Towards Fully Additively-Manufactured Permanent Magnet Synchronous Machines: Opportunities and Challenges

With the growing interest in electrification and as hybrid and pure electric powertrains are adopted in more applications, electrical machine design is facing challenges in terms of meeting very demanding performance metrics for example high specific power, harsh environments, etc. This provides clear motivation to explore the impact of advanced materials and manufacturing on the performance of electrical machines. This paper provides an overview of additive manufacturing (AM) approaches that can be used for constructing permanent magnet (PM) machines, with a specific focus on additively-manufactured iron core, winding, insulation, PM as well as cooling systems. Since there has only been a few attempts so far to explore AM in electrical machines (especially when it comes to fully additively-manufactured machines), the benefits and challenges of AM have not been comprehensively understood. In this regard, this paper offers a detailed comparison of multiple multi-material AM methods, showing not only the possibility of fully additively-manufactured PM machines but also the potential significant improvements in their mechanical, electromagnetic and thermal properties. The paper will provide a comprehensive discussion of opportunities and challenges of AM in the context of electrical machines

High Specific Power Electrical Machines: A System Perspective

There has been a growing need for high specific power electrical machines for a wide range of applications. These include hybrid/electric traction applications, aerospace applications and Oil and Gas applications. A lot of work has been done to accomplish significantly higher specific power electrical machines especially for aerospace applications. Several machine topologies as well as thermal management schemes have been proposed. Even though there has been a few publications that provided an overview of high-speed and high specific power electrical machines [1-3], the goal of this paper is to provide a more comprehensive review of high specific power electrical machines with special focus on machines that have been built and tested and are considered the leading candidates defining the state-of-the art. Another key objective of this paper is to highlight the key “system-level” tradeoffs involved in pushing electrical machines to higher specific power. Focusing solely on the machine specific power can lead to a sub-optimal solution at the system-level

High-Torque-Density Low-Cost Magnetic Gear Utilizing Hybrid Magnets and Advanced Materials

Two major challenges of existing high-performance magnetic gears are: (i) High content of rare-earth permanent magnets which results in high cost as well as price fluctuation; (ii) Conflict between mechanical and electromagnetic performances, especially in the design of highspeed rotor. A magnetic gear using a blend of magnet types, i.e NdFeB, or Dy-free NdFeB and ferrites, is proposed in this paper. The goal is to bring down the cost while retaining comparable torque-transducing performance to a baseline magnetic gear only using rare-earth NdFeB magnets. A variety of topologies based on different combinations of magnet types and geometric shapes have been studied and compared. In addition, the potential impact of using an advanced dual-phase material is evaluated. The goal is to eliminate the well-known tradeoff between rotor mechanical integrity and PM flux leakage

Sagging and hogging strengthening of continuous reinforced concrete beams using CFRP sheets.

yesThis paper reports the testing of 11 reinforced concrete (RC) two-span beams strengthened in flexure with externally bonded carbon fiber-reinforced polymer (CFRP) sheets. The beams were classified into two groups according to the arrangement of the internal steel reinforcement. Each group included one unstrengthened control beam. The main parameters studied were the position, length, and number of CFRP layers. External strengthening using CFRP sheets was found to increase the beam load capacity. All strengthened beams exhibited less ductility compared with the unstrengthened control beams, however, and showed undesirable sudden failure modes. There was an optimum number of CFRP layers beyond which there was no further enhancement in the beam capacity. Extending the CFRP sheet length to cover the entire hogging or sagging zones did not prevent peeling failure of the CFRP sheets, which was the dominant failure mode of beams tested

Comparison and Design Optimization of a Five-Phase Flux-Switching PM Machine for In-Wheel Traction Applications

A comparative study of five-phase outer-rotor flux-switching permanent magnet (FSPM) machines with different topologies for in-wheel traction applications is presented in this paper. Those topologies include double-layer winding, single-layer winding, C-core, and E-core configurations. The electromagnetic performance in the low-speed region, the flux-weakening capability in the high-speed region, and the fault-tolerance capability are all investigated in detail. The results indicate that the E-core FSPM machine has performance advantages. Furthermore, two kinds of E-core FSPM machines with different stator and rotor pole combinations are optimized, respectively. In order to reduce the computational burden during the large-scale optimization process, a mathematical technique is developed based on the concept of computationally efficient finite-element analysis. While a differential evolution algorithm serves as a global search engine to target optimized designs. Subsequently, multiobjective tradeoffs are presented based on a Pareto-set for 20 000 candidate designs. Finally, an optimal design is prototyped, and some experimental results are given to confirm the validity of the simulation results in this paper

