Thermal analysis of a high speed electrical machine

This work has analysed, designed, commissioned and validated the performance of a novel cooling system for an innovative high speed, three-phase synchronous permanent magnet machine designed for an aero-engine starter/generator with a power rating of 45 kW and maximum speed of 32,000 rpm. The cooling system designed consisted into inserting a 1 mm non-electrically conductive stator sleeve in the machine airgap, this separates the rotor region from the stationary components letting the rotor running dry at all times; the stator region can then be flooded with oil. Oil enters from one side of the machine through some radial openings impinging directly over the end-winding, it then flows through two rows of equally sized axial ducts located along the inner and outer diameter of the stator to give an even distribution of the coolant, and finally it flows over the surface of the rear end-winding and leaves the machine. The thermal modelling was carried out by the joint use of Computational Fluid Dynamics (CFD) and Lumped Parameter Thermal Network (LPTN); this allowed the investigation of heat transfer phenomena and the optimisation of the cooling design. CFD was primarily employed to investigate the fluid flow and to perform conjugate heat transfer analyses; these allowed the determination of heat transfer coefficients and the prediction of temperature distribution inside the machine. Thermal networks were developed to investigate the heat flow through machine components, to perform the design optimisation and to maximise overall machine performance. A thermal network was also developed by the author to investigate the heat transfer phenomena inside the bearing chambers. An experimental apparatus was designed and commissioned in order experimentally validate the thermal models developed. Temperatures, pressures and torque up to 20,000 rpm were recorded throughout the tests and data collected were compared to quantities predicted analytically and numerically. Maximum winding temperatures measured performing a short circuit test agree well with analytical and numerical prediction with a maximum difference of 10%; mechanical losses measured carrying out a no-load test agree well at speeds over 10,000 rpm with differences between 2 and 12%. Throughout tests, pressure drops were monitored across the machine and an agreement of 13% with prediction were achieved. Design improvements are also proposed to further enhance the cooling of stator slots and of rotor components

Progress towards a methodology for high throughput 3D reconstruction of soot nanoparticles via electron tomography

The aim of this work is to make progress towards the development of 3D reconstruction as a legitimate alternative to traditional 2D characterisation of soot. Time constraints are the greatest opposition to its implementation, as currently reconstruction of a single soot particle takes around 5-6 hours to complete. As such, the accuracy and detail gains are currently insufficient to challenge 2D characterisation of a representative sample (e.g. 200 particles). This work is a consideration of the optimisation of the steps included within the computational reconstruction and manual segmentation of soot particles. Our optimal process reduced the time required by over 70% in comparison to a typical procedure, whilst producing models with no appreciable decrease in quality

Morphological characterisation of diesel soot in oil and the associated extraction dependence

The size and morphology of soot particles and agglomerates extracted from lubricating oil drawn from the sump of a diesel engine have been investigated and compared using Transmission Electron Microscopy (TEM) and Nanoparticle Tracking Analysis (NTA). Samples were prepared for electron microscopy imaging by both centrifugation and solvent extraction to investigate the impact of these procedures on the morphological characteristics, such as skeleton length and width and circularity, of the obtained soot. It was shown that centrifugation increases the extent of agglomeration within the sample, with 15% of the agglomerates above 200 nm compared to only 11% in the solvent extracted soot. It was also observed that the width of centrifugation extracted soot was typically 10 nm to 20 nm larger than that of solvent extracted soot, suggesting that centrifugation forces the individual agglomerate chains together. Moreover, centrifugation fails to extract a large percentage of particles below 50 nm, with only 4% of the agglomerates smaller than 50 nm in the centrifugation extracted soot, whereas agglomerates in this size range accounted for 19 % using solvent extraction. As TEM represents a comparatively time and cost expensive characterisation tool, unsuitable for high throughput testing required by industry, NTA was explored as a low cost, rapid alternative method for measuring particle size. It was found that results generated by NTA, within the limits of detection, correlated well with those obtained using TEM. This correlative electron microscopy and light scattering approach was further used to appraise the morphological characteristics of two commercial sources of carbon black (CB), enabling the selection of the most suitable soot surrogate, essential for the further development of oils with optimised functional properties

Towards keeping diesel fuel supply and demand in balance: dual-fuelling of diesel engines with natural gas

