Comparison and Design Optimization of a Five-Phase Flux-Switching PM Machine for In-Wheel Traction Applications

A comparative study of five-phase outer-rotor flux-switching permanent magnet (FSPM) machines with different topologies for in-wheel traction applications is presented in this paper. Those topologies include double-layer winding, single-layer winding, C-core, and E-core configurations. The electromagnetic performance in the low-speed region, the flux-weakening capability in the high-speed region, and the fault-tolerance capability are all investigated in detail. The results indicate that the E-core FSPM machine has performance advantages. Furthermore, two kinds of E-core FSPM machines with different stator and rotor pole combinations are optimized, respectively. In order to reduce the computational burden during the large-scale optimization process, a mathematical technique is developed based on the concept of computationally efficient finite-element analysis. While a differential evolution algorithm serves as a global search engine to target optimized designs. Subsequently, multiobjective tradeoffs are presented based on a Pareto-set for 20 000 candidate designs. Finally, an optimal design is prototyped, and some experimental results are given to confirm the validity of the simulation results in this paper

Saliency Ratio and Power Factor of IPM Motors Optimally Designed for High Efficiency and Low Cost Objectives

This paper uses formal mathematical optimization techniques based on parametric finite-element-based computationally efficient models and differential evolution algorithms. For constant-power applications, in the novel approach described, three concurrent objective functions are minimized: material cost, losses, in order to ensure high efficiency, and the difference between the rated and the characteristic current, aiming to achieve very high constant-power flux-weakening range. Only the first two objectives are considered for constant-torque applications. Two types of interior permanent magnet rotors in a single- and double-layer V-shaped configuration are considered, respectively. The stator has the typical two slots per pole and phase distributed winding configuration. The results for the constant-torque design show that, in line with expectations, high efficiency and high power factor machines are more costly, and that the low-cost machines have poorer efficiency and power factor and most importantly, and despite a common misconception, the saliency ratio may also be lower in this case. For constant-power designs, the saliency ratio can be beneficial. Nevertheless, despite a common misconception, when cost is considered alongside performance as an objective, a higher saliency ratio does not necessarily improve the power factors of motors suitable for ideal infinite flux weakening

Modeling and Control for Smart Grid Integration of Solar/Wind Energy Conversion System

Performance optimization, system reliability and operational efficiency are key characteristics of smart grid systems. In this paper a novel model of smart grid-connected PV/WT hybrid system is developed. It comprises photovoltaic array, wind turbine, asynchronous (induction) generator, controller and converters. The model is implemented using MATLAB/SIMULINK software package. Perturb and observe (P&O) algorithm is used for maximizing the generated power based on maximum power point tracker (MPPT) implementation. The dynamic behavior of the proposed model is examined under different operating conditions. Solar irradiance, temperature and wind speed data is gathered from a grid connected, 28.8kW solar power system located in central Manchester. Real-time measured parameters are used as inputs for the developed system. The proposed model and its control strategy offer a proper tool for smart grid performance optimization

Towards Fully Additively-Manufactured Permanent Magnet Synchronous Machines: Opportunities and Challenges

With the growing interest in electrification and as hybrid and pure electric powertrains are adopted in more applications, electrical machine design is facing challenges in terms of meeting very demanding performance metrics for example high specific power, harsh environments, etc. This provides clear motivation to explore the impact of advanced materials and manufacturing on the performance of electrical machines. This paper provides an overview of additive manufacturing (AM) approaches that can be used for constructing permanent magnet (PM) machines, with a specific focus on additively-manufactured iron core, winding, insulation, PM as well as cooling systems. Since there has only been a few attempts so far to explore AM in electrical machines (especially when it comes to fully additively-manufactured machines), the benefits and challenges of AM have not been comprehensively understood. In this regard, this paper offers a detailed comparison of multiple multi-material AM methods, showing not only the possibility of fully additively-manufactured PM machines but also the potential significant improvements in their mechanical, electromagnetic and thermal properties. The paper will provide a comprehensive discussion of opportunities and challenges of AM in the context of electrical machines

Modular switched reluctance machines to be used in automotive applications

In the last decades industry, including also that of electrical machines and drives, was pushed near to its limits by the high market demands and fierce competition. As a response to the demanding challenges, improvements were made both in the design and manufacturing of electrical machines and drives. One of the introduced advanced technological solutions was the modular construction. This approach enables on a hand easier and higher productivity manufacturing, and on the other hand fast repairing in exploitation. Switched reluctance machines (SRMs) are very well fitted for modular construction, since the magnetic insulation of the phases is a basic design requirement. The paper is a survey of the main achievements in the field of modular electrical machines, (especially SRMs), setting the focus on the machines designed to be used in automotive applications

