Performance indexes’ evaluation of a novel synchronous reluctance motor with sinusoidal rotor shape

Abstract: This paper presents the evaluation of performance indexes of a novel Synchronous Reluctance Motor (SynRM), which has an axially sinusoidal rotor lamination shape. The stator of a 5.5 kW, 4-pole, 50 Hz conventional three-phase squirrel cage induction motor, with distributed and chorded by one slot, double layer winding, is used for both standard and novel synchronous reluctance motors. Due to the nature of the sinusoidal rotor structure, the 3D Finite Element Analysis (FEA) is utilized to study the electromagnetic parameters of interests. The SynRM with sinusoidal rotor shape results are compared with the standard SynRM without cut-off on the q-axis. The FEA results are validated by means of practical measurements. From both FEA and measured results, it is evident that the novel SynRM enhances the performance indexes of interests such as torque density, torque ripple factor and efficiency

Novel synchronous reluctance motor with sinusoidal rotor lamination shape for less torque ripple contents

Abstract: This paper presents the analysis of a novel Synchronous Reluctance Motor (SynRM), which has an axially sinusoidal rotor lamination shape. The sinusoidal lamination shape is used to vary magnetic flux in the q-axis direction. Therefore, cancelling some torque harmonics produced by stator slotting effects and rotor anisotropy, while maintaining the average torque. The stator of a 5.5 kW, 4-pole, 50 Hz conventional three-phase squirrel cage induction motor, with distributed and chorded by one slot, double layer winding, is used for both standard and novel motors. The Finite Element Analysis (FEM) is used to study the electromagnetic parameters of interests. The FEA results are validated by means of practical measurements. The results obtained from both FEA and practical measurements evidenced that the novel SynRM dropped tremendously the torque ripple contents while still maintained the average torque. The drop in torque ripple contents is mainly due to mitigation of the most dominant torque harmonics caused by stator slotting and rotor anisotropy

Design Simulation and Experiments on Electrical Machines for Integrated Starter-Generator Applications

This thesis presents two different non-permanent magnet machine designs for belt-driven integrated starter-generator (B-ISG) applications. The goal of this project is to improve the machine performance over a benchmark classical switched reluctance machine (SRM) in terms of efficiency, control complexity, torque ripple level and power factor. The cost penalty due to the necessity of a specially designed H-bridge machine inverter is also taken into consideration by implementation of a conventional AC inverter. The first design changes the classical SRM winding configuration to utilise both self-inductance and mutual-inductance in torque production. This allows the use of AC sinusoidal current with lower cost and comparable or even increased torque density. Torque density can be further increased by using a bipolar square current drive with optimum conduction angle. A reduction in control difficulty is also achieved by adoption of standard AC machine control theory. Despite these merits, the inherently low power factor and poor field weakening capability makes these machines unfavourable in B-ISG applications. The second design is a wound rotor synchronous machine (WRSM). From FE analysis, a six pole geometry presents a lower loss level over four pole geometry. Torque ripple and iron loss are effectively reduced by the use of an eccentric rotor pole. To determine the minimum copper loss criteria, a novel algorithm is proposed over the conventional Lagrange method, where the deviation is lowered from ± 10% to ± 1%, and the simulation time is reduced from hours to minutes on standard desktop PC hardware. With the proposed design and control strategies, the WRSM delivers a comparable field weakening capability and a higher efficiency compared with the benchmark SRM under the New European Driving Cycle, where a reduction in machine losses of 40% is possible. Nevertheless, the wound rotor structure brings mechanical and thermal challenges. A speed limit of 11,000 rpm is imposed by centrifugal forces. A maximum continuous motoring power of 3.8 kW is imposed by rotor coil temperature performance, which is extended to 5 kW by a proposed temperature balancing method. A prototype machine is then constructed, where the minimum copper loss criteria is experimentally validated. A discrepancy of no more than 10% is shown in back-EMF, phase voltage, average torque and loss from FE simulation

