Neural network-based diagnostic tool for detecting stator inter-turn faults in line start permanent magnet synchronous motors

Three-phase line-start permanent magnet synchronous motors are considered among the most promising types of motors in industrial applications. However, these motors experience several faults, which may cause significant financial losses. This paper proposed a feed-forward neural network-based diagnostic tool for accurate and fast detection of the location and severity of stator inter-turn faults. The input to the neural network is a group of representative statistical and frequency-based features extracted from the steady-state three-phase stator current signals. The current signals with different numbers of shorted turns and loading conditions are captured using the developed finite element JMAG ™ model for interior mount LSPMSM. In addition, an experimental set-up was built to validate the finite element model and the proposed diagnostics tool. The simulation and experimental test results showed an overall accuracy of 93.125% in detecting the location and the size of inter-turn, whereas, the accuracy in detecting the location of the fault is 100%

Stable and robust design of active disturbance-rejection current controller for permanent magnet machines in transportation systems

Active disturbance-rejection control (ADRC) as a current control (CC) method for ac drive systems has been recently shown to have significant strengths. Its robustness to system uncertainties and its high disturbance-rejection capability render it an attractive control scheme for various mobile applications. Until now, however, all the known tuning methods available in literature are based on a number of assumptions that may lead to the degraded drive performance and even to the loss of stability. This article, thus, provides a rigorous analysis and proposes a new CC design method based on the ADRC technique. The design derives a generic closed-loop transfer function considering system delays and the dynamics of the extended state observer. Based on this analysis, a tuning method able to guarantee a set performance to avoid unstable operation is thus proposed. The effects of model uncertainties on the current loop system stability and robustness are also analyzed and reported. A tuning criterion to enhance system robustness and to improve its dynamic performance is developed and validated experimentally on a case study system

Energy efficient machine tools

The growing global energy demand from industry results in significant ecological and economical costs. Aiming to decrease the impact of machining operations, an increasing number of research activities and publications regarding energy efficient machine tools and machining processes can be found in the literature. This keynote paper provides an overview of current machine- and process-related measures to improve the energy efficiency of metal cutting machine tools. Based on an analysis of the energy requirements of machine tool components, design measures to reduce the energy demand of main and support units are introduced. Next, methods for an energy efficient operation of machine tools are reviewed. Furthermore, latest developments and already available energy efficiency options in the machine tool industry are discussed. The paper concludes with recommendations and future research questions for more energy efficient machine tools

Investigation of Control Concepts for High-Speed Induction Machine Drives and Grid Side Pulse-Width Modulation Voltage Source Converters

Control of a low voltage ac/dc/ac converter for high-speed induction machine drive applications has been investigated. Such a configuration can be applied, for example, in microturbines and high-speed spindles. Scalar control is usually applied for the control of high-speed drives especially in the case of very high-speed drives. Indirect rotor-flux-oriented control and direct torque control are designed and compared for the control of an exemplary high-speed induction machine drive. The 2L VSC is the most widely applied converter for high-speed drives. However, the 3L-NPC VSC is an attractive topology if drastically increased switching frequencies are required. A detailed comparison between a 2L VSC and a 3L-NPC VSC as the machine side converter of the exemplary high-speed induction machine drive is carried out. Voltage-oriented control is applied for the control of the grid side PWM active front end converter. In several industrial applications PWM active front end converters commonly operate in parallel to thyristor converter fed dc drives. Behavior of the voltage-oriented controlled active front end converter with L-filter in the presence of a parallel thyristor converter is investigated. The design of the LCL-filter components according to the given maximum grid current harmonics (e.g. IEEE-519) is a complex task. So far a precise and clear design procedure has not been presented. A new procedure to design the grid side filter (L- and LCL-filter) is proposed using the analytical expression of the converter voltage harmonics based on Bessel functions to achieve the compliance with the grid standard of IEEE-519. Voltage-oriented control with active damping is used to control the active front end converter with LCL-filter. A simple method is proposed to design the required lead-lag compensator in the active damping loop

Sensorless Passive Control Algorithms for Medium to High Power Synchronous Motor Drives

