Engineering design project : series 1

This book is a compilation of engineering design projects which illustrates a detail explanation on the design process including all tools and methods involved in each design stage. The presented projects have been selected to prepare engineering students with the adequate knowledge and skills required in organizing product based project, formulating problems, generating and evaluating alternatives, preparing technical documentation and considering the sustainable and economic constraints for the product development and realization stage using the integration of various disciplines in mechanical and manufacturing engineering. This book is generally suitable as a reference to project-oriented problem-based learning (POPBL) activities at engineering institutions

Improved current-regulated delta modulator for reducing switching frequency and low-frequency current error in permanent magnet brushless AC drives

The conventional current-regulated delta modulator (CRDM) results in a high current ripple and a high switching frequency at low rotational speeds, and in low-frequency current harmonics, including a fundamental current error, at high rotational speeds. An improved current controller based on CRDM is proposed which introduces a zero-vector zone and a current error correction technique. It reduces the current ripple and switching frequency at low speeds, without the need to detect the back-emf, as well as the low-frequency error at high speeds. The performance of the modulator is verified by both simulation and measurements on a permanent magnet brushless ac drive

Fault-Tolerant Control of a Flux-switching Permanent Magnet Synchronous Machine

Je jasné, že nejúspěšnější konstrukce zahrnuje postup vícefázového řízení, ve kterém každá fáze může být považována za samostatný modul. Provoz kterékoliv z jednotek musí mít minimální vliv na ostatní, a to tak, že v případě selhání jedné jednotky ostatní mohou být v provozu neovlivněny. Modulární řešení vyžaduje minimální elektrické, magnetické a tepelné ovlivnění mezi fázemi řízení (měniče). Synchronní stroje s pulzním tokem a permanentními magnety se jeví jako atraktivní typ stroje, jejíž přednostmi jsou vysoký kroutící moment, jednoduchá a robustní konstrukce rotoru a skutečnost, že permanentní magnety i cívky jsou umístěny společně na statoru. FS-PMSM jsou poměrně nové typy střídavého stroje stator-permanentní magnet, které představují významné přednosti na rozdíl od konvenčních rotorů - velký kroutící moment, vysoký točivý moment, v podstatě sinusové zpětné EMF křivky, zároveň kompaktní a robustní konstrukce díky umístění magnetů a vinutí kotvy na statoru. Srovnání výsledků mezi FS-PMSM a klasickými motory na povrchu upevněnými PM (SPM) se stejnými parametry ukazuje, že FS-PMSM vykazuje větší vzduchové mezery hustoty toku, vyšší točivý moment na ztráty v mědi, ale také vyšší pulzaci díky reluktančnímu momentu. Pro stroje buzené permanentními magnety se jedná o tradiční rozpor mezi požadavkem na vysoký kroutící moment pod základní rychlostí (oblast konstantního momentu) a provozem nad základní rychlostí (oblast konstantního výkonu), zejména pro aplikace v hybridních vozidlech. Je předložena nová topologie synchronního stroje s permanentními magnety a spínaným tokem odolného proti poruchám, která je schopná provozu během vinutí naprázdno a zkratovaného vinutí i poruchách měniče. Schéma je založeno na dvojitě vinutém motoru napájeném ze dvou oddělených vektorově řízených napěťových zdrojů. Vinutí jsou uspořádána takovým způsobem, aby tvořila dvě nezávislé a oddělené sady. Simulace a experimentální výzkum zpřesní výkon během obou scénářů jak za normálního provozu, tak za poruch včetně zkratových závad a ukáží robustnost pohonu za těchto podmínek. Tato práce byla publikována v deseti konferenčních příspěvcích, dvou časopisech a knižní kapitole, kde byly představeny jak topologie pohonu a aplikovaná řídící schémata, tak analýzy jeho schopnosti odolávat poruchám.It has become clear that the most successful design approach involves a multiple phase drive in which each phase may be regarded as a single-module. The operation of any one module must have minimal impact upon the others, so that in the event of that module failing the others can continue to operate unaffected. The modular approach requires that there should be minimal electrical, magnetic and thermal interaction between phases of the drive. Flux-Switching permanent magnet synchronous machines (FS-PMSM) have recently emerged as an attractive machine type virtue of their high torque densities, simple and robust rotor structure and the fact that permanent magnets and coils are both located on the stator. Flux-switching permanent magnet (FS-PMSM) synchronous machines are a relatively new topology of stator PM brushless machine. They exhibit attractive merits including the large torque capability and high torque (power) density, essentially sinusoidal back-EMF waveforms, as well as having a compact and robust structure due to both the location of magnets and armature windings in the stator instead of the rotor as those in the conventional rotor-PM machines. The comparative results between a FS-PMSM and a traditional surface-mounted PM (SPM) motor having the same specifications reveal that FS-PMSM exhibits larger air-gap flux density, higher torque per copper loss, but also a higher torque ripple due to cogging -torque. However, for solely permanent magnets excited machines, it is a traditional contradiction between the requests of high torque capability under the base-speed (constant torque region) and wide speed operation above the base speed (constant power region) especially for hybrid vehicle applications. A novel fault-tolerant FS-PMSM drive topology is presented, which is able to operate during open- and short-circuit winding and converter faults. The scheme is based on a dual winding motor supplied from two separate vector-controlled voltage-sourced inverter drives. The windings are arranged in a way so as to form two independent and isolated sets. Simulation and experimental work will detail the driver’s performance during both healthy- and faulty- scenarios including short-circuit faults and will show the drive robustness to operate in these conditions. The work has been published in ten conference papers, two journal papers and a book chapter, presenting both the topology of the drive and the applied control schemes, as well as analysing the fault-tolerant capabilities of the drive.

