Optimal design of a three-phase AFPM for in-wheel electrical traction

Sinusoidally fed permanent magnet synchronous motors (PMSM) fulfill the special features required for traction motors to be applied in electric vehicles (EV). Among them, axial flux permanent magnet (AFPM) synchronous motors are especially suited for in-wheel applications. Electric motors used in such applications must meet two main requirements, i.e. high power density and fault tolerance. This paper deals with the optimal design of an AFPM for in-wheel applications used to drive an electrical scooter. The single-objective optimization process carried out in this paper is based on designing the AFPM to obtain an optimized power density while ensuring appropriate fault tolerance requirements. For this purpose a set of analytical equations are applied to obtain the geometrical, electric and mechanical parameters of the optimized AFPM and several design restrictions are applied to ensure fault tolerance capability. The optimization process is based on a genetic algorithm and two more constrained nonlinear optimization algorithms in which the objective function is the power density. Comparisons with available data found in the technical bibliography show the appropriateness of the approach developed in this work.Postprint (published version

Multi-objective optimal design of a five-phase fault-tolerant axial flux PM motor

Electric motors used for traction purposes in electric vehicles (EVs) must meet several requirements, including high efficiency, high power density and faulttolerance. Among them, permanent magnet synchronous motors (PMSMs) highlight. Especially, five-phase axial flux permanent magnet (AFPM) synchronous motors are particularly suitable for in-wheel applications with enhanced fault-tolerant capabilities. This paper is devoted to optimally design an AFPM for in-wheel applications. The main geometric, electric and mechanical parameters of the designed AFPM are calculated by applying an iterative method based on a set of analytical equations, which is assisted by means of a reduced number of three-dimensional finite element method (3D-FEM) simulations to limit the computational burden. To optimally design the AFPM, a constrained multi-objective optimization process based on a genetic algorithm is applied, in which two objective functions are considered, i.e. the power density and the efficiency. Several fault-tolerance constraints are settled during the optimization process to ensure enhanced fault-tolerance in the resulting motor design. The accuracy of the best solution attained is validated by means of 3D-FEM simulations.Postprint (published version

Detection of inter-turns short circuits in permanent magnet synchronous motors operating under transient conditions by means of the zero sequence voltage

This work proposes the zero sequence voltage component (ZSVC) of the stator three-phase voltages as a method for detecting winding inter-turns short circuits in permanent magnet synchronous motors PMSM operating under transient conditions. Additionally it proves the linear relationship between the ZSVC and speed, which is effectively used as a fault severity index. The acquired ZSVC temporal signal is processed by means of the Hilbert-Huang transform (HHT). Experimental results presented in this work show the advantages of the method to provide helpful data for online diagnosis of stator winding inter-turn faults.Peer ReviewedPostprint (author’s final draft

Analysis and design of fault tolerant axial flux permanent magnet synchronous motors

