Performance assessment of ferrite- and neodymiumassisted synchronous reluctance machines

Growing attention towards environmental sustainability of energy conversion and stricter efficiency standards are encouraging the market penetration of high-efficiency electrical motors. Current regulations define international efficiency classes and the testing procedures for direct-on-line machines only, commonly induction motors. Synchronous reluctance machines are a valid alternative to the widely employed induction motors for variable-speed applications, due to their low manufacturing cost and higher efficiency. With proper design, torque ripple can be mitigated as much as to make rotor skewing unnecessary for most of applications. The low power factor downside can be fixed by inserting low-cost ferrite magnet into the rotor barriers, with benefits also on the torque capability and constant power speed range. The aim of this paper is to assess the performance and efficiency potential of one synchronous reluctance and two permanent magnet-assisted synchronous reluctance machine prototypes, obtained by replacing the rotor of a general-purpose induction motor with the said synchronous reluctance ones. The rotor barriers have been designed by means of a genetic optimization algorithm has and then adapted to insert commercially available magnets, compliant with minimum extracost requirements. The two prototypes were comprehensively characterized, to validate the design phase and to investigate the performance of the machines. The provided experimental results are critically examined and commented

Two Design Procedures for PM Synchronous Machines for Electric Powertrains

This paper presents a design environment for permanent-magnet synchronous motors (PMSMs). Two design examples for electric vehicle (EV) traction are presented: one interior PM machine of the PM-assisted synchronous reluctance (PM-SyR) type and one concentrated-winding surface-mounted PM motor (CW-SPM). The parametric design software used in the paper includes design equations, finite element analysis (FEA) and multi-objective optimization algorithms for the design of PMSMs. The paper presents two possible design methodologies, for the two mentioned test cases. EV application was chosen for its many challenging aspects, involving flux weakening for extended speed range, discontinuous duty cycles, high transient overload requirements, high efficiency over a large area of operation, and so forth. The design examples are compared to selected benchmark designs in terms of operating range in the torque versus speed domain and efficiency maps, all FEA evaluated. Besides magnetics, thermal and structural aspects are included in the study

A Novel Flux Barrier Parametrization for Synchronous Reluctance Machines

This paper presents a novel parametrization for the flux barrier profiles of synchronous reluctance and permanent magnet assisted reluctance machines. In literature there are several methods used to design rotor flux barriers of various types, however the vast majority use only a few parameters to characterize their shape. These approaches are proven to be effective in terms of simplicity and computational burden required to achieve an optimal design. However, simplified parametrizations certainly decrease the degrees of freedom when designing the whole barrier shape. In this paper, an attempt to increase the degrees of freedom, introducing a novel rotor flux barrier parametrization, is presented. The method proposed uses natural splines, defined by the positions of a set of control points, to form the shape of the flux barriers. The spline and state-of-the-art barrier profiles are compared from both electromagnetic and mechanical perspectives. The results of this investigation show that by increasing the degrees of freedom it is possible to obtain better performance characteristics. The proposed parametrization is applied to a 6-pole synchronous reluctance motor and its permanent magnet assisted variant, optimized for a traction application. A prototype has been manufactured and tested to experimentally validate the design methodology

Design Methods for Surface-Mounted Permanent Magnet Synchronous Machines

Permanent magnet synchronous machines (PMSMs) provide several advantages compared with induction machine, such as higher power and torque density, and better dynamic response. Among PMSMs, Surface-mounted permanent magnet (SPM) machine has simple rotor configuration and easy control strategy due to its isotropic characteristics. Plenty of publications have illustrated the fundamentals and the design methods of SPM machines. Based on these, this dissertation presents new design methods for SPM machines. Both design methods are comprehensively illustrated. The presented design methods are embedded into a machine design platform available online. One of the new methods is an automatic design procedure using multi objective optimization method, whose principle is to combine multi objective differential evolution (MODE) optimization with finite element analysis (FEA) to obtain the machine with the best trade-off among the targeted objectives, like maximum torque, minimum torque ripple, good flux weakening capability, etc. Two cases are reported by using such automatic design method, one for a SPM machine with concentrated winding (CW-SPM) and the other with distributed windings (DW-SPM), respectively. The CW-SPM machine is designed for traction application. In this case, design equations, magnetic FEA, multi objective optimization, simplified structural and thermal co-design are presented. Torque and power profiles of the designed machine are reported. The losses and efficiency map are also presented. The DW-SPM machine is capable of low cogging torque thanks to the automatic design procedure. Dependent on demagnetization limit and optimal magnet span calculation, the magnet bounds in optimization process are obtained. The cogging torque and maximum torque waveforms of three different machines on Pareto front are shown, which are obtained by MODE optimization and FEA simulations. One optimum machine is selected as the best trade-off machine among PM volume, torque and cogging torque behaviors. Besides the automatic design process, the other design method called parametric design for SPM machines is reported. The parametric design provides a very effective and concise solution for SPM machine design without losing precision on the machine performance calculation. Three steps of parametric design development are reported. For each step, design flowcharts and examples are presented. Firstly, a parametric design plane was established based on rotor split ratio x and per unit magnetic loading b. All the sizing equations, torque and power factor calculation are functions of x and b. An example for designing a CW-SPM for traction application is reported. Later the parametric design plane was modified into the x and l_m⁄g plane, the latter parameter being the magnet-airgap length ratio. The design process of DW-SPM machines using the parametric plane is described. A prototype 一s built and verified the validity of the design process. Then, a general design approach based on accurate steel loading for both DW and CW SPM machines is proposed. By using subdomain model during the design process, the stator sizing equations are improved by considering the only one most loaded slot pitch rather than the entire pole pitch. Five different cases of SPM machines are analyzed to get the precise flux quantities passing through the most loaded teeth in one slot. A comprehensive parametric design flowchart for SPM machines is addressed. By using the parametric method, machine models are built according to each sizing situation. The steel loadings on both each tooth and yoke are measured by FEA and compared with target steel loading B_fe at open load condition, which shows good agreements with analytical cases. Finally, the designs are also tested at the respective rated currents. The presented methods give insightful and effective means in SPM machine desig

