Design and implementation of a linear motor for multi-car elevators

The multi-car elevator system is a revolutionary new technology for high-rise buildings, promising outstanding economic benefits, but also requiring new technology for propulsion, safety and control. In this paper we report on experimental results with new components for linear motor driven multi-car elevators. We show that linear synchronous motors with optimized design and with our new safety and control system can be considered as core components of a new generation of elevator systems. The main new results concern the development of a safety system integrated into the propulsion system, the design methodology of a linear motor optimized for the multi-car elevator task, and the motion control system that is expected to be usable for extra high-rise buildings

Theoretical and Experimental Investigations of a Permanent Magnet Excited Transverse Flux Machine with a Segmented Stator for In-Wheel Motor Applications

A three-phase transverse flux permanent magnet (PM) motor with flux concentrating (FC-) topology that has a segmented stator is studied in this dissertation. The phases of the stator have been placed around the rotational axis of the machine instead of placing them in a classical way over each other along the axial direction. Through this phase arrangement, the electrical and mechanical shifts between the phases are considered to ensure proper operation of the transverse flux machine (TFM) without the need of extra components such as a start-up capacitor or a special designed power supply. The segmented stator construction has required that the conventional ring coils to be replaced by a type of concentric winding that take a saddle shape enabling parallel magnetic circuits to take place. This has initiated studying the effect of the distances located between the phases on all over the performances of the machine. In order to select an initial construction for the stator, a preliminary assessment study of some conventional PM-TFMs having ring coils are carried out, through which they are re-designed as outer rotor motors and compared based on the level of electromagnetic torque and the inductance profile. As the main application of the design is to achieve a compact construction for an outer rotor, low noise and speed too for possible future in-wheel applications, the most interesting issue in this study is how to bring all the phases of the machine around the shaft in one layer without losing the torque productivity as when the phases are placed under each other in the conventional way. Therefore, the designed machine is set in further theoretical evaluation studies via finite element method (FEM) with the conventional layered TFM, and it shows that the TFM with segmented windings has a better torque density as its correspondence in the conventional layered structure. This result is in favor to the segmented structure, in particular, about 31% of the PMs number in the segmented structure (i.e., total number of PMs located between the phases) will not have an active role in the torque production. A detailed mathematical theory has been analytically developed and investigated to show the validity and limitation of the design. The study has incorporated how the segmentation of each phase and placement of the two parts opposite to each other can improve the mechanical balance of the TFM and hence quite rotation. The approach has been shown for two- and three-phase PM-TFMs. Moreover, illustration for applying the same principle of segmented stator to surface PM topology of TFMs is analytical verified and shown via FEM. Possible constructions with segmented stators are developed in a periodical table format to give the machine designer a shortcut for a possible construction with the selected number of magnets, number of segments per phase and the desired space between the phases. Since the noise is a well-known problem of TFMs, due to the ripple in the electromagnetic torque waveform and the natural magnetic normal forces, the normal and axial forces in PM-TFM with segmented stator have been investigated too, where introducing more segments per phase will reduce their effects. In order to validate the theoretical investigation, a low-scaled test machine is designed, constructed and a complete test bench has been built to experimentally test the machine. The experimental investigations have included generator and motor operation modes as well as measuring the ratings, performances of the machine and the starting methods. The test machine has reached via the conducted tests an average torque of about 2.1 Nm with an efficiency of 53% and it has a great development potential to be improved via shaping of stator poles, the room available for the windings, fill factor and more optimization possibilities. Based on the theoretical and experimental investigations, the operation of the segmented winding design of PM-TFM proves itself to work and to have a future for compact motors in industrial operation, or as in-wheel outer rotor motor for mobile platforms. For higher power applications, a machine with such type of stator should be designed with big diameters that will allow the utility of more PMs as well as more segments per phase, where both are involved in the torque production, i.e., more torque density for the segmented TFM