Electric vehicles (EVs) are attractive comparted to internal combustion engine powered vehicles due to several benefits, including low emissions, higher efficiency, less maintenance costs, stronger acceleration or lower fuel price, among others. EVs require traction motors with especial features, including high efficiency, high power and torque density, compactness, precise torque control, extended speed range. This work focuses on the analysis and optimal electromagnetic design of fault tolerant permanent magnet synchronous motors. The study is mainly based on the research of analytical design procedures and the effect of electrical faults in the motor behavior, according to the configurations of each machine. The study will be developed by using analytical tools, and validated by applying 2-D and 3-D finite element methods (FEM). A brief study about the main achievements regarding the design of fault tolerant machines is made, identifying the possible improvements and main rules of design in this kind of machines. Then a study focused on the requirements of a fault tolerant design is made, in order to select the appropriate motor configuration. Since the consequences of inter-turn faults can be catastrophic in PMSMs, chapter 3 studies the influence of the winding configuration on the detection of such faults. This detection is based on the analysis of the stator currents and the (zero-sequence voltage component) ZSVC spectra. Several types of winding configurations are selected for analysis i.e. fractional- and integral-slot windings, overlapping- and non-overlappingwindings, single- and double-layer, full- and short-pitch, constant- and variable-pitch windings. Taking into the fault tolerant tendencies about the redundancy of the system, the study of the effect of inter turn fault is extended to the five phase machine, thus a parametric model of the five-phase PMSM is developed, this model accounts for the effects of inter-turn faults. This parametric model is used to select the harmonic frequencies to be studied to detect such faults. Likewise, the amplitudes of these harmonic frequencies are further analyzed by means of FEM simulations, therefore showing the potential of the proposed system to detect inter-turn faults in their early stage, which is a desirable characteristic for a fault tolerant system. The demagnetization effect on AFPMM torque is also analyzed. The main objective was to study the influence of the magnet shape in the performance of an AFPMM working under faulty condition, in order to select the most suitable type of magnet for the design of a fault tolerant machine. After an exhaustive analysis of the main electromagnetic faults on PMSMs, the work is focused on the optimal electromagnetic design of an AFPMM. The optimal design is based on a set of analytical equations whose accuracy is validated by means of FEM simulations. Next, to find the optimal solution, the huge set of possible motor solutions is explored by means of computationally efficient optimization algorithms leading to an optimum solution while minimizing the computational burden. The set of analytical equations are solved to obtain the geometrical, electric and mechanical parameters of the optimized AFPMM and several design restrictions are applied to ensure fault tolerance capability, along with the recommended features that have been drawn from the fault analysis study. Finally, a dual outer rotor AFPMM with NN configuration for automotive applications is optimized by applying accurate analytical sizing equations and taking into account fault tolerant constraints. For optimization purpose, a multi-objective design strategy is applied, in which the optimization variables are the motor efficiency and power density and ten input geometric and electric parameters are considered, with their respective bounds and constraints. At last the model is verified by applying 3D-FEM simulations and the main performance characteristics are compared.Debido a las nuevas políticas de conservación medio ambiental, los vehículos eléctricos toman una posición más importante en la sociedad actual. Los motores eléctricos constituyen el corazón de la cadena de tracción de un EV, por esta razón se debe encaminar la investigación hacia el diseño de motores de mayor eficiencia y fiabilidad. Este trabajo se enfoca en el análisis y diseño óptimo de un motor de flujo axial con tolerancia a fallos. Como base, se parte de la investigación de los procedimientos analíticos de diseño de motores eléctricos y del estudio de los efectos de los fallos eléctricos en el comportamiento de estos, de acuerdo a la configuración específica de cada máquina. Para desarrollar esta tesis se hará uso de herramientas analíticas y de métodos de simulación basados en métodos finitos (FEM). En primera parte se hace un estudio del estado del arte del diseño de motores eléctricos tolerantes a fallos, en el cual se identifican las posibles configuraciones a usar y las principales reglas de diseño de estos motores. Debido a que las consecuencias de un cortocircuito entre espiras pueden ser catastróficas para el motor de imanes permanentes, en el siguiente capítulo se analiza su efecto en dependencia de la configuración de los devanados del motor, además de su posible detección. La detección del cortocircuito se basa en el análisis del espectro de frecuencias de las corrientes del estator y la componente homopolar de voltaje (ZSVC). Para este estudio se seleccionan los 5 tipos de bobinados generalmente usados en motores eléctricos. Tomando en cuenta las tendencias de sistemas tolerantes a fallos de utilizar la redundancia de elementos, el estudio del cortocircuito se extiende al motor de 5 fases, para esto se desarrolla un modelo paramétrico del motor, el cual es utilizado para seleccionar los armónicos de frecuencias que permitan la detección del cortocircuito entre espiras en su fase más temprana. De la misma manera estos armónicos son analizados en modelos de simulación por elementos finitos, probando su potencial para el desarrollo de algoritmo de detección de fallos, característica deseable en los sistemas tolerantes a fallos. En última parte de este capítulo se estudia el efecto de la desmagnetización en el comportamiento de motores, en particular la influencia de la forma de los imanes cuando el motor funciona en régimen de fallo, como conclusión de este estudio se selecciona la forma de imán que mejor se comporta ante este tipo de fallos. Una vez analizado los posibles fallos eléctricos en el motor, el trabajo se centra en el diseño electromagnético óptimo de una máquina de flujo axial. El diseño optimo se apoya en el uso de ecuaciones analíticas del motor (AFPMM) y se valida por medio de simulaciones FEM. Para lograr el diseño óptimo de hace uso de algoritmo de optimización heurísticos, en particular los algoritmos genéticos. A estos algoritmos se les aplica las restricciones anteriormente encontradas en los estudios de fallos y en el estado de arte de motores tolerantes a fallos. Finalmente aplicando una serie de ecuaciones analíticas y teniendo en cuenta las restricciones de un diseño tolerante a fallos previamente seleccionadas se obtiene el diseño electromagnético óptimo de un motor de flujo axial tolerante a fallos. Para el proceso de optimización se utilizan algoritmos genéticos multi-objetivos en donde se busca maximizar la densidad de potencia y la eficiencia. Por último, el modelo del motor pentafásico de flujo axial es verificado por medio de simulaciones en elementos finitos.Postprint (published version

Detection of inter-turn faults in five-phase permanent magnet synchronous motors

Five-phase permanent magnet synchronous motors (PMSMs) have inherent fault-tolerant capabilities. This paper analyzes the detection of inter-turn short circuit faults in five-phase PMSMs in their early stage, i.e. with only one turn in short circuit by means of the analysis of the stator currents and the zero-sequence voltage component (ZSVC) spectra. For this purpose, a parametric model of five-phase PMSMs which accounts for the effects of inter-turn short circuits is developed to determine the most suitable harmonic frequencies to be analyzed to detect such faults. The amplitudes of these fault harmonic are analyzed in detail by means of finite-elements method (FEM) simulations, which corroborate the predictions of the parametric model. A low-speed five-phase PMSM for in-wheel applications is studied and modeled. This paper shows that the ZSVC-based method provides better sensitivity to diagnose inter-turn faults in the analyzed low-speed application. Results presented under a wide speed range and different load levels show that it is feasible to diagnose such faults in their early stage, thus allowing applying a post-fault strategy to minimize their effects while ensuring a safe operation

Inter-turn fault detection in five-phase PMSMs. Effects of the fault severity

This paper deals with the effects of inter-turn short circuit faults in five-phase permanent magnet synchronous motors (PMSMs). For this purpose a finiteelements model (FEM) of a faulty machine with 1, 2 and 4 inter-turns in short circuit is analyzed. From the results of this model the effects of these fault severities in the stator currents and zero-sequence voltage components (ZSVC) harmonics is analyzed and the possibility of developing a fault diagnosis scheme based on the changes in their spectral content is exposed. Moreover, the effect of the fault severity on the total power losses in the machine is presented. Inter-turn faults generate large circulating currents which may lead to catastrophic failures. Therefore it is very important to know the increase in power losses in the machine due to the occurrence of