This study is focused on the definition of sensorless algorithms for Surface-Mounted Permanent Magnet Synchronous Motors (SM-PMSM) and Electrically Excited Synchronous Motors (EESM). Even if these types of motors are rather different from a constructive point of view, they have some common issues regarding sensorless drives. Indeed, SM-PMSMs, which are usually used for low-medium power applications, have a low rotor anisotropy, therefore it is complicated to use sensorless active methods (which are based on high-frequency voltage injection), due to the low signal to noise ratio. On the other hand, active methods on high-power EESM have the drawback of high torque ripple. For these reasons, both for SM-PMSM and EESM, it is interesting to define and use sensorless passive algorithms (i.e., based on observers and estimators). The drawback of such algorithms is that their performance deteriorates significantly in the low-speed region. The aim of this thesis is to define a robust sensorless passive algorithm that could work in a wide speed region and that could start the motor from standstill even with a high load torque. The initial objective of the work is to find, among the various algorithms proposed in the technical literature, the most promising one. For this purpose, four different algorithms are selected. They are chosen considering the most recent articles presented in the technical literature on high reputable journals. Since many improvements are proposed in the literature for the different algorithms, the most recent ones are candidates for being the ones with higher performance. Even if the experimental tests of the four different algorithms are shown in the literature, it is difficult to evaluate a priori which offers the best performance. As a matter of facts, for each algorithm different tests are carried out (e.g., different speed and torque profiles). In addition to that, motor sizing and features are different. Moreover, the test bench characteristics can significantly affect sensorless performance. As an example, inverter features and non-linearities (e.g., switching frequency, dead times, parasitic capacitance) and current measures (e.g., noise, linearity, bias) play a key role in the estimation of rotor position. The added value of this thesis is to perform a fair comparison of the four algorithms, performing the same tests with the same test bench. Additional tests are performed on the most performing algorithm. Even if this sensorless technique is already proposed in the technical literature, a methodology for observer gain tuning is not shown, which is proposed, instead, in this thesis. Moreover, the algorithm is enhanced by adding a novel management of direct axis current, which ensures the stability during fast transient from medium-high speed to low speed. The algorithm is tested with different test benches in order to verify the control effectiveness in various operating conditions. As a matter of facts, it is tested at first in the University of Genoa PETRA Lab on two different test benches. The first test bench is composed of two coupled motors, in which the braking motor could realize different torque profiles (linear torque, quadratic torque and constant torque), whereas in the second test bench the motor is coupled with an air compressor, which is a demanding load since high and irregular torque is applied at standstill. After the test at the University of Genoa, the algorithm is implemented in Phase Motion Control and Physis drive and tested on a six-meter diameter fan. Regarding the EESMs, for these type of motor is necessary to estimate the stator flux amplitude and angle. Indeed, the stator angle is usually used to perform the Park transformations in the FOC scheme and the stator flux amplitude is used to control the excitation current. In this study, the RFO is adapted for estimating the stator flux of an EESM. Regarding the control for EESM, it is tested on a simulative model for high-power motors provided by NIDEC ASI and tested on a small-scale test bench at the University of Genoa

Thermal Modeling of Permanent Magnet Synchronous Motors for Electric Vehicle Application

Permanent magnet synchronous motor (PMSM) is a better choice as a traction motor since it has high power density and high torque capability within compact structure. However, accommodating such high power within compact space is a great challenge, as it is responsible for significant rise of heat in PMSM. As a result, there is considerable increase in operating temperature which in turn negatively affects the electromagnetic performance of the motor. Further, if the temperature rise exceeds the permissible limit, it can cause demagnetization of magnets, damage of insulation, bearing faults, etc. which in turn affect the overall lifecycle of the motor. Therefore, thermal issues need to be dealt with carefully during the design phase of PMSM. Hence, the main focus of this thesis is to develop efficient ways for thermal modeling to address thermal issues properly. Firstly, a universal lumped parameter thermal network (LPTN) is proposed which can be used for all types of PMSMs regardless of any winding configuration and any position of magnets in the rotor. Further, a computationally efficient finite element analysis (FEA) thermal model is proposed with a novel hybrid technique utilizing LPTN strategy for addressing the air gap convection in an efficient way. Both proposed LPTN and FEA thermal models are simplified ways to predict motor temperature with a comparatively less calculation process. Finally, the proposed thermal models have been experimentally validated for the newly designed interior and surface mounted PMSM prototypes. Again, a procedure for effective cooling design process of PMSM has been suggested by developing an algorithm for cooling design optimization of the motor. Further, a computational fluid dynamics (CFD) model with a proposed two-way electro-thermal co-analysis strategy has been developed to predict both thermal and electromagnetic performance of PMSM more accurately considering the active cooling system. The developed step algorithm and CFD modeling approach will pave the way for future work on cooling design optimization of the newly designed interior and surface mounted PMSM prototypes

Volume 1 – Symposium

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group A: Materials Group B: System design & integration Group C: Novel system solutions Group D: Additive manufacturing Group E: Components Group F: Intelligent control Group G: Fluids Group H | K: Pumps Group I | L: Mobile applications Group J: Fundamental