Minimization of Eddy-Current Loss in a Permanent-Magnet Tubular Linear Motor

This paper presents a minimization of eddy-current loss (ECL) in permanent-magnet (PM) of three tubular linear PM motors (TLPMMs). Three-dimensional Finite-Element Analysis has been used for the simulations. The ECL component is usually not taken into consideration in conventional PM motors. In present technologies, ECL is generated inside magnets of PM motors, due to both the high conductivity of the rare-earth magnets and the harmonics of the slot. This loss can increase the temperature inside the magnets and that may deteriorate their magnetic properties and potential risk of thermal demagnetization. Therefore, in the translator, segmented magnets has been used, because the cancelation of the ECL with this technique is possible as illustrated by the FEA results. Meanwhile, for the stator core of the three proposed motors, soft magnetic composite (SMC) material, Somaloy 700 has been used for its low cost and approximately zero ECL

Multi-level-objective design optimization of permanent magnet synchronous wind generator and solar photovoltaic system for an urban environment application

This Ph.D. thesis illustrates a novel study on the analytical and numerical design optimization of radial-flux permanent magnet synchronous wind generators (PMSGs) for small power generation in an urban area, in which an outer rotor topology with a closed-slot stator is employed. The electromagnetic advantages of a double-layer fractional concentration non-overlapping winding configuration are discussed. The analytical behavior of a PMSG is studied in detail; especially for magnetic flux density distribution, time and space harmonics, flux linkages, back-EMF, cogging torque, torque, output power, efficiency, and iron losses computation. The electromagnetic behavior of PMSGs are evaluated when a number of various Halbach array magnetization topologies are presented to maximize the generator’s performance. In addition, the thermal behavior of the PMSG is improved using an innovative natural air-cooling system for rated speed and higher to decrease the machine’s heat mainly at the stator teeth. The analytical investigation is verified via 2-D and 3-D finite element analysis along with a good experimental agreement. Design optimization of electrical machines plays the deterministic role in performance improvements such as the magnetization pattern, output power, and efficiency maximization, as well as losses and material cost minimization. This dissertation proposes a novel multi-objective design optimization technique using a dual-level response surface methodology (D-RSM) and Booth’s algorithm (coupled to a memetic algorithm known as simulated annealing) to maximize the output power and minimize material cost through sizing optimization. Additionally, the efficiency maximization by D-RSM is investigated while the PMSG and drive system are on duty as the whole. It is shown that a better fit is available when utilizing modern design functions such as mixed-resolution central composite (MR-CCD) and mixed-resolution robust (MR-RD), due to controllable and uncontrollable design treatments, and also a Window-Zoom-in approach. The proposed design optimization was verified by an experimental investigation. Additionally, there are several novel studies on vibro-acoustic design optimization of the PMSGs with considering variable speed analysis and natural frequencies using two techniques to minimize the magnetic noise and vibrations. Photovoltaic system design optimization considered of 3-D modeling of an innovative application-oriented urban environment structure, a smart tree for small power generation. The horizon shading is modeled as a broken line superimposed onto the sun path diagram, which can hold any number of height/azimuth points in this original study. The horizon profile is designed for a specific location on the Barcelona coast in Spain and the meteorological data regarding the location of the project was also considered. Furthermore, the input weather data is observed and stored for the whole year (in 2016). These data include, ambient temperature, module’s temperature (open and closed circuits tests), and shading average rate. A novel Pareto-based 3-D analysis was used to identify complete and partial shading of the photovoltaic system. A significant parameter for a photovoltaic (PV) module operation is the nominal operating cell temperature (NOCT). In this research, a glass/glass module has been referenced to the environment based on IEC61215 via a closed-circuit and a resistive load to ensure the module operates at the maximum power point. The proposed technique in this comparative study attempts to minimize the losses in a certain area with improved output energy without compromising the overall efficiency of the system. A Maximum Power Point Track (MPPT) controller is enhanced by utilizing an advanced perturb & observe (P&O) algorithm to maintain the PV operating point at its maximum output under different temperatures and insolation. The most cost-effective design of the PV module is achieved via optimizing installation parameters such as tilt angle, pitch, and shading to improve the energy yield. The variation of un-replicated factorials using a Window-Zoom-in approach is examined to determine the parameter settings and to check the suitability of the design. An experimental investigation was carried out to verify the 3-D shading analysis and NOCT technique for an open-circuit and grid-connected PV module.Esta tesis muestra un novedoso