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

Modeling, Analysis and Control of a Variable Flux Machine

Electric motors are the key elements in electric propulsion systems. The performance of Electric vehicles (EVs) significantly depends on the electric motors. Permanent magnet synchronous machines (PMSMs) with rare-earth magnets are widely used in EV applications because they fulfill most requirements of EV motors. However, low efficiency at high speed, limited resources and fluctuating prices of rare-earth permanent magnets (PMs) have forced industries to develop alternatives to rare-earth machine technologies. Recently, Variable-Flux PMSMs (VF-PMSMs) also known as memory motors have been introduced to overcome the drawbacks of PMSMs. This thesis focuses on the modeling, analysis and control of the Aluminum-Nickel-Cobalt (AlNiCo) magnet-based VF-PMSMs. This thesis presents the effect of different magnetization pulse widths and methods on the magnetization level, back-EMF and no-load losses of the VF-PMSM. The injection of the magnetization or de-magnetization current pulse will change the magnet flux linkage and back-EMF harmonics. An adaptive nonlinear filter is used to estimate the back-EMF during the motoring mode. The harmonics present in the machine back-EMF due to different magnetization and de-magnetization current pulse widths and magnetization methods are analyzed. Besides, the quality of the back-EMF for different speeds and machine no-load losses are presented for different magnetization states (MSs)