Design optimization of a high-speed synchronous reluctance machine

Synchronous reluctance machines, including the per¬manent magnet assisted variants are competitive motor topologies if the application requires high efficiency and a cost effective solution with a high flux weakening capability. However, increas¬ing operating speeds incur challenging design and development decisions, mainly in order to find design solutions that ensure the machines structural integrity without compromising the overall performance. In this paper, a comprehensive design procedure for high speed synchronous reluctance machines is presented. In order to validate the procedure, a 5 kW, 80000 rpm machine is considered. The proposed strategy consists of a two-step procedure in which the electromagnetic and structural designs have been properly decoupled dividing the design space in two subsets. Each subset mainly affects the electromagnetic or the structural performances. Several structural design optimizations have been then performed with the aim of finding the optimal trade-off between the rotor geometrical complexity (that defines the required computational resources) and the electromagnetic performance. The reported experimental tests of the prototyped machine validate the proposed design strategy which can be used as general guidelines on the structural design of synchronous reluctance machines

Transient Overload Characteristics of PM-Assisted Synchronous Reluctance Machines, Including Sensorless Control Feasibility

Synchronous reluctance machines are a highefficiency alternative to induction motors for variable-speed applications. To mitigate the well-known downside of their lower power factor, permanent-magnet-assisted topologies, in which either rare-earth or ferrite magnets are inserted into the rotor in suitable quantities, are often adopted. The design and optimization procedures for PM-assisted topologies have been thoroughly discussed in the related literature. This paper compares synchronous reluctance machines assisted with NdFeB and ferrite magnets, focusing on torque overload capability and feasibility of saliency-based position estimation algorithms. Three prototypes were realized and tested. They all have the stator of a commercial induction motor and the same customdesigned synchronous reluctance rotor laminations. Of the three prototypes, one is a pure synchronous reluctance motor, and the other two have NdFeB and ferrite magnets, respectively; both are designed to give the same torque at rated current. Results from simulations and experiments are presented comparing the transient overload capability of the three machines, in terms of torque capability and de-magnetization limit. A dynamic thermal model of the machines was developed within this scope. Moreover, the feasibility of saliency-based sensorless methods was investigated and is presented here for the three machines, both at high- and low-current loads. The results of the paper suggest that the ferrite-assisted solution is the best candidate for replacing induction motors in variable-speed applications, for its optimal tradeoff between performance and cost

Optimal parameter inference method for effective design of synchronous reluctance machines

Abstract: This paper presents a method for evaluating, both qualitatively and quantitatively, the effects of specific rotor design parameters on the performance of a synchronous reluctance machine. The method uses multi-factor experimental design, with Analysis of Variance (ANOVA), and Finite Element Analysis (FEA) to determine the optimal rotor design parameter according to a specific objective. Using this method, two factors - rotor flux barrier pitch angle and barrier width - are selected at simultaneously varied levels for assessment with the aim of analyzing the response variables, which are, the average torque and torque ripple. Results from the investigation show that the influence of the rotor flux barrier pitch angle on the torque ripple is more statistically significant than the influence of the barrier width. However, the effect of the barrier width on the average torque is more significant

A SyR and IPM machine design methodology assisted by optimization algorithms

The design optimization of synchronous reluctance (SyR) machine and its extension to internal permanent magnet (IPM) motors for wide speed ranges is considered in this paper by means of a Finite Element Analysis-based multi-objective genetic algorithm (MOGA). The paper is focused on the rotor design, that is controversial key aspect of the design of high saliency SyR and IPM machines, due to the difficult modeling dominated by magnetic saturation. A three step procedure is presented, to obtain a starting SyR design with the optimal torque versus torque ripple compromise and then properly include PMs into the SyR geometry, given the desired constant power speed range of the final IPM machine. The designed rotors have been extensively analyzed by computer simulations and two SyR prototypes have been realized to demonstrate the feasibility of the design procedur

Contribution to multi-physical studies of small synchronous-reluctance machine for automotive equipment