Water-pumping permanent magnet synchronous motor optimization based on customized torque-speed operating area and performance characteristics

© 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 worksThis paper presents a novel methodology for optimizing Permanent Magnet Synchronous Motors for Water-Pumping applications. The algorithm is designed to start the optimization process from a predefined torque-speed area, its desired envelope, and the performance characteristics of the motor to be obtained after the optimization process, providing the information in an efficiency map, according to a predefined control strategy (MTPA, MTPV, etc.). This work also implements an image comparison technique based on the structural similarity index to evaluate the objective function.Peer ReviewedPostprint (author's final draft

Computationally Efficient Strand Eddy Current Loss Calculation in Electric Machines

A fast finite element (FE) based method for the calculation of eddy current losses in the stator windings of randomly wound electric machines is presented in this paper. The method is particularly suitable for implementation in large-scale design optimization algorithms where a qualitative characterization of such losses at higher speeds is most beneficial for identification of the design solutions that exhibit the lowest overall losses including the ac losses in the stator windings. Unlike the common practice of assuming a constant slot fill factor s f for all the design variations, the maximum s f in the developed method is determined based on the individual slot structure/dimensions and strand wire specifications. Furthermore, in lieu of detailed modeling of the conductor strands in the initial FE model, which significantly adds to the complexity of the problem, an alternative rectangular coil modeling subject to a subsequent flux mapping technique for determination of the impinging flux on each individual strand is pursued. Rather than pursuing the precise estimation of ac conductor losses, the research focus of this paper is placed on the development of a computationally efficient technique for the derivation of strand eddy current losses applicable in design optimization, especially where both the electromagnetic and thermal machine behavior are accounted for. A fractional-slot concentrated winding permanent magnet synchronous machine is used for the purpose of this study due to the higher slot leakage flux and slot opening fringing flux of such machines, which are the major contributors to strand eddy current losses in the windings. The analysis is supplemented with an investigation on the influence of the electrical loading on ac winding loss effects for this machine design, a subject that has received less attention in the literature. Experimental ac loss measurements on a 12-slot 10-pole stator assembly will be discussed to verify the existing trends in the simulation result

Performance comparison of conventional synchronous reluctance machines and PM-assisted types with combined star-delta winding

This paper compares four prototype Synchronous Reluctance Motors (SynRMs) having an identical geometry of iron lamination stacks in the stator and rotor. Two different stator winding layouts are employed: a conventional three-phase star connection and a combined star-delta winding. In addition, two rotors are considered: a conventional rotor without magnets and a rotor with ferrite magnets. The performance of the four SynRMs is evaluated using a two-dimensional (2D) Finite Element Model (FEM). For the same copper volume and current, the combined star-delta-connected stator with Permanent Magnets (PMs) in the rotor corresponds to an approximately 22% increase in the output torque at rated current and speed compared to the conventional machine. This improvement is mainly thanks to adding ferrite PMs in the rotor as well as to the improved winding factor of the combined star-delta winding. The torque gain increases up to 150% for low current. Moreover, the rated efficiency is 93.60% compared to 92.10% for the conventional machine. On the other hand, the impact on the power factor and losses of SynRM when using the star-delta windings instead of the star windings is merely negligible. The theoretical results are experimentally validated using four identical prototype machines with identical lamination stacks but different rotors and winding layouts

Optimal design of a three-phase AFPM for in-wheel electrical traction

Sinusoidally fed permanent magnet synchronous motors (PMSM) fulfill the special features required for traction motors to be applied in electric vehicles (EV). Among them, axial flux permanent magnet (AFPM) synchronous motors are especially suited for in-wheel applications. Electric motors used in such applications must meet two main requirements, i.e. high power density and fault tolerance. This paper deals with the optimal design of an AFPM for in-wheel applications used to drive an electrical scooter. The single-objective optimization process carried out in this paper is based on designing the AFPM to obtain an optimized power density while ensuring appropriate fault tolerance requirements. For this purpose a set of analytical equations are applied to obtain the geometrical, electric and mechanical parameters of the optimized AFPM and several design restrictions are applied to ensure fault tolerance capability. The optimization process is based on a genetic algorithm and two more constrained nonlinear optimization algorithms in which the objective function is the power density. Comparisons with available data found in the technical bibliography show the appropriateness of the approach developed in this work.Postprint (published version