2017SGR967.Peer ReviewedPostprint (author's final draft

Power Hardware-in-the-Loop Emulation of Permanent Magnet Synchronous Machines with Nonlinear Magnetics - Concept & Verification

This paper presents a power hardware-in-the-loop emulation test bench (PHIL), based on a modular multiphase multilevel converter (MMPMC), to mimic arbitrary permanent magnet synchronous machines with nonlinear magnetics as they are used in automotive applications. Measurements in stationary operation as well as high dynamic torque steps are conducted at a real automotive machine and precisely reproduced at the PHIL system to demonstrate the excellent performance of the PHIL test bench. Moreover, the superiority of a PHIL test bench over conventional motor test benches is proven by the unproblematic emulation of a blocking rotor or a cracking shaft

Real-Time Hardware-in-the-Loop Simulation of Permanent Magnet Synchronous Motor Drives under Stator Faults

Hardware-in-the-loop (HIL) testing methods can facilitate the development of control strategies in a safe and inexpensive environment particularly when extreme operating conditions such as faults are considered. HIL methods rely on accurate real-time emulation of the equipment under investigation. However, no validated tools for real-time emulation of electrical drives under fault conditions are available. This paper describes the implementation of a high-fidelity real-time emulator of a Permanent Magnet Synchronous Motor (PMSM) drive in a platform suitable for HIL tests. The emulator is capable of representing the drive operation under both healthy conditions and during inter-turn stator winding faults. Nonlinearities due to saturation, higher order harmonics, slotting effects, etc. are accounted for using fourdimensional look-up tables obtained by finite element analysis (FEA). The proposed model is computationally efficient and capable of running in real-time in a FPGA platform and is validated against simulations and experimental results in a wide range of operating conditions. Potential applications of the proposed emulation environment to the development of drive control, fault detection and diagnostic algorithms are proposed

A Nine-Phase 18-Slot 14-Pole Interior Permanent Magnet Machine with Low Space Harmonics for Electric Vehicle Applications

© 1986-2012 IEEE.One of the key challenges of utilizing concentrated winding in interior permanent magnet machines (IPMs) is the high rotor eddy current losses in both magnets and rotor iron due to the presence of a large number of lower and higher order space harmonics in the stator magnetomotive force (MMF). These MMF harmonics also result in other undesirable effects, such as localized core saturation, acoustic noise, and vibrations. This paper proposes a nine-phase 18-slot 14-pole IPM machine using the multiple three-phase winding sets to reduce MMF harmonics. All the subharmonics and some of the higher order harmonics are cancelled out, while the advantages of the concentrate windings are retained. The proposed machine exhibits a high efficiency over wide torque and speed ranges. A 10-kW machine prototype is built and tested in generator mode for the experimental validation. The experimental results indicate the effectiveness of the MMF harmonics cancellation in the proposed machine

Current residual based stator inter-turn fault detection in permanent magnet machines

Inter-turn short circuit fault, also known as turn fault is a common fault in electric machines which can cause severe damages if no prompt detection and mitigation are conducted. This paper proposes a turn fault detection method for permanent magnet machines based on current residual. After the impact of the turn fault is firstly analyzed on a simplified mathematical machine model to assess the fault signature, a finite element (FE) model is developed to obtain healthy machine behavior. The residual between the measured and estimated currents by the model with the same applied voltages contains mainly the fault features. The quality of the fault detection can be improved because the fault signatures are enhanced, and the impact of the current controller bandwidth on fault signature is minimized. The dc components in the negative sequence current residuals are extracted through angular integration and their magnitude is defined as the fault indicator. The robustness of the fault detection against transient states is achieved. The effectiveness of the proposed method is validated on a triple redundant fault tolerant permanent magnet assisted synchronous reluctance machine (PMA SynRM)

A High-Fidelity and Computationally Efficient Model for Interior Permanent-Magnet Machines Considering the Magnetic Saturation, Spatial Harmonics, and Iron Loss Effect

Interior permanent-magnet (IPM) machines exhibit relatively large spatial harmonics in phase voltages and high nonlinearity in torque production due to both the presence of reluctance torque and the magnetic saturation in stator and rotor cores. To simulate the real electromagnetic behavior of IPM machines, this paper proposes a high-fidelity and computationally efficient machine model considering the magnetic saturation, the spatial harmonics, and the iron loss effect based on the inverse solution of the flux linkages extracted via finite-element analysis (FEA). Neither FEA nor a derivative computation is involved in the time-stepping simulation; thereby, the proposed model is computationally efficient and numerically robust. The high fidelity of the proposed machine model is validated by both the FEA and the experimental results

