On the Modeling, Analysis and Development of PMSM: For Traction and Charging Application

Permanent magnet synchronous machines (PMSMs) are widely implemented commercially available traction motors owing to their high torque production capability and wide operating speed range. However, to achieve significant electric vehicle (EV) global market infiltration in the coming years, the technological gaps in the technical targets of the traction motor must be addressed towards further improvement of driving range per charge of the vehicle and reduced motor weight and cost. Thus, this thesis focuses on the design and development of a novel high speed traction PMSM with improved torque density, maximized efficiency, reduced torque ripple and increased driving range suitable for both traction and integrated charging applications. First, the required performance targets are determined using a drive cycle based vehicle dynamic model, existing literature and roadmaps for future EVs. An unconventional fractional–slot distributed winding configuration with a coil pitch of 2 is selected for analysis due to their short end–winding length, reduced winding losses and improved torque density. For the chosen baseline topology, a non–dominated sorting genetic algorithm based selection of optimal odd slot numbers is performed for higher torque production and reduced torque ripple. Further, for the selected odd slot–pole combination, a novel star–delta winding configuration is modeled and analyzed using winding function theory for higher torque density, reduced spatial harmonics, reduced torque ripple and machine losses. Thereafter, to analyze the motor performance with control and making critical decisions on inter–dependent design parameter variations for machine optimization, a parametric design approach using a novel coupled magnetic equivalent circuit model and thermal model incorporating current harmonics for fractional–slot wound PMSMs was developed and verified. The developed magnetic circuit model incorporates all machine non–linearities including effects of temperature and induced inverter harmonics as well as the space harmonics in the winding inductances of a fractional–slot winding configuration. Using the proposed model with a pareto ant colony optimization algorithm, an optimal rotor design is obtained to reduce the magnet utilization and obtain maximized torque density and extended operating range. Further, the developed machine structure is also analyzed and verified for integrated charging operation where the machine’s winding inductances are used as line inductors for charging the battery thereby eliminating the requirement of an on–board charger in the powertrain and hence resulting in reduced weight, cost and extended driving range. Finally, a scaled–down prototype of the proposed PMSM is developed and validated with experimental results in terms of machine inductances, torque ripple, torque–power–speed curves and efficiency maps over the operating speed range. Subsequently, understanding the capabilities and challenges of the developed scaled–down prototype, a full–scale design with commercial traction level ratings, will be developed and analyzed using finite element analysis. Further recommendations for design improvement, future work and analysis will also be summarized towards the end of the dissertation

Modeling And Analysis Of Multi–Phase Permanent Magnet Synchronous Machines: Direct–Drive Electric Vehicle Application

In commercially existing electric vehicles (EVs), power is transferred from the motor to the wheels through a fixed gear mechanical transmission system. However, such a transmission system contributes to a power loss between 2% to 20% of output power of the motor depending on the operating speed and torque of the motor. Therefore, by removing the transmission, a direct–drive EV configuration is obtained with lower component count, improved motor to wheel efficiency and frequency dependent losses. However, challenges in developing a single on–board permanent magnet synchronous machine (PMSM) for such a configuration include high torque density, low torque ripple and high torque per permanent magnet (PM) volume. Therefore, this dissertation proposes a novel PMSM addressing the aforementioned challenges for a direct–drive application. Initially, the design targets, stator and rotor configuration and phase numbers of the PMSM are chosen to satisfy the requirements of a direct drive application. A novel torque and torque ripple model based on multiple reference frames is proposed, in which the torque ripple from spatial harmonics of flux, inductances and the time harmonics of stator currents are included. Using the analytical model, optimal slot–pole combination of the machine is selected based on adaptive gradient descent algorithm. A new consequent pole rotor topology is proposed to improve the torque density and torque per PM volume thereby reducing the usage of expensive rare earth magnets. The proposed PMSM with novel rotor is further improved in terms of torque density, losses and cost by performing an intensive structural optimization based on novel hybrid analytical model, finite element analysis and supervised learning. The optimized PMSM is then analyzed for various drive cycles and performance in terms of torque, speed and efficiency are discussed. A scaled–down prototype of the proposed PMSM is developed and comprehensive experimental analysis in terms of torque ripple, torque–speed characteristics and efficiency are performed under different speeds and load conditions and are compared with the results obtained from proposed analytical model

The investigation of electromagnetic radial force and associated vibration in permanent magnet synchronous machines

