Design and Test of a Linear Switched Reluctance Generator for use in Wave-Energy Applications

This paper describes the design of a double-sided linear switched reluctance generator for use in wave energy applications, and the build and test of a working bench-scale prototype. Beginning with a standard shape, the development of the design, from concept to detail, is presented. Numerical simulation results – magnetic, mechanical and electrical – inform the detailed design. Construction of the generator and test rig is described. Experimental results give good agreement with simulation predictions

Development of high efficiency high speed permanent magnet generator

Renewable energy technology is steadily gaining importance in the energy market because of the limited nature of fossil fuels, as well as the political pressures to reduce carbon emissions. To ensure sustainable development, adequate and affordable energy should be made available to satisfy the demand of electric energy. The High Speed Permanent Magnet (HSPM) generator is designed and developed and is expected to deliver 10 kW output power as well as to achieve a speed of 30000 RPM, however, to achieve a compact and efficient design with lower excitation losses, magnetizing currents and rotor losses requires the HSPM generator to be operated at high rated speeds of approximately 30000 RPM. However, at high speeds these machines produce a substantial amount of heat. This makes the thermal management of these machines difficult and complicated, which leads to demagnetization and the reduction of the output power and shortens the lifetime of the critical components such as the bearings. This thesis presents the design and development of the HSPM generator. It also identifies the heat generated by means of electromagnetic, mechanical and core losses. The development of an adequate cooling system (cooling jacket) is presented to avoid hot spots in the generator and thermal damage to the magnets, resulting in demagnetization. The use of pressurized oil air particles as a lubrication method for the bearings of the generator is also considered to avoid: thermal damage and starvation at the rolling element and to address the predominant concern of effectively cooling the HSPM generator ball bearings at elevated speeds. The HSPM generator is designed and developed to operate at a maximum speed of 30000 RPM to deliver 10 kW output power and is subjected to 80~92°C temperature rise with an idle power consumption of ~2kW, enough to cause hot spots on the generator, demagnetization of the magnets and severe impact to the rolling elements of the bearings. The developed cooling jacket and the newly developed oil air mist lubrication arrangement enables the control of the temperature rise of the generator and the temperature rise at the rolling element, respectively. A steady state analysis was also carried out at motor maximum power output to determine its safe operation with the objective of finding an optimal operating condition by performing a parametric study on the effect of cooling. A 3D steady state model of a 10-kW electric permanent magnet machine was generated and investigated with one cooling jacket layout. The end windings and bearings were not considered to simplify the motor model. Numerical analysis is performed with two different coolant flow rates, no flow and maximum flow (3.5 m3 /h) with special emphasis on the maximum motor temperature. The analytical calculations for the role of coolant flowrate on heat transfer characteristics for a high speed generator, showed that the convection heat transfer coefficient increases with an increase in flowrate (0.3 – 3.5 m3 /hr), while the numerical simulations showed that the maximum coolant flowrate conditions achieved lower temperature generation (27.9°C at the front bearing) throughout the generator compared to no coolant flowrate (43.7°C at the front bearing). The detailed understanding of the effects of these parameters on the generator’s temperature field will help in validating the performance of the generator with actual results

Advanced propulsion systems for linear motion with high performance requirements

Traditionally linear actuator applications are addressed by the use of hydraulic systems. The high maintenance cost and poor reliability will always be the most critical problem in the real applications. Benefited from both the high mechanical advantage of the roll screw and the simple structure of the switched reluctance motor, a new SRM driven linear actuator is proposed as a replacement for the traditional hydraulic system. The key factor is to improve drive system reliability without losing the high thrust/ high power density characteristic of the original system. Through the Landing Craft Air Cushion (LCAC) project example, the detail of the magnetic design is done step-by-step to maximize the SRM power density. The technique credibility is crosschecked by both the SRDaS software and the finite element method. For further improvement of system reliability, converter structure, sensorless control and fault tolerance ability are also investigated. Both the computer simulation and the experimental results verified the validity of the high thrust linear actuator design. The Linear Induction Motor (LIM) is another type of low cost, low maintenance linear actuator for medium/high speed application. There are several constraints which should be considered during the LIM design procedure. The motor manufacturer needs to minimize the motor weight to save material and also limit the total supply current for thermal consideration. The drive designers are always looking for the maximum thrust with less supplied voltage. The wide operating speed requirement also makes the design decision more complex. In the research new asymmetric structure is proposed in the design, which can ideally double the design option from just even coil numbers per slot to the full integer range. The asymmetric structure has the potential to introduce a new balance point between the low-speed and high-speed performance of the LIM. Experimental results demonstrate the significant gain of the asymmetric motor compared with its symmetric counterpart. The airgap length is also found to be a key factor for the application in the experiments.Keywords: linear actuator, SRM, LI

