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

Design and Validation of a Synchronous Reluctance Motor With Single Tooth Windings

This paper presents for the first time the analysis and experimental validation of a six-slot four-pole synchronous reluctance motor with nonoverlapping fractional slot-concentrated windings. The machine exhibits high torque density and efficiency due to its high fill factor coils with very short end windings, facilitated by a segmented stator and bobbin winding of the coils. These advantages are coupled with its inherent robustness and low cost. The topology is presented as a logical step forward in advancing synchronous reluctance machines that have been universally wound with a sinusoidally distributed winding. The paper presents the motor design, performance evaluation through finite element studies and validation of the electromagnetic model, and thermal specification through empirical testing. It is shown that high performance synchronous reluctance motors can be constructed with single tooth wound coils, but considerations must be given regarding torque quality and the d-q axis inductances

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

Design of a synchronous reluctance motor with non-overlapping fractional-slot concentrated windings

This paper presents the detailed design and finite element study of a synchronous reluctance machine with a non-overlapping fractional slot concentrated windings. The machine design employs single tooth wound coils with short end windings and high fill factor, which facilitates the machines high torque density and efficiency. As no magnets are required, the machine is low cost and of robust construction like the induction motor. This machine topology is presented as a step forward in synchronous reluctance technology which are usually wound with a distributed winding with long end turns. Analytical design methodologies and performance through finite element studies are presented. Scaling and design options, along with manufacturing options are discussed, the future development of the topology for automotive traction and other demanding applications is also presented

Investigation of Interior Permanent Magnet Machines with Concentrated Windings for High Dynamics Applications

Interior permanent magnet (IPM) machines and non-overlapping concentrated windings (CW) are two design philosophies that have grown in popularity over the last decade. This is due to the many benefits and flexibility they provide. The combination of these philosophies and the tradeoffs involved, however, have not yet been fully discovered. The hope is that the performance enhancing properties of the IPM can be combined with the manufacturability of the CW. An investigation of these two philosophies have been done, focusing on torque performances and magnet losses caused by eddy currents. In order to do the investigation the finite element method (FEM) analysis software, COMSOL Multiphysics have been used. Two IPM models have been compared to a surface mounted permanent magnet (SPM) machine using the same stator design and winding philosophies. The IPM machines showed capability of reaching approxi- mately the same average torque as the SPM machine, although performing poorly when considering torque ripple performance. Considering magnet losses, the IPM machines showed little tendency to reduce the full-load magnet losses. No-load losses, however, was drastically reduced in the IPM models compared to the SPM model. The effect of magnet segmentation on magnet losses was also demonstrated

A Computationally Efficient Method for Calculation of Strand Eddy Current Losses in Electric Machines

In this paper, a fast finite element (FE)-based method for the calculation of eddy current losses in the stator windings of randomly wound electric machines with a focus on fractional slot concentrated winding (FSCW) permanent magnet (PM) machines will be presented. 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 which exhibit the lowest overall losses including the ac losses in the stator windings. Unlike the common practice of assuming a constant slot fill factor, sf, for all the design variations, the maximum sf 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. The research focus of the paper is placed on development of a computationally efficient technique for the ac winding loss derivation applicable in design-optimization, where both the electromagnetic and thermal machine behavior are accounted for. The analysis is supplemented with an investigation on the influence of the electrical loading on ac winging loss effects for a particular machine design, a subject which 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 results

Synchronous reluctance motors with toroidal windings

This paper introduces the concept of a four-pole toroidally wound synchronous reluctance machine as an alternative to conventional and fractional slot concentrated winding designs. The toroidal windings, which are wound around the stator coreback have very short end windings, limiting the copper loss as with fractional slot concentrated windings, facilitating an increase in machine efficiency. However, unlike fractional slot concentrated windings, even space-harmonics in the air gap do not exist and the associated parasitic effects are minimized. The machine concept is described and its relationship with conventional and fractional slot concentrated winding machines is discussed. Construction methods are discussed with emphasis on manufacturability and the advantages and disadvantages of this topology are presented

Leakage Inductance of a Prototyped Single Tooth Wound Synchronous Reluctance Motor

This paper explores the inductance characteristics present in single tooth wound synchronous reluctance motors, specifically the stator leakage inductance. Despite the nature of the single tooth design resulting in increased air gap harmonic content, having has consequences for the machines' design, performance & operation, the topology has been shown previously to be competitive for high efficiency drives. A key design constraint in the design of synchronous reluctance motors is maximizing the direct axis inductance and minimizing the quadrature axis inductance for a high saliency ratio. The effect of increased leakage inductance on this saliency ratio is explored with emphasis placed on design aspects of such single tooth wound synchronous reluctance motors. It is shown that careful design of the machine is required to maximize the saliency ratio in this machine topology and that the dominant leakage inductance component is the air gap harmonic leakage

Application of fractional slot concentrated windings to synchronous reluctance machines

Due to the advancement of electric vehicles, the desire for high torque density electric motors for traction applications is steadily increasing. It is advantageous to design such a motor with little or no rare earth permanent magnet (PM) material due to the associated environmental, political and economic challenges with its extraction and processing. This paper explores a novel synchronous reluctance machine (RSM), with fractional slot concentrated windings (cRSM) as an alternative to PM, induction machine (IM) and switched reluctance (SRM) traction motors. The impact of applying fractional slot concentrated windings to RSMs is presented and the outline of the design options for such a machine is detailed. Scaling of the fractional slot wound synchronous reluctance motor is also briefly discussed, in order to realise a torque dense synchronous reluctance machine for future traction applications. A finite element analysis comparison between IM and conventional synchronous reluctance with the proposed cRSM is also presented

Design Synthesis and Optimization of Permanent Magnet Synchronous Machines Based on Computationally-Efficient Finite Element Analysis

In this dissertation, a model-based multi-objective optimal design of permanent magnet ac machines, supplied by sine-wave current regulated drives, is developed and implemented. The design procedure uses an efficient electromagnetic finite element-based solver to accurately model nonlinear material properties and complex geometric shapes associated with magnetic circuit design. Application of an electromagnetic finite element-based solver allows for accurate computation in intricate performance parameters and characteristics. The first contribution of this dissertation is the development of a rapid computational method that allows accurate and efficient exploration of large multi-dimensional design spaces in search of optimum design(s). The computationally efficient finite element-based approach developed in this work provides a framework of tools that allow rapid analysis of synchronous electric machines operating under steady-state conditions. In the developed modeling approach, major steady-state performance parameters such as, winding flux linkages and voltages, average, cogging and ripple torques, stator core flux densities, core losses, efficiencies and saturated machine winding inductances, are calculated with minimum computational effort. In addition, the method includes means for rapid estimation of distributed stator forces and three-dimensional effects of stator and/or rotor skew on the performance of the machine. The second contribution of this dissertation is the development of the design synthesis and optimization method based on a differential evolution algorithm. The approach relies on the developed finite element-based modeling method for electromagnetic analysis and is able to tackle large-scale multi-objective design problems using modest computational resources. Overall, computational time savings of up to two orders of magnitude are achievable, when compared to current and prevalent state-of-the-art methods. These computational savings allow one to expand the optimization problem to achieve more complex and comprehensive design objectives. The method is used in the design process of several interior permanent magnet industrial motors. The presented case studies demonstrate that the developed finite element-based approach practically eliminates the need for using less accurate analytical and lumped parameter equivalent circuit models for electric machine design optimization. The design process and experimental validation of the case-study machines are detailed in the dissertation