Design of High Efficiency Brushless Permanent Magnet Machines and Driver System

The dissertation is concerned with the design of high-efficiency permanent magnet synchronous machinery and the control system. The dissertation first talks about the basic concept of the permanent magnet synchronous motor (PMSM) design and the mathematics design model of the advanced design method. The advantage of the design method is that it can increase the high load capacity at no cost of increasing the total machine size. After that, the control method of the PMSM and Permanent magnet synchronous generator (PMSG) is introduced. The design, simulation, and test of a permanent magnet brushless DC (BLDC) motor for electric impact wrench and new mechanical structure are first presented based on the design method. Finite element analysis based on the Maxwell 2D is built to optimize the design and the control board is designed using Altium Designer. Both the motor and control board have been fabricated and tested to verify the design. The electrical and mechanical design are combined, and it provides an analytical IPMBLDC design method and an innovative and reasonable mechanical dynamical calculation method for the impact wrench system, which can be used in whole system design of other functional electric tools. A 2kw high-efficiency alternator system and its control board system are also designed, analyzed and fabricated applying to the truck auxiliary power unit (APU). The alternator system has two stages. The first stage is that the alternator three-phase outputs are connected to the three-phase active rectifier to get 48V DC. An advanced Sliding Mode Observer (SMO) is used to get an alternator position. The buck is used for the second stage to get 14V DC output. The whole system efficiency is much higher than the traditional system using induction motor

High efficiency sensorless fault tolerant control of permanent magnet assisted synchronous reluctance motor

In the last decades, the development trends of high efficiency and compact electric drives on the motor side focused on Permanent Magnet Synchronous Machines (PMSMs) equipped with magnets based on the rare-earth elements. The permanent magnet components, however, dramatically impact the overall bill of materials of motor construction. This aspect has become even more critical due to the price instability of the rare-earth elements. This is why the Permanent Magnet Assisted Synchronous Reluctance Motor (PMaSynRM) concept was brought to the spotlight as it gives comparable torque density and similar efficiencies as PMSM although at a lower price accredited for the use of magnets built with ferrite composites. Despite these advantages, PMaSynRM drive design is much more challenging because of nonlinear inductances resulting from deep cross saturation effects. It is also true for multi-phase PMSM motors that have gained a lot of attention as they proportionally split power by the increased number of phases. Furthermore, they offer fault-tolerant operation while one or more phases are down due to machine, inverter, or sensor fault. The number of phases further increases the overall complexity for modeling and control design. It is clear then that a combination of multi-phase with PMaSynRM concept brings potential benefits but confronts standard modeling methods and drive development techniques. This Thesis consists of detailed modeling, control design, and implementation of a five-phase PMaSynRM drive for normal healthy and open phase fault-tolerant applications. Special emphasis is put on motor modeling that comprises saturation and space harmonics together with axial asymmetry introduced by rotor skewing. Control strategies focused on high efficiency are developed and the position estimation based on the observer technique is derived. The proposed models are validated through Finite Element Analysis (FEA) and experimental campaign. The results show the effectiveness of the elaborated algorithms and methods that are viable for further industrialization in PMaSynRM drives with fault-tolerant capabilities.En últimas décadas, las tendencias de desarrollo de accionamientos eléctricos compactos y de alta eficiencia en el lado del motor se centraron en las maquinas síncronas de imanes permanentes (PMSM) equipadas con imanes basados en elementos de tierras raras. Sin embargo, los componentes de imán permanente impactan dramáticamente en el coste de construcción del motor. Este aspecto se ha vuelto aún más crítico debido a la inestabilidad de precios de los elementos de tierras raras. Esta es la razón por la que el concepto de motor de reluctancia síncrona asistido por imán permanente (PMaSynRM) se ha tomado en consideración, ya que ofrece una densidad de par comparable y eficiencias similares a las de PMSM, aunque a un precio más bajo acreditado para el uso de imanes construidos con compuestos de ferritas. A pesar de drive PMaSynRM resulta muy complejo debido a las inductancias no lineales que resultan de los efectos de saturación cruzada profunda. Esto también es cierto para los motores PMSM polifásicos que han ganado mucha atención en los últimos años, en los que se divide proporcionalmente la potencia por el mayor número de fases. Además, ofrecen operación tolerante a fallas mientras una o más fases están inactivas debido a fallas en la máquina, el inversor o el sensor. Sin embargo, el número de fases aumenta aún más la complejidad general del diseño de modelado y control. Está claro entonces que una combinación de multifase con el concepto PMaSynRM tiene beneficios potenciales, pero dificulta los métodos de modelado estándar y las técnicas de desarrollo del sistema de accionamiento. Esta tesis consiste en el modelado detallado, el diseño de control y la implementación de un drive PMaSynRM de cinco fases para aplicaciones normales en buen estado y tolerantes a fallas de fase abierta. Se pone especial énfasis en el modelado del motor que comprende la saturación y los armónicos espaciales junto con la asimetría axial introducida por la inclinación del rotor. Se desarrollan estrategias de control enfocadas a la alta eficiencia y se deriva la estimación de posición basada en la técnica del observador. Los modelos propuestos se validan mediante Análisis de Elementos Finitos (FEA) y resultados experimentales. Los resultados muestran la efectividad de los algoritmos y métodos elaborados, que resultan viables para la industrialización de unidades PMaSynRM con capacidades tolerantes a fallas.Postprint (published version