Synchronous reluctance motors with fractional slot-concentrated windings

PhD ThesisToday, high efficiency and high torque density electrical machines are a growing research interest and machines that contain no permanent magnet material are increasingly sought. Despite the lack of interest over the last twenty years, the permanent magnet-free synchronous reluctance machine is undergoing a revival and has become a research focus due to its magnet-free construction, high efficiency and robustness. They are now considered a potential future technology for future industrial variable speed drive applications and even electric vehicles. This thesis presents for the first time a synchronous reluctance motor with fractional slot-concentrated windings, utilizing non-overlapping single tooth wound coils, for high efficiency and high torque density permanent magnet-free electric drives. It presents all stages of the design and validation process from the initial concept stage through the design of such a machine, to the test and validation of a constructed prototype motor. The prototype machine utilizes a segmented stator core back iron arrangement for ease of winding and facilitating high slot fill factors. The conventional synchronous reluctance motor topology utilizes distributed winding systems with a large number of stator slots, presenting some limitations and challenges when considering high efficiency, high torque density electrical machines with low cost. This thesis aims to present an advancement in synchronous reluctance technology by identifying limitations and improving the design of synchronous reluctance motors through development of a novel machine topology. With the presented novel fractional slot concentrated winding machine design, additional challenges such as high torque ripple and low power factor arise, they are explored and analysed - the design modified to minimise any unwanted parasitic effects. The electrical and electromagnetic characteristics of the developed machine are also explored and compared with that of a conventional machine. A novel FEA post-processing technique is developed to analyse individual air-gap field harmonic torque contributions and the machines dq theory also modified in order to account for additional effects. The developed machine is found to be lower cost, lower mass and higher efficiency than an equivalent induction or conventional synchronous reluctance motor, but does suffer higher torque ripples and lower power factor. The prototype is validated using static and dynamic testing with the results showing a good match with finite element predictions. The work contained within this thesis can be considered as a first step to developing commercial technology based on the concept for variable speed drive applications.Financial assistance was provided by was provided by the UK Engineering and Physical Sciences Research Council (EPSRC) in the form of a Doctoral Training Award and additional financial assistance was kindly provided by Cummins Generator Technologies, Stamford, UK, through industrial sponsorship of this wor

Magnetic Material Modelling of Electrical Machines

The need for electromechanical energy conversion that takes place in electric motors, generators, and actuators is an important aspect associated with current development. The efficiency and effectiveness of the conversion process depends on both the design of the devices and the materials used in those devices. In this context, this book addresses important aspects of electrical machines, namely their materials, design, and optimization. It is essential for the design process of electrical machines to be carried out through extensive numerical field computations. Thus, the reprint also focuses on the accuracy of these computations, as well as the quality of the material models that are adopted. Another aspect of interest is the modeling of properties such as hysteresis, alternating and rotating losses and demagnetization. In addition, the characterization of materials and their dependence on mechanical quantities such as stresses and temperature are also considered. The reprint also addresses another aspect that needs to be considered for the development of the optimal global system in some applications, which is the case of drives that are associated with electrical machines

An Analytical Method for Generating Determined Torque Ripple in Synchronous Machine with Interior Magnets by Harmonic Current Injection

In this paper, we present an extension for an analytical method of calculating the required amplitudes and phase angles of the injected harmonic currents, to generate a determined torque ripple for synchronous machines. With the consideration of reluctance torque in the system equations, this method is valid not only for synchronous machines with surface magnets, but also for those with interior magnets. First, we describe the machine equations as a function of the phase current and the back electromotive force. We then introduce an analytical way to calculate the reluctance torque. After combining the equations, we establish a linear system of equations. The solution of the equation system yields the amplitudes and phase angles of the harmonic currents to be injected. Finally, we validate the equations for calculating the reluctance Torque and the method to generate the determined torque ripple with several finite element method simulations. This allowed us to generate the desired torque fluctuations even for synchronous machines with interior magnets

Study on Performance Characteristics of Interior Permanent Magnet Synchronous Motor Due to Rotor Configuration

This research study was conducted in an effort to understand what effects the rotor configuration has on the performance of a permanent magnet synchronous machine, independent of the stator configuration. Three motors were designed with different interior permanent magnet rotor configurations with the same stator laminations and were analyzed using a combination FEA dq -axis circuit model. The results show that the performance characteristics affected by the rotor configuration were synchronous and reluctance torque production, torque ripple, efficiency and parameter variation. The V-shaped rotor configuration produced the most torque at 70 Nm. The Flat rotor configuration had the second highest torque production at 67 Nm. The Radial rotor configuration had the highest efficiency but had the highest torque ripple. The parameter variation had an effect on the reluctance torque production capabilities of each rotor configuration due to the saturation in the machines

A Review of Transverse Flux Machines Topologies and Design

High torque and power density are unique merits of transverse flux machines (TFMs). TFMs are particularly suitable for use in direct-drive systems, that is, those power systems with no gearbox between the electric machine and the prime mover or load. Variable speed wind turbines and in-wheel traction seem to be great-potential applications for TFMs. Nevertheless, the cogging torque, efficiency, power factor and manufacturing of TFMs should still be improved. In this paper, a comprehensive review of TFMs topologies and design is made, dealing with TFM applications, topologies, operation, design and modeling

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