Analysis, design optimisation and experimental performance of synchronous reluctance and permanent magnet assisted synchronous reluctance machines

The research studies, in detail, the synchronous reluctance machine (SynRM) and permanent magnet assisted synchronous reluctance machine (PMSynRM) to improve the machine performances. In this study, the SynRM analytical models are revisited, and functional characteristics are mathematically developed to improve the machine performance. The performance parameters such as torque density, power factor, and efficiency are investigated along with torque ripples. SynRM is known for its high torque density in a compact size. Its improvement is analytically studied further by optimising rotor properties. The power factor of these machines is rather low compared with its equivalent AC machines. Although the machine’s power factor can be improved using control techniques, it is still not high enough. The machine has gone through significant development over the years since J.K Kostko published the first paper on reluctance machines back in 1923. The researchers have tested various types of anisotropies, such as axially laminated and transversally laminated. The machine torque and power factor depend on its saliency ratio. Although the axially laminated structure offers high saliency ratio due to the naturally distributed flux barrier structure, it has mechanical constraints. The axial rotor segments are fixed together by specially designed bolts that are conductive material in nature. This mechanical arrangement increases quadrature axis inductance, consequently reduces the saliency ratio of the machine. On the other hand, the transversally laminated structure is more mechanically feasible and offers comparatively high performance. One of the primary focus of this study is to improve the power factor. It has been comprehensively investigated. The SynRM machine is also known for high torque ripples. The non-linear structure and its reluctance path along the air-gap make the machine highly susceptible to torque pulsation. The cross induction due to the D and Q axis along the air-gap increases the machine’s ripples. Besides, poor stator winding (both sinusoidal and step excitation) also increases the machine torque ripples. The existing ripple reduction practices are revisited in this study to further understand the torque ripples of this machine. The rotor of SynRM is redesigned and optimised to reduce the ripples effect. The causes of ripples are also analytically studied in detail, and mathematical models are developed and presented for understanding the phenomena. Two different ways of analysing the ripple effects are considered, and the pros and cons of both methods are discussed. The SynRM is simulated using an advanced finite element analysis (FEM) software to verify the analytical models as well as optimise the machine performance. Firstly, primitive rotor structures are developed so that they can be automatically varied during parameterisation and optimisation. Four flux barrier shapes are analysed to determine the optimum shape for high performance by investigating flux’s natural path. From the results, a multi-barrier arrangement is studied with an advanced algorithm for three and four-layer designs, and an optimum rotor is proposed based on the simulations. Using a single-objective and multi-objective optimisation techniques, the SynRM is optimised from the simulated design. An advanced topology is developed for automated optimisation that can offer flexibility in varying optimisation variables as part of this research. The optimised design’s performance is analysed in detail and compared with analytical models. The torque ripples are discussed in detail, and an advanced torque ripple minimisation topology is developed. Then the design is optimised for two types of barrier shapes. A number of designs are prototyped for experimental verification. Finally, the current trend in rare-earth magnets is investigated with its cost per volume ratio. The rare-earth neodymium magnets are focused on this study for improved performance with optimum volume. The analytical model of PM assisted design is studied in detail, and its performance parameters are compared with SynRM. A PMSynRM with a linear-barrier is simulated for a detailed analysis of the machine that discusses different PM volumes and the impact on machine performance due to the volume of PM and location. The performance parameters, discussed in the analytical model, are compared with the simulation results. The improvement in power factor and torque density is investigated using various designs. The optimisation is performed in two ways. The first one is adding PMs to the optimised SynRM. Single-objective and multi-objective optimisation are performed using an advanced optimisation algorithm. Secondly, the topology of SynRM is modified for PMSynRM in such a way the entire machine can be automated during optimisation by adding the PM’s variables to the existing one. The performances of the two optimised designs have been compared. PMSynRM prototypes are developed to verify the simulation results. The eight SynRM designs are prototyped to report the practical results. Six of them are to verify various performance parameters of SynRM and two of them to test the ripples effect. Moreover, two PMSynRM prototypes are fabricated to verify the simulation results. The saliency of each SynRM is measured and compared with simulated results. Then, each design is tested experimentally in all possible scenarios and compared. Extensive testing is performed on all prototypes under various operating conditions and reported