The rising public awareness of climate change and urban air pollution has been one of the key drivers for transport electrification. Such trend drastically accelerates the quest for high-power-and-torque-density electric drive systems. The rare-earth permanent magnet synchronous machine, with its excellent steady-state and dynamic characteristics, has been the ideal candidate for these applications. Specifically, the fractional-slot and concentrated-winding configuration is widely adopted due to its distinctive merits such as short end winding, low torque pulsation, and high efficiency. The vibration and the associated acoustic noise become one of the main parasitic issues of high-performance permanent magnet synchronous drives. These undesirable features mainly arise from mechanical connection failure, imperfect assembly, torque pulsation, and electromagnetic radial and axial force density waves. The high-power-and-torque-density requirement will only be ultimately fulfilled by the reduction of both electromagnetic active material and passive support structure. This results in inflated electromagnetic force density inside the electric machine. Besides, the sti.ness of the machine parts can be compromised and the resultant natural frequencies are significantly brought down. Therefore, the vibration and acoustic noise that are associated with the electromagnetic radial and axial force density waves become a burden for large deployment of these drives. This study is mainly dedicated to the investigation of the electromagnetic radial forced density and its associated vibration and acoustic noise in radial-flux permanent magnet synchronous machines. These machines are usually powered by voltage source inverter with pulse width modulation techniques and various control strategies. Consequently, the vibration problem not only lies on the permanent magnet synchronous machine but also highly relates to its drive and controller. Generally, the electromagnetic radial force density and its relevant vibration can be divided into low-frequency and high-frequency components based on their origins. The low-frequency electromagnetic radial force density waves stem from the magnetic field components by the permanent magnets and armature reaction of fundamental and phase-belt current harmonic components, while the high-frequency ones are introduced by the interactions between the main low-frequency and sideband highfrequency magnetic field components. Both permanent magnets and armature reaction current are the main sources of magnetic field in electric machines. Various drive-level modeling techniques are first reviewed, explored, and developed to evaluate the current harmonic components of the permanent magnet synchronous machine drive. Meanwhile, a simple yet e.ective analytical model is derived to promptly estimate the sideband current harmonic components in the drive with both sinusoidal and space-vector pulse width modulation techniques. An improved analytical method is also proposed to predict the magnetic field from permanent magnets in interior permanent magnet synchronous machines. Moreover, a universal permeance model is analytically developed to obtain the corresponding armature-reaction magnetic field components. With the permanent magnet and armature-reaction magnetic field components, the main electromagnetic radial force density components can be identified and estimated based on Maxwell stress tensor theory. The stator tooth structure has large impacts on both electromagnetic radial force density components and mechanical vibration behaviors. The stator tooth modulation e.ect has been comprehensively demonstrated and explained by both finite element analysis and experimental results. Analytical models of such e.ect are developed for prompt evaluation and insightful revelation. Based on the proposed models, multi-physics approaches are proposed to accurately predict low-frequency and high-frequency electromagnetic radial vibration. Such method is quite versatile and applicable for both integral-slot and fractional-slot concentrated-winding permanent magnet synchronous machines. Comprehensive experimental results are provided to underpin the validity of the proposed models and methods. This study commences on the derivations of the drive parameters such as torque angle, modulation index, and current harmonic components from circuit perspective and further progresses to evaluate and decouple the air-gap magnetic field components from field perspective. It carries on to dwell on the analytical estimations of the main critical electromagnetic radial force density components and stator tooth modulation e.ect. Based on the stator mechanical structure, the corresponding electromagnetic radial vibration and acoustic noise can be accurately predicted. Various analytical models have been developed throughout this study to provide a systematic tool for quick and e.ective investigation of electromagnetic radial force density, the associated vibration and acoustic noise in permanent magnet synchronous machine drive. They have all been rigorously validated by finite element analysis and experimental results. Besides, this study reveals not only a universal approach for electromagnetic radial vibration analysis but also insightful correlations from both machine and drive perspectives

Multiphase induction motor drives - a technology status review

The area of multiphase variable-speed motor drives in general and multiphase induction motor drives in particular has experienced a substantial growth since the beginning of this century. Research has been conducted worldwide and numerous interesting developments have been reported in the literature. An attempt is made to provide a detailed overview of the current state-of-the-art in this area. The elaborated aspects include advantages of multiphase induction machines, modelling of multiphase induction machines, basic vector control and direct torque control schemes and PWM control of multiphase voltage source inverters. The authors also provide a detailed survey of the control strategies for five-phase and asymmetrical six-phase induction motor drives, as well as an overview of the approaches to the design of fault tolerant strategies for post-fault drive operation, and a discussion of multiphase multi-motor drives with single inverter supply. Experimental results, collected from various multiphase induction motor drive laboratory rigs, are also included to facilitate the understanding of the drive operatio

