Prediction of the electromagnetic torque in synchronous machines through Maxwell stress harmonic filter (HFT) method

For the calculation of torque in synchronous motors a local method is analysed, based on the Maxwell stress theory and the filtered contributions due to the harmonics of the magnetic vector potential in the motor air-gap. By considering the space fundamental field only, the method can efficiently estimate the average synchronous torque for a variety or motor topologies, including concentrated winding designs. This approach employs an analytical filter for the Maxwell stress tensor and `frozen permeability' technique. The proposed method is validated by comparison with FE results for several synchronous motor types: interior permanent magnet motors, wound field motor, synchronous reluctance motor

Optimal Design of IPM Motors With Different Cooling Systems and Winding Configurations

Performance improvement of permanent magnet (PM) motors through optimization techniques has been widely investigated in the literature. Oftentimes the practice of design optimization leads to derivation/interpretation of optimal scaling rules of PM motors for a particular loading condition. This paper demonstrates how these derivations vary with respect to the machine ampere loading and ferrous core saturation level. A parallel sensitivity analysis using a second-order response surface methodology followed by a large-scale design optimization based on evolutionary algorithms are pursued in order to establish the variation of the relationships between the main design parameters and the performance characteristics with respect to the ampere loading and magnetic core saturation levels prevalent in the naturally cooled, fan-cooled, and liquid-cooled machines. For this purpose, a finite-element-based platform with a full account of complex geometry, magnetic core nonlinearities, and stator and rotor losses is used. Four main performance metrics including active material cost, power losses, torque ripple, and rotor PM demagnetization are investigated for two generic industrial PM motors with distributed and concentrated windings with subsequent conclusions drawn based on the results

Magnetic noise reduction of in-wheel permanent magnet synchronous motors for light-duty electric vehicles

This paper presents study of a multi-slice subdomain model (MS-SDM) for persistent low-frequency sound, in a wheel hub-mounted permanent magnet synchronous motor (WHM-PMSM) with a fractional-slot non-overlapping concentrated winding for a light-duty, fully electric vehicle applications. While this type of winding provides numerous potential benefits, it has also the largest magnetomotive force (MMF) distortion factor, which leads to the electro-vibro-acoustics production, unless additional machine design considerations are carried out. To minimize the magnetic noise level radiated by the PMSM, a skewing technique is targeted with consideration of the natural frequencies under a variable-speed-range analysis. To ensure the impact of the minimization technique used, magnetic force harmonics, along with acoustic sonograms, is computed by MS-SDM and verified by 3D finite element analysis. On the basis of the studied models, we derived and experimentally verified the optimized model with 5 dBA reduction in A-weighted sound power level by due to the choice of skew angle. In addition, we investigated whether or not the skewing slice number can be of importance on the vibro-acoustic objectives in the studied WHM-PMSM.Postprint (published version

Assessment of torque components in brushless permanent-magnet machines through numerical analysis of the electromagnetic field

For the calculation of torque in brushless (BL) alternating current motors a local method is proposed, based on the Maxwell stress theory and the filtered contributions due to the harmonics of the magnetic vector potential in the motor air gap. By considering the space fundamental field only, the method can efficiently estimate the average synchronous torque for a variety or motor topologies, including concentrated winding designs. For BL direct current motor analysis a global method is introduced, based on the virtual work principle expressed in terms of energy components in various motor regions. The method leads to simplifications in the average torque calculation and enables the direct identification of the cogging and ripple components. The mathematical procedures have been validated against experiments and other numerical techniques

Cogging torque reduction for interior permanent magnet synchronous motors

Interior permanent magnet synchronous machines show a good range of behaviours, which make these kinds of machines good candidates for an electromechanical energy conversion. However, in order to improve their accuracy in their torque responses, the cogging torque and torque ripple phenomena should be mitigated to obtain better performance of the machine. In order to reduce the cogging torque and torque ripple, control techniques as well as geometric parameters of the machine have to be improved. In this thesis, geometric parameters such as the use of the fractional slot windings, the improvement of the pole-arc to pole-pitch ratio and the dimensions of the stator slots are considered for the better minimization of the cogging torque and torque ripple. The results are presented to show the performance of the IPMSM with fractional slot windings as well as the reduction of the cogging torque and torque ripple. Furthermore, four models of IPMSM with fractional and integer slot windings are going to be compared with the aim of the attenuation of the cogging torque phenomenon

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

Analytical prediction of the electromagnetic torques in single-phase and two-phase AC motors

The single-phase and two-phase versions of AC motors can be modelled by means of the two-axis (d-q) theory with sufficient accuracy when the equivalent circuit parameters are correctly estimated. This work attempts to present a unified approach to the analytical prediction of the electromagnetic torque of these machines. Classical d-q axes formulation requires that the reference frame should be fixed on the frame where the asymmetries arise, i.e. the stator and rotor. The asynchronous torques that characterize the induction motors are modelled in a stationary reference frame, where the d-q axes coincide with the physical magnetic axes of the stator windings. For the permanent magnet motors, that may exhibit asymmetries on both stator and rotor, the proposed solution includes: a series of frame transformations, followed by symmetrical components decomposition. As in single-phase and two-phase systems the homopolar component is zero; each symmetrical component – negative and positive – is further analysed using d-q axes theory. The superposition principle is employed to consider the magnets and rotor cage effects. The developed models account for the most important asymmetries of the motor configuration. These are, from the stator point of view, different distribution, conductors' dimensions and number of effective turns, non-orthogonal magnetic axes windings and from the rotor point of view, asymmetrical rotor cage, variable reluctance, and permanent magnets effect. The time and space harmonics effect is ignored. Test data are compared with the computed data in order to observe how the simplifying assumptions affect the level of accuracy. The analytical prediction methods make possible torque computation according to the nature of the torque being computed, namely, induction, reluctance and excitation (permanent magnet). The results are available for quasi steady-state, steady-state (rated or synchronous speed) and dynamic analyses. All the developed mathematical models can be used in preliminary design for further optimisation and accurate estimation in complex numerical models. Another important feature of the analytical models for single-phase and two-phase AC motors, is that they can be directly implemented in any suitable electrical drives control strategy.reviewe

Slot/pole Combinations Choice for Concentrated Multiphase Machines dedicated to Mild-Hybrid Applications

Version de l'éditeur à l'adresse suivante : http://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=6119910&isnumber=6119266This paper presents multiphase permanent magnet machines with concentrated non-overlapped winding as a good candidate for automotive low voltage mild-hybrid applications. These machines often require a trade-off between low speed performances such as high torque density and high speed performances like flux weakening capabilities. This paper describes how to choose a key design parameter to ease this compromise, the slots/poles combination, according to three parameters: winding factor including harmonics factor, rotor losses amount thanks to a comparison factor and radial forces balancing. The comparison criterion are based on both analytical formula and Finite Element Analysis.Projet MHYGALE/ ADEM

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