With the continuous growth of energy demand for the commercial transport sector, the market share of diesel vehicles is rising in several areas worldwide. Global demand for transport energy is therefore believed to be strongly skewed towards heavier fuels; particularly diesel. The strengthen emissions legislation is another issue facing the current generation of diesel engines; where there is an increasing concern with their high NOx and PM emissions. Dual-fuelling of diesel engines with natural gas (NG) stands as an attractive solution to reduce the dependence on diesel fuel and mitigate the harmful effects of diesel engines emissions. The main attractions of NG as a contributor to a more sustainable fuel market include its lower carbon content and relatively higher natural reserves, in addition to the renewable aspect of methane production from biogas. In dual-fuelling strategy, most of the engine power output is provided by the NG, while a pilot amount of diesel fuel is used as an ignition source for the NG-air mixture. While the concept is not new and it has been deliberated lengthily in the past two decades, several uncertainties still exist as relative to engine combustion, exhaust emissions, and practicality. The present contribution aims at critically reviewing part of the prevalent literature about NG-diesel dual-fuel engines; highlighting the concepts and challenges. Throughout this review, several topics are explored and evaluated based on research importance and maturity. The overview of these works indicates that research effort in this field could be broadly categorized into fuel delivery researches or charge composition studies; where each category is directly linked to either the NG or the pilot fuel. Following this, a roadmap for future research directions in the field is presented, to spot some potential topics for proceedings and continuation

Quantifying soot nanostructures: Importance of image processing parameters for lattice fringe analysis

Fringe analysis is a commonly used method to quantify soot nanostructures. However, the settings of the involved filters and their impact on the results are rarely addressed. In this study, the influence of the three filter parameters as well as two aspects of the image acquisition was assessed experimentally. For the analysis, a carbon black as well as one diesel engine and one gasoline direct injection (GDI) engine soot sample were used. Gaussian low-pass filter standard deviations larger 1.5 yielded only minor differences in fringe metrics. Standard deviations between 2.0 and 3.0 enabled realistic representation of fringes. A linear correlation was found between the white top-hat transformation disk size and all fringe analysis metrics. For realistic nanostructure representation, disk sizes of 5 px and 7 px are most suitable. Threshold values as calculated by Otsu's method generally yielded the best nanostructure representation. Any deviation distorted the extracted fringes and noticeably reduced their total number. Thus, consistent use of Otsu thresholds without alterations is advised. Deviating from the neutral electron microscope focus point by under- and over-focusing resulted in distinctive drops in both fringe lengths and Otsu thresholds. Consistent focusing with the help of fast Fourier transformations of the respective particles is vital for reliable results. The effect of reduced noise levels by repeated averaged images was found to be minor beyond the model of the camera used. The region of interest size correlated linearly with the number of extracted fringes, however, it did not affect the fringe metrics. For statistically reliable analysis, a minimum of 4000 fringes is suggested. The GDI sample exhibited the shortest fringes and the highest tortuosity. For diesel soot and carbon black, similar fringe lengths could be observed. The highest tortuosity was found for GDI soot, followed by diesel soot and carbon black

Torque Limiters for Aerospace Actuator Application

Safety and reliability of electrical actuators are essential for success of all electric and more electric aircrafts (MEA). Torque limiters improve the reliability of electromechanical actuators (EMA) by restricting the amount of force experienced by the actuator drive train components. If transmitted torque in the shaft exceeds a limit, it gives way in a controlled manner. This protects the actuator from potential failure and jamming. In this paper, different types of existing torque limiters are investigated for their suitability in aerospace EMA application and further integration within the electric motor. They classified based on the torque transmission mechanism and each type is described in detail. Operating principle and basic characteristics are reported. Comparative evaluation of commercially available devices is presented. It is found that those based on friction based and permanent magnet are most suitable due to their good torque density, reliability and high speed capability. Further, based on the characteristics, integration of torque limiter within the actuator motor is investigated in this paper. An example actuator motor is considered for integration. Different integration options suitable for the different types of torque limiting devices are described. Reduction in overall volume is shown for the integration options. Such integration can lead to improved reliability as well as higher power density resulting in next-generation actuator electrical drives for MEA

Soot-in-oil 3D volume reconstruction through the use of electron tomography: an introductory study