Computationally Efficient Optimization of a Five-Phase Flux-Switching PM Machine Under Different Operating Conditions

This paper investigates the comparative design optimizations of a five-phase outer-rotor flux-switching permanent magnet (FSPM) machine for in-wheel traction applications. To improve the comprehensive performance of the motor, two kinds of large-scale design optimizations under different operating conditions are performed and compared, including the traditional optimization performed at the rated operating point and the optimization targeting the whole driving cycles. Three driving cycles are taken into account, namely, the urban dynamometer driving schedule (UDDS), the highway fuel economy driving schedule (HWFET), and the combined UDDS/HWFET, representing the city, highway, and combined city/highway driving, respectively. Meanwhile, the computationally efficient finite-element analysis (CE-FEA) method, the cyclic representative operating points extraction technique, as well as the response surface methodology (in order to minimize the number of experiments when establishing the inverse machine model), are presented to reduce the computational effort and cost. From the results and discussion, it will be found that the optimization results against different operating conditions exhibit distinct characteristics in terms of geometry, efficiency, and energy loss distributions. For the traditional optimization performed at the rated operating point, the optimal design tends to reduce copper losses but suffer from high core losses; for UDDS, the optimal design tends to minimize both copper losses and PM eddy-current losses in the low-speed region; for HWFET, the optimal design tends to minimize core losses in the high-speed region; for the combined UDDS/HWFET, the optimal design tends to balance/compromise the loss components in both the low-speed and high-speed regions. Furthermore, the advantages of the adopted optimization methodologies versus the traditional procedure are highlighted

Surface PM machine parameter selection for wide field-weakening applications

Recent work on fractional-slot pitch, concentrated winding (FSCW) surface PM machines has shown that these machines can achieve a wide constant-power speed range. This paper shows that defining the allowable machine design parameter plane using the characteristic current and the peak back-emf provides useful insights into how application requirements restrict the machine parameters. The parameter plane also shows the influence of changing the parameters on the machine's current rating and magnet losses. As an example of a practical application, the parameter plane is used to study the FreedomCAR traction motor drive requirements and the characteristics of five FSCW surface PM machine designs.W.L. Soong, P.B. Reddy, A.M. El-Refaie, T.M. Jahns and N. Ertugru

Design and experimental verification of a 50 kW interior permanent magnet synchronous machine

This paper presents the design details for an IPM machine designed to deliver 50 kW constant power over a 5:1 speed range extending from 850 rpm to 4250 rpm, with a gradual reduction in the required output power up to 8000 rpm (25 kW). Electromagnetic, thermal, and structural considerations have been included in the design optimization process. The resulting machine is designed with two magnet layers per pole and a distributed stator winding. Special features of the machine include its deep stator slots and four-layer winding, made necessary by the desire to minimize the machine's moment of inertia. Test results available to date demonstrate that the machine is capable of delivering the required output torque and power, and the agreement between the predicted and measured machine parameters is generally quite good. Calculated iron losses for high-speed flux-weakening operation are presented in the final section of the paper, illustrating the challenges associated with minimizing the impact of high-frequency harmonic flux density components.Jahns, T.M.; Seok-Hee Han; El-Refaie, A.M.; Jei-Hoon Baek; Aydin, M.; Guven, M.K.; Soong, W.L

Performance Testing and Analysis of Synchronous Reluctance Motor Utilizing Dual-phase Magnetic Material

While interior permanent magnet (1PM) machines have been considered the state-of-the art for traction motors, synchronous reluctance (SynRel) motors with advanced materials can provide a competitive alternative. 1PM machines typically utilize Neodymium 1ron Boron (NdFeB) permanent magnets, which pose an issue in terms of price, sustainability, demagnetization at higher operating temperatures, and uncontrolled generation. On the other hand, SynRel machines do not contain any magnets and are free from these issues. However, the absence of magnets as well the presence of bridges and centerposts limit the flux-weakening capability of a SynRel machine and limit the achievable constant power speed ratio (CPSR) without having to significantly oversize the machine and/or the power converter. 1n this paper, a new material referred to as the dual-phase magnetic material where nonmagnetic regions can be selectively introduced within each lamination will be evaluated for SynRel designs. The dual-phase feature of this material enables non-magnetic bridges and posts, eliminating one of the key limitations of the SynRel designs in terms of torque density and flux-weakening. This paper will present, the design, analysis and test results of an advanced proof-of-concept SynRel design utilizing dual-phase material with traction applications as the ultimate target application