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

Permanent Magnet Vernier Machine: A Review

Permanent magnet vernier machines (PMVMs) gained a lot of interest over the past couple of decades. This is mainly due to their high torque density enabled by the magnetic gearing effect. This study will provide a thorough review of recent advances in PMVMs. This review will cover the principle of operation and nature of magnetic gearing in PMVMs, and a better understanding of novel PMVM topologies using different winding configuration as well as different modulation poles and rotor structures. Detailed discussions on the choice of gear ratio, slot-pole combinations, design optimisation and role of advanced materials in PMVMs will be presented. This will provide an update on the current state-of-the art as well as future areas of research. Furthermore, the power factor issue, fault tolerance as well as cost reduction will be discussed highlighting the gap between the current state-of-the art and what is needed in practical applications

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

Survey of Insulation Systems in Electrical Machines

Insulating materials and insulation systems design have been gaining more attentions as more electrical machines tend to operate in harsher environments for various applications. Harsh environments include high temperature, humidity, erosion, low air pressure, etc. This paper discusses recent advances in insulation systems for electrical machines. Insulation tests as well as test standards that have been used to evaluate insulation systems and detect insulation failures will be discussed. Insulating materials used for a wide range of industrial applications such as wind turbine generators, aerospace hybrid/electric powertrain, and hydro generators have been summarized. For the emerging high-altitude, highvoltage aerospace applications, partial discharge and its impact on insulation systems will be discussed. Finally, polymer nanocomposite materials with excellent thermal conductivity and dielectric strength are highlighted as an outlook

An Isolated Step-Down Multi-Port DC-DC Power Converter for Electric Refrigerated Vehicles Auxiliary Power Unit System

This paper proposes an isolated step-down DC-DC multi-port converter (MPC) for the auxiliary power unit of refrigerated vehicles. Mercedes-Benz eSprinter is used as the baseline for this design with 400V battery pack and 2kW of auxiliary loads. TR-300T refrigeration unit from GUCHEN THERMO is chosen to provide temperatures as low as −18 degrees Celsius for the van\u27s 12 cubic meter cargo space. Similar to Mercedes-Benz Sprinter model, two auxiliary battery units are used to design this MPC. The proposed MPC can provide up to 5kW, while benefiting from two additional paths to the freezer unit during idling and/or fault modes. The proposed MPC has 35% fewer active components compared to the state of the art, while offering higher reliability for the overall system. Simulation and experimental results demonstrate the effectiveness of the proposed MPC, and the control system designed for this application and efficiencies up to 95% were recorded

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