estudio referente al diseño optimizado de forma analítica y numérica de un generador síncrono de imanes permanentes (PMSGs) para una aplicación de microgeneración eólica en un entorno urbano, donde se ha escogido una topología de rotor exterior con un estator de ranuras cerradas. Las ventajas electromagnéticas de los arrollamientos fraccionarios de doble capa, con bobinas concentradas se discuten ampliamente en la parte inicial del diseño del mismo, así como las características de distribución de la inducción, los armónicos espaciales y temporales, la fem generada, el par de cogging así como las características de salida (par, potencia generada, la eficiencia y la distribución y cálculo de las pérdidas en el hierro que son analizadas detalladamente) Posteriormente se evalúan diferentes configuraciones de estructuras de imanes con magnetización Halbach con el fin de maximizar las prestaciones del generador. Adicionalmente se analiza la distribución de temperaturas y su mejora mediante el uso de un novedoso diseño mediante el uso de ventilación natural para velocidades próximas a la nominal y superiores con el fin de disminuir la temperatura de la máquina, principalmente en el diente estatórico. El cálculo analítico se completa mediante simulaciones 2D y 3D utilizando el método de los elementos finitos así como mediante diversas experiencias que validan los modelos y aproximaciones realizadas. Posteriormente se desarrollan algoritmos de optimización aplicados a variables tales como el tipo de magnetización, la potencia de salida, la eficiencia así como la minimización de las pérdidas y el coste de los materiales empleados. En la tesis se proponen un nuevo diseño optimizado basado en una metodología multinivel usando la metodología de superficie de respuesta (D-RSM) y un algoritmo de Booth (maximizando la potencia de salida y minimizando el coste de material empleado) Adicionalmente se investiga la maximización de la eficiencia del generador trabajando conjuntamente con el circuito de salida acoplado. El algoritmo utilizado queda validado mediante la experimentación desarrollada conjuntamente con el mismo. Adicionalmente, se han realizado diversos estudios vibroacústicos trabajando a velocidad variable usando dos técnicas diferentes para reducir el ruido generado y las vibraciones producidas. Posteriormente se considera un sistema fotovoltaico orientado a aplicaciones urbanas que hemos llamado “Smart tree for small power generation” y que consiste en un poste con un generador eólico en la parte superior juntamente con uno o más paneles fotovoltaicos. Este sistema se ha modelado usando metodologías en 3D. Se ha considerado el efecto de las sombras proyectadas por los diversos elementos usando datos meteorológicos y de irradiación solar de la propia ciudad de Barcelona. Usando una metodología basada en un análisis 3D y Pareto se consigue identificar completamente el sistema fotovoltaico; para este sistema se considera la temperatura de la célula fotovoltaica y la carga conectada con el fin de generar un algoritmo de control que permita obtener el punto de trabajo de máxima potencia (MPPT) comprobándose posteriormente el funcionamiento del algoritmo para diversas situaciones de funcionamiento del sistemaLa tesis desenvolupa un nou estudi per al disseny optimitzat, analític i numèric, d’un generador síncron d’imants permanents (PMSGs) per a una aplicació de microgeneració eòlica en aplicacions urbanes, on s’ha escollit una configuració amb rotor exterior i estator amb ranures tancades. Es discuteixen de forma extensa els avantatges electromagnètics dels bobinats fraccionaris de doble capa així com les característiques resultats vers la distribució de les induccions, els harmònics espacials i temporals, la fem generada, el parell de cogging i les característiques de sortida (parell, potencia, eficiència i pèrdues) Tanmateix s’afegeix l’estudi de diferents estructures Halbach per als imants permanents a fi i efecte de maximitzar les característiques del generador. Tot seguit s’analitza la distribució de temperatures i la seva reducció mitjançant la utilització d’una nova metodologia basada en la ventilació natural. Els càlculs analítics es complementen mitjançant anàlisi en 2 i 3 dimensions utilitzant elements finits i diverses experiències que validen els models i aproximacions emprades. Una vegada fixada la geometria inicial es desenvolupen algoritmes d’optimització per a diverses variables (tipus de magnetització dels imants, potencia de sortida, eficiència, minimització de pèrdues i cost dels materials) La tesi planteja una optimització multinivell emprant la metodologia de superfície de resposta i un algoritme de Booth; a més, es realitza la optimització considerant el circuit de sortida. L’algoritme resta validat per la experimentació realitzada. Finalment, s’han considerat diversos estudis vibroacústic treballant a velocitat variable, emprant dues tècniques diferents per a reduir el soroll i les vibracions desenvolupades. Per a finalitzar l’estudi es considera un sistema format per una turbina eòlica instal·lada sobre un pal de llum autònom, els panells fotovoltaics corresponents i el sistema de càrrega. Per a modelitzar l’efecte de l’ombrejat s’ha emprat un model en 3D i les dades del temps i d’irradiació solar de la ciutat de Barcelona. El model s’ha identificat completament i s’ha generat un algoritme de control que considera, a més, l’efecte de la temperatura de la cèl·lula fotovoltaica y la càrrega connectada al sistema per tal d’aconseguir el seguiment del punt de màxima potenciaPostprint (published version