Understanding soot nanoparticle interaction with oil additives and the causes of soot-induced thickening would assist in lubricant formulation, prolonging engine life and improving engine efficiency. Three-dimensional measurement of soot structures is currently not undertaken as established techniques are limited to two dimensions. While they give valuable information on the structure and reactivity of soot nanoparticles, it is not easy to correlate this to geometry of primary particles and agglomerates. In this work, we investigate the development and application of 3D-TEM for characterisation of soot agglomerates as a new capability to yield information on the volumetric character of fractal nanoparticles. This investigation looks at the feasibility for volume reconstruction of nanometric soot particles in used engine oil from multiple imaging at different tilt angles. Bright-field TEM was used to capture two-dimensional images of soot. Heptane and diethyl ether washes were used to remove volatile contaminants and allowed for images from −60° to +60° tilt with no sign of carbon build-up to be acquired. Tomographic reconstruction from the aligned tilt-series images based on weighted back-projection algorithm has yielded useful information about complex soot nanoparticle size. Estimation of soot mass in oil by nanoparticle tracking analysis (NTA) can be considerably improved by taking into account the three-dimensional shape of the soot agglomerate including the shape factor in the calculations. 3D-TEM measurements were compared with values calculated by using a single-sphere approach when tracking nanoparticles moving under Brownian motion. A shape factor was calculated, dividing the surface area and volume calculated using spherical geometrical estimates, by the respective values calculated using the 3D models. The spherical model of the particle is found on average to overestimate the surface area by sevenfold, and the volume to the actual soot agglomerate by 23 times. Applying the calculated shape factor as a correction reduces the NTA overestimation by one order of magnitude

Numerical investigations of convective phenomena of oil impingement on end-windings

A novel experimental rig for analysing intensive liquid cooling of highly power-dense electrical machine components has been developed. Coupled fluid flow and heat transfer have been modelled, using computational fluid dynamics (CFD), to inform the design of a purpose-built enclosure for optimising the design of submerged oil jet cooling approaches for electrical machine stators. The detailed modelling methodology presented in this work demonstrates the value in utilising CFD as a design tool for oil-cooled electrical machines. The predicted performance of the final test enclosure design is presented, as well as examples of the sensitivity studies which helped to develop the design. The sensitivity of jet flow on resulting heat transfer coefficients has been calculated, while ensuring parasitic pressure losses are minimised. The CFD modelling will be retrospectively validated using experimental measurements from the test enclosure

Assessing the Accuracy of Soot Nanoparticle Morphology Measurements Using Three- Dimensional Electron Tomography

Morphology plays an important role in determining behaviour and impact of soot nanoparticles, including effect on human health, atmospheric optical properties, contribution to engine wear, and role in marine ecology. However, its nanoscopic size has limited the ability to directly measure useful morphological parameters such as surface area and effective volume. Recently, 3D morphology characterization of soot nanoparticles via electron tomography has been the subject of several introductory studies. So-called '3D-TEM' has been posited as an improvement over traditional 2D-TEM characterization due to the elimination of the error-inducing information gap that exists between 3-dimensional soot structures and 2-dimensional TEM projections. Little follow-up work has been performed due to difficulties with developing methodologies into robust high-throughput techniques. Recent work by the authors has exhibited significant improvements in efficiency, though as yet due consideration has not been given to assessing fidelity of the technique. This is vital to confirm significant and tangible improvements in soot-characterization accuracy that will establish 3D-TEM as a legitimate tool. Synthetic ground-truth data was developed to closely mimic real soot structures and the 3D-TEM volume-reconstruction process. A variety of procedures were tested to assess the magnitude and nuances of deviations from ground-truth values. Results showed average Z-elongation due to the 'missing-wedge' at 3.5% for the previously developed optimized procedure. Mean deviations from ground-truth in volume and surface area were 2.0% and-0.1% respectively. Results indicate highly accurate 3D-reconstruction can be achieved with an optimized procedure that can bridge the gap to permit high-throughput 3D morphology characterization of soot

Comparative nanostructure analysis of gasoline turbocharged direct injection and diesel soot-in-oil with carbon black

Two gasoline turbocharged direct injection (GTDI) and two diesel soot-in-oil samples were compared with one flame-generated soot sample. High resolution transmission electron microscopy imaging was employed for the initial qualitative assessment of the soot morphology. Carbon black and diesel soot both exhibit core-shell structures, comprising an amorphous core surrounded by graphene layers; only diesel soot has particles with multiple cores. In addition to such particles, GTDI soot also exhibits entirely amorphous structures, of which some contain crystalline particles only a few nanometers in diameter. Subsequent quantification of the nanostructure by fringe analysis indicates differences between the samples in terms of length, tortuosity, and separation of the graphitic fringes. The shortest fringes are exhibited by the GTDI samples, whilst the diesel soot and carbon black fringes are 9.7% and 15.1% longer, respectively. Fringe tortuosity is similar across the internal combustion engine samples, but lower for the carbon black sample. In contrast, fringe separation varies continuously among the samples. Raman spectroscopy further confirms the observed differences. The GTDI soot samples contain the highest fraction of amorphous carbon and defective graphitic structures, followed by diesel soot and carbon black respectively. The AD1:AG ratios correlate linearly with both the fringe length and fringe separation