A New Fixed Switching Frequency Direct Torque Controlled PMSM Drives with Low Ripple in Flux and Torque

Direct Torque Control (DTC) has gained popularity for development of advanced motor control due to its simplicity and offers fast instantaneous torque and flux controls. However, the conventional DTC which is based on hysteresis controller has major drawbacks, namely high torque ripple and variable inverter switching frequency. This paper presents an improved switching strategy for reducing flux and torque ripples in DTC of PMSM drives; wherein the torque hysteresis controller and the look-up table used in the conventional DTC are replaced with a constant frequency torque controller (CFTC) and an optimized look-up table, respectively. It can be shown that a constant switching frequency is established due to the use of the CFTC while the reduction of torque and flux ripples is achieved mainly because of the selection of optimized voltage vector (i.e. with an optimized look-up table). This paper also will explain the construction of DTC schemes implemented using MATLAB-Simulink blocks. Simulation results were shown that a significant reduction of flux and torque ripples which is about 90% can be achieved through the proposed DTC scheme

Effective Torque Ripple Reduction of Permanent Magnet Brushless DC Motor

To reduce commutation torque ripple, a model predictive control (MPC) for permanent brushless DC motors (BLDCM) is presented (CTR). Torque ripples cause vibration noise and decrease efficiency. The suggested MPC system is constructed by forecasting the phase current with the aim of minimizing the BLDCM\u27s CTR and taking into consideration the CTR sources. The method presented in this paper is a unique methodology for suppressing CTR over the whole speed range, avoids more complex current controllers or modulation models, and overcomes the challenges of commutated-phase-current control. The ideal switching state is instantly selected and implemented during the next sample period according to the preset cost function in order to match the slope rates of outgoing and incoming phase currents during commutation, ensuring the minimum of commutation torque ripple. The modelling and experiment findings show that the suggested method can effectively reduce CTR over a wide speed range and achieve the better CTR minimization performance. The results are then compared to the outcomes of various torque ripple reduction(TRR) techniques

Impact of the motor magnetic model on direct flux vector control of interior PM motors

The stator-field-oriented, direct-flux vector control has been proven to be effective in terms of linear torque control and model independent performance at limited voltage and current (i.e. in flux weakening) for AC drives of various types. The performance of the direct-flux vector control relies on the accuracy of the flux estimation, as for any field oriented control. The knowledge of the motor magnetic model is critical for flux estimation when the operating at low speed. This paper addresses the effects of a limited knowledge of the motor model on the performance of the control at low speed, for an Interior Permanent Magnet motor drive. Experimental results are give