Two-phase linear hybrid reluctance actuator with low detent force

In this paper, a novel two-phase linear hybrid reluctance actuator with the double-sided segmented stator, made of laminated U cores, and an interior mover with permanent magnets is proposed. The permanent magnets are disposed of in a way that increases the thrust force of a double-sided linear switched reluctance actuator of the same size. To achieve this objective, each phase of the actuator is powered by a single H-bridge inverter. To reduce the detent force, the upper and the lower stator were shifted. Finite element analysis was used to demonstrate that the proposed actuator has a high force density with low detent force. In addition, a comparative study between the proposed linear hybrid reluctance actuator, linear switched reluctance, and linear permanent magnet actuators of the same size was performed. Finally, experimental tests carried out in a prototype confirmed the goals of the proposed actuator.Peer ReviewedPostprint (published version

Comparison of Induction and PM Synchronous motor drives for EV application including design examples

Three different motor drives for electric traction are compared, in terms of output power and efficiency at the same stack dimensions and inverter size. Induction motor (IM), surface-mounted permanent-magnet (PM) (SPM), and interior PM (IPM) synchronous motor drives are investigated, with reference to a common vehicle specification. The IM is penalized by the cage loss, but it is less expensive and inherently safe in case of inverter unwilled turnoff due to natural de-excitation. The SPM motor has a simple construction and shorter end connections, but it is penalized by eddy-current loss at high speed, has a very limited transient overload power, and has a high uncontrolled generator voltage. The IPM motor shows the better performance compromise, but it might be more complicated to be manufactured. Analytical relationships are first introduced and then validated on three example designs and finite element calculated, accounting for core saturation, harmonic losses, the effects of skewing, and operating temperature. The merits and limitations of the three solutions are quantified comprehensively and summarized by the calculation of the energy consumption over the standard New European Driving Cycl

A Comparative Study of Yokeless and Segmented Armature versus Single Sided Axial Flux PM Machine Topologies for Electric Traction

This article systematically compares two axial flux permanent magnet machines designed for a university student racing car application: a double-rotor single-stator yokeless and segmented armature (YASA) structure, and a single-stator single-rotor configuration. Both machines are optimized for minimum loss and active weight using three-dimensional finite element analysis and the highest performing candidate designs are compared in more detail. The studies indicate that the benefits offered by the YASA configuration over the single-stator single-rotor machine are achieved only for specific designs that are heavier. For the design space with lower mass, albeit with increased losses, the Pareto front designs overlap. In this envelope, the YASA configuration demonstrates higher efficiencies at higher speeds, whilst the single-stator single-rotor is more efficient in high torque duty cycles. This shows the performance of the two machines is very similar and the choice is application specific. To validate the finite element analysis used in the optimization, a prototype was built and tested. Results showed good alignment between simulation and experimental data