Design and Analysis of Long-Stroke Planar Switched Reluctance Motor for Positioning Applications

This paper presents the design, control, and experimental performance evaluation of a long-stroke planar switched reluctance motor (PSRM) for positioning applications. Based on comprehensive consideration of the electromagnetic and mechanical characteristics of the PSRM, a motor design is first developed to reduce the force ripple and deformation. A control scheme with LuGre friction compensation is then proposed to improve the positioning accuracy of the PSRM. Furthermore, this control scheme is proven to ensure the stable motion of the PSRM system. Additionally, the response speed and steady-state error of the PSRM system with this control scheme are theoretically analyzed. Finally, the experimental results are presented and analyzed. The effectiveness of the precision long-stroke motion of the PSRM and its promise for use in precision positioning applications are verified experimentally

A new converter topology for high-speed high-starting-torque three-phase switched reluctance motor drive system

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Switched reluctance motor (SRM) has become a competitive selection for many applications of electric machine drive systems recently due to its relative simple construction and its robustness. The advantages of those motors are high reliability, easy maintenance and good performance. The absence of permanent magnets and windings in rotor gives possibility to achieve very high speeds (over 10000 rpm) and turned SRM into perfect solution for operation in hard conditions like presence of vibrations or impacts. Such simple mechanical structure greatly reduces its price. Due to these features, SRM drives are used more and more into aerospace, automotive and home applications. The major drawbacks of the SRM are the complicated algorithm to control it due to the high degree of nonlinearity, also the SRM has always to be electronically commutated and the need of a shaft position sensor to detect the shaft position, the other limitations are strong torque ripple and acoustic noise effects

Fractional slot concentrated winding PM synchronous motors for transport electrification applications

Moving towards electrification of transport including electric vehicles (EV), more electric aircraft (MEA), and electric ships offers a crucial way in dealing with global carbon emissions and climate change. Electric motors are a key enabling technique in these applications, but their increased use is associated with requirements of extreme power/torque density, excellent fault-tolerance, high efficiency, and good manufacturability. The main goal of this thesis is to study permanent magnet electric machine winding theory to determine the suitable electric machine winding topologies for different applications. Two separate vehicle transport applications are investigated, including an EV traction motor and a novel modular electromechanical actuator (EMA) for MEA. The study of the EV traction motor involves the investigation of methods for reducing the significant stator MMF harmonics in fractional slot concentrated winding (FSCW) electric machines, and the development of novel FSCW topologies while keeping the benefits of easy manufacturing and the non-overlapping characteristic of concentrated windings. The novel FSCW topologies can be extended to multi-phase FSCW motors. A traction motor equipped with a novel 24 slots, 14 poles FSCW topology and interior PM (IPM) rotor is developed for evaluation. The performance under normal and fault conditions is fully explored and validated with simulation and experimental results, which demonstrates the applicability and strong potential of the proposed 24 slots, 14 poles IPM motor in fault-tolerant traction motor applications. The second topic focuses on modular fault-tolerant EMAs for aircraft actuation systems which can meet a diverse range of requirements. The architecture and design considerations of the actuator system are firstly determined considering reliability, fault-tolerance, and weight. The modular EMA scheme consisting of a direct-drive rotary motor and mechanical screw is identified. A dual 3-phase 24 slots, 22 poles FSCW motor with a surface-mounted permanent magnet (SPM) rotor is developed and evaluated in terms of electromagnetics, thermal management, and fault-tolerance. Experimental results of the modular EMA motor prototypes agree well with predicted results. All this confirms the applicability and satisfactory implementation of the modular EMA motor for aircraft actuation system applications

Design and Construction Modifications of Switched Reluctance Machines

Although the design principles of the Switched Reluctance Machines (SRMs) are available in different fragments in numerous bibliography positions, there no exists the complex design procedure of whole drive system taking into account the SR Machine, control system and supply device as well. The hybrid design method for SRM drives with application of new analytical calculation methods, finite element method and simulation models is proposed in this thesis. The calculation/design system is characterised by important effectivity and reliability. The new possibilities in analytical determination of saturation effects and core losses under various modes of control, including sensorless method, are also taken into account. The correctness of the proposed design algorithms are verified by laboratory tests made on three motor prototypes manufactured in industry for concrete application. This dissertation provides the elements indispensable for more accurate and complex analysis and design of drives with switch reluctance motors. The elements of electrical motor and control system design as well as the considerations on the choice of supply device and controller subsystems are jointed in the thesis for final receiving of the design tool for considered industrial drive system