Due to environmental concern related to CO_{2} emissions, automobile manufacturers has been increasingly engaging in electrifying multiples on-board applications. Functions that are being electrified involve crucial and complex applications such as clutches, power steering, assisted brakes and others. Furthermore, these functions are often placed in a particularly challenging environment in terms of spaces, thermal, vibration and acoustic. As results, research on electrical motors to find the most suitable motor to a given applications has been intensified. In this environment, machines optimal design requires simultaneous consideration of numerous physical phenomena ; both in terms of expected performance and constraints to be respected. The physics that can be affected includes the electromagnetic / electromechanical performance, thermal behavior and vibro-acoustic behavior. Among a large choice of machine, with the manufacturer cost and manufacturing concern taken into account, the synchronous reluctance machine with segmented rotor has been found to be particularly interesting for application with severe ambient temperature and encumbrance limitation. This study has therefore as objectives to evaluate the capacity of the synchronous reluctance machine in all physics mentioned and eventually shows the interaction between these physics, thus performance alteration of the machine operated in automobile equipment environment. Multi-physics model were developed and confronted to experimental validations using a prototype machine that was designed for an electrical clutch. Using the validated model, different performance figures of synchronous reluctance machines with different rotor topologies were compared. Resulting from the study, valid electromagnetic, electromechanical, thermal and vibro-acoustic models are now available to be used as tools in future machine design. The synchronous reluctance with segmented rotor prototype machine has been shown to be capable to be used in the electrical clutch application studied in particular. Following performance evaluations in different physics, suggestions of improvements have also been proposed

Optimal rotor design of synchronous reluctance machines considering the effect of current angle

The torque density and efficiency of synchronous reluctance machines (SynRMs) are greatly affected by the geometry of the rotor. Hence, an optimal design of the SynRM rotor geometry is highly recommended to achieve optimal performance (i.e., torque density, efficiency, and power factor). This paper studies the impact of considering the current angle as a variable during the optimization process on the resulting optimal geometry of the SynRM rotor. Various cases are analyzed and compared for different ranges of current angles during the optimization process. The analysis is carried out using finite element magnetic simulation. The obtained optimal geometry is prototyped for validation purposes. It is observed that when considering the effect of the current angle during the optimization process, the output power of the optimal geometry is about 3.32% higher than that of a fixed current angle case. In addition, during the optimization process, the case which considers the current angle as a variable has reached the optimal rotor geometry faster than that of a fixed current angle case. Moreover, it is observed that for a fixed current angle case, the torque ripple is affected by the selected value of the current angle. The torque ripple is greatly decreased by about 34.20% with a current angle of 45 degrees compared to a current angle of 56.50 degrees, which was introduced in previous literature

Performance evaluation of synchronous reluctance motors with and without permanent magnets

Nowadays, a growing interest in the efficiency and the cost of electrical machines has been noticed. Therefore, Synchronous Reluctance Motors (SynRMs) have become more attractive, thanks to their higher efficiency and nevertheless acceptable cost compared to induction machines. The rotor design of SynRMs with or without permanent magnets (PMs) has a huge effect on the motor efficiency, torque density and power factor. This paper introduces an evaluation for the performance of SynRMs with and without PMs in terms of efficiency, torque and power factor maps. Three different rotor designs for the same machine have been compared. For one machine, the experimental measurements have been obtained and the validation of the simulation results have been confirme

Performance comparison of conventional synchronous reluctance machines and PM-assisted types with combined star-delta winding

This paper compares four prototype Synchronous Reluctance Motors (SynRMs) having an identical geometry of iron lamination stacks in the stator and rotor. Two different stator winding layouts are employed: a conventional three-phase star connection and a combined star-delta winding. In addition, two rotors are considered: a conventional rotor without magnets and a rotor with ferrite magnets. The performance of the four SynRMs is evaluated using a two-dimensional (2D) Finite Element Model (FEM). For the same copper volume and current, the combined star-delta-connected stator with Permanent Magnets (PMs) in the rotor corresponds to an approximately 22% increase in the output torque at rated current and speed compared to the conventional machine. This improvement is mainly thanks to adding ferrite PMs in the rotor as well as to the improved winding factor of the combined star-delta winding. The torque gain increases up to 150% for low current. Moreover, the rated efficiency is 93.60% compared to 92.10% for the conventional machine. On the other hand, the impact on the power factor and losses of SynRM when using the star-delta windings instead of the star windings is merely negligible. The theoretical results are experimentally validated using four identical prototype machines with identical lamination stacks but different rotors and winding layouts

Sensored and sensorless speed control methods for brushless doubly fed reluctance motors

The study considers aspects of scalar V/f control, vector control and direct torque (and flux) control (DTC) of the brushless doubly fed reluctance machine (BDFRM) as a promising cost-effective alternative to the existing technological solutions for applications with restricted variable speed capability such as large pumps and wind turbine generators. Apart from providing a comprehensive literature review and analysis of these control methods, the development and results of experimental verification, of an angular velocity observerbased DTC scheme for sensorless speed control of the BDFRM which, unlike most of the other DTC-concept applications, can perform well down to zero supply frequency of the inverter-fed winding, have also been presented in the study