Optimization of cogging torque in interior permanent magnet synchronous motor using optimum magnet v-angle

Introduction. At present, the most important requirement in the field of electrical engineering is the better utilization of electrical power, due to its increasing demand and not-so-increasing availability. A permanent magnet synchronous motor (PMSM) is increasingly gaining popularity in various household and industrial applications because of its superior performance compared to conventional electrical motors. Purpose. PMSM is designed based on the selection of various design variables and optimized to fulfill the same. Being superiorly advantageous over other motors, PMSM has the major disadvantage of higher cogging torque. Higher cogging torque generates torque ripple in the PMSM motor leading to various problems like vibration, rotor stress, and noisy operation during starting and steady state. The designer should aim to reduce the cogging torque at the design stage itself for overall better performance. Methods. An interior rotor v-shaped web-type PMSM is designed and its performance analysis is carried out using finite element analysis (FEA). Magnet v-angle is optimized with the objective of cogging torque reduction. Performance comparison is carried out between the optimized motor and the initially designed motor with FEA. Novelty. Magnet v-angle analysis is performed on the same keeping all other parameters constant, to obtain minimum cogging torque. The proposed method is practically viable as it does not incur extra costs and manufacturing complexity. Practical value. It is observed that the magnet v-angle is an effective technique in the reduction of cogging torque. Cogging torque is reduced from 0.554 N×m to 0.452 N×m with the application of the magnet v-angle optimization technique.Вступ. В даний час найважливішою вимогою в галузі електротехніки є найкраще використання електроенергії через зростаючу потребу в ній і не настільки зростаючу доступність. Синхронний двигун з постійними магнітами (СДПМ) набуває все більшої популярності в різних побутових та промислових застосуваннях завдяки своїм чудовим характеристикам у порівнянні зі звичайними електродвигунами. Мета. СДПМ, спроєктований на основі вибору різних конструктивних змінних та оптимізований для їх виконання. Будучи чудовим у порівнянні з іншими двигунами, СДПМ має головний недолік: вищий крутний момент. Вищий крутний момент викликає пульсації крутного моменту в двигуні з постійними магнітами, що призводить до різних проблем, таких як вібрація, напруга ротора і шумна робота під час запуску і режиму. Проєктувальник повинен прагнути зменшити крутний момент зубчастого колеса на стадії проєктування для підвищення загальної продуктивності. Методи. Розроблено СДПМ з внутрішнім ротором v-подібної форми та стрижневого типу, та аналіз його характеристик виконаний з використанням аналізу методом скінченних елементів (FEA). Кут v-подібного магніту оптимізовано з метою зниження зубчастого моменту. Порівняння продуктивності здійснюється між оптимізованим двигуном та двигуном, спочатку спроєктованим за допомогою FEA. Новизна. Аналіз кута v-подібного магніту виконується таким же чином, зберігаючи решту всіх параметрів постійними, щоб отримати мінімальний зубчастий крутний момент. Запропонований спосіб практично життєздатний, оскільки не вимагає додаткових витрат та складності виготовлення. Практична цінність. Помічено, що v-подібний кут магніту є ефективним способом зниження зубчастого моменту. Зубчастий крутний момент зменшений з 0,554 Н×м до 0,452 Н×м за рахунок застосування методу оптимізації v-подібного кута магніту

Mathematical Models for the Design of Electrical Machines

This book is a comprehensive set of articles reflecting the latest advances and developments in mathematical modeling and the design of electrical machines for different applications. The main models discussed are based on the: i) Maxwell–Fourier method (i.e., the formal resolution of Maxwell’s equations by using the separation of variables method and the Fourier’s series in 2-D or 3-D with a quasi-Cartesian or polar coordinate system); ii) electrical, thermal and magnetic equivalent circuit; iii) hybrid model. In these different papers, the numerical method and the experimental tests have been used as comparisons or validations

Torque and torque components in high-speed permanent-magnet synchronous machines with a shielding cylinder

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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

Sensorless Control of Switched-Flux Permanent Magnet Machines

This thesis investigates the sensorless control strategies of permanent magnet synchronous machines (PMSMs), with particular reference to switched-flux permanent magnet (SFPM) machines, based on high-frequency signal injection methods for low speed and standstill and the back-EMF based methods for medium and high speeds