A New Fixed Switching Frequency Direct Torque Controlled PMSM Drives with Low Ripple in Flux and Torque

Direct Torque Control (DTC) has gained popularity for development of  advanced  motor  control  due  to  its  simplicity  and  offers  fast  instantaneous torque  and  flux  controls.  However,  the  conventional  DTC  which  is  based  on hysteresis  controller  has  major  drawbacks,  namely  high  torque  ripple  and variable  inverter  switching  frequency.  This  paper  presents  an  improved switching strategy for reducing flux and torque ripples in DTC of PMSM drives; wherein  the  torque  hysteresis  controller  and  the  look-up  table  used  in  the conventional  DTC  are  replaced  with  a  constant  frequency  torque  controller (CFTC)  and  an  optimized  look-up  table,  respectively.  It  can  be  shown  that  a constant switching frequency is established due to the use of the CFTC while the reduction of torque and flux ripples is achieved mainly because of the selection of optimized  voltage  vector (i.e.  with an optimized  look-up  table).  This paper also  will  explain  the  construction  of  DTC  schemes  implemented  using MATLAB-Simulink  blocks.  Simulation  results  were  shown  that  a  significant reduction of flux and torque ripples which is about 90% can be achieved through the proposed DTC scheme.

Control Strategies for Open-End Winding Drives Operating in the Flux-Weakening Region

This paper presents and compares control strategies for three-phase open-end winding drives operating in the flux-weakening region. A six-leg inverter with a single dc-link is associated with the machine in order to use a single energy source. With this topology, the zero-sequence circuit has to be considered since the zero-sequence current can circulate in the windings. Therefore, conventional over-modulation strategies are not appropriate when the machine enters in the flux-weakening region. A few solutions dealing with the zero-sequence circuit have been proposed in literature. They use a modified space vector modulation or a conventional modulation with additional voltage limitations. The paper describes the aforementioned strategies and then a new strategy is proposed. This new strategy takes into account the magnitudes and phase angles of the voltage harmonic components. This yields better voltage utilization in the dq frame. Furthermore, inverter saturation is avoided in the zero-sequence frame and therefore zero-sequence current control is maintained. Three methods are implemented on a test bed composed of a three-phase permanent-magnet synchronous machine, a six-leg inverter and a hybrid DSP/FPGA controller. Experimental results are presented and compared for all strategies. A performance analysis is conducted as regards the region of operation and the machine parameters.Projet SOFRACI/FU

Critical Aspects of Electric Motor Drive Controllers and Mitigation of Torque Ripple - Review

Electric vehicles (EVs) are playing a vital role in sustainable transportation. It is estimated that by 2030, Battery EVs will become mainstream for passenger car transportation. Even though EVs are gaining interest in sustainable transportation, the future of EV power transmission is facing vital concerns and open research challenges. Considering the case of torque ripple mitigation and improved reliability control techniques in motors, many motor drive control algorithms fail to provide efficient control. To efficiently address this issue, control techniques such as Field Orientation Control (FOC), Direct Torque Control (DTC), Model Predictive Control (MPC), Sliding Mode Control (SMC), and Intelligent Control (IC) techniques are used in the motor drive control algorithms. This literature survey exclusively compares the various advanced control techniques for conventionally used EV motors such as Permanent Magnet Synchronous Motor (PMSM), Brushless Direct Current Motor (BLDC), Switched Reluctance Motor (SRM), and Induction Motors (IM). Furthermore, this paper discusses the EV-motors history, types of EVmotors, EV-motor drives powertrain mathematical modelling, and design procedure of EV-motors. The hardware results have also been compared with different control techniques for BLDC and SRM hub motors. Future direction towards the design of EV by critical selection of motors and their control techniques to minimize the torque ripple and other research opportunities to enhance the performance of EVs are also presented.publishedVersio

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