Modeling And Simulation Of All-electric Aircraft Power Generation And Actuation

Modern aircraft, military and commercial, rely extensively on hydraulic systems. However, there is great interest in the avionics community to replace hydraulic systems with electric systems. There are physical challenges to replacing hydraulic actuators with electromechanical actuators (EMAs), especially for flight control surface actuation. These include dynamic heat generation and power management. Simulation is seen as a powerful tool in making the transition to all-electric aircraft by predicting the dynamic heat generated and the power flow in the EMA. Chapter 2 of this dissertation describes the nonlinear, lumped-element, integrated modeling of a permanent magnet (PM) motor used in an EMA. This model is capable of representing transient dynamics of an EMA, mechanically, electrically, and thermally. Inductance is a primary parameter that links the electrical and mechanical domains and, therefore, is of critical importance to the modeling of the whole EMA. In the dynamic mode of operation of an EMA, the inductances are quite nonlinear. Chapter 3 details the careful analysis of the inductances from finite element software and the mathematical modeling of these inductances for use in the overall EMA model. Chapter 4 covers the design and verification of a nonlinear, transient simulation model of a two-step synchronous generator with three-phase rectifiers. Simulation results are show

Active suspension control of electric vehicle with in-wheel motors

In-wheel motor (IWM) technology has attracted increasing research interests in recent years due to the numerous advantages it offers. However, the direct attachment of IWMs to the wheels can result in an increase in the vehicle unsprung mass and a significant drop in the suspension ride comfort performance and road holding stability. Other issues such as motor bearing wear motor vibration, air-gap eccentricity and residual unbalanced radial force can adversely influence the motor vibration, passenger comfort and vehicle rollover stability. Active suspension and optimized passive suspension are possible methods deployed to improve the ride comfort and safety of electric vehicles equipped with inwheel motor. The trade-off between ride comfort and handling stability is a major challenge in active suspension design. This thesis investigates the development of novel active suspension systems for successful implementation of IWM technology in electric cars. Towards such aim, several active suspension methods based on robust H∞ control methods are developed to achieve enhanced suspension performance by overcoming the conflicting requirement between ride comfort, suspension deflection and road holding. A novel fault-tolerant H∞ controller based on friction compensation is in the presence of system parameter uncertainties, actuator faults, as well as actuator time delay and system friction is proposed. A friction observer-based Takagi-Sugeno (T-S) fuzzy H∞ controller is developed for active suspension with sprung mass variation and system friction. This method is validated experimentally on a quarter car test rig. The experimental results demonstrate the effectiveness of proposed control methods in improving vehicle ride performance and road holding capability under different road profiles. Quarter car suspension model with suspended shaft-less direct-drive motors has the potential to improve the road holding capability and ride performance. Based on the quarter car suspension with dynamic vibration absorber (DVA) model, a multi-objective parameter optimization for active suspension of IWM mounted electric vehicle based on genetic algorithm (GA) is proposed to suppress the sprung mass vibration, motor vibration, motor bearing wear as well as improving ride comfort, suspension deflection and road holding stability. Then a fault-tolerant fuzzy H∞ control design approach for active suspension of IWM driven electric vehicles in the presence of sprung mass variation, actuator faults and control input constraints is proposed. The T-S fuzzy suspension model is used to cope with the possible sprung mass variation. The output feedback control problem for active suspension system of IWM driven electric vehicles with actuator faults and time delay is further investigated. The suspended motor parameters and vehicle suspension parameters are optimized based on the particle swarm optimization. A robust output feedback H∞ controller is designed to guarantee the system’s asymptotic stability and simultaneously satisfying the performance constraints. The proposed output feedback controller reveals much better performance than previous work when different actuator thrust losses and time delay occurs. The road surface roughness is coupled with in-wheel switched reluctance motor air-gap eccentricity and the unbalanced residual vertical force. Coupling effects between road excitation and in wheel switched reluctance motor (SRM) on electric vehicle ride comfort are also analysed in this thesis. A hybrid control method including output feedback controller and SRM controller are designed to suppress SRM vibration and to prolong the SRM lifespan, while at the same time improving vehicle ride comfort. Then a state feedback H∞ controller combined with SRM controller is designed for in-wheel SRM driven electric vehicle with DVA structure to enhance vehicle and SRM performance. Simulation results demonstrate the effectiveness of DVA structure based active suspension system with proposed control method its ability to significantly improve the road holding capability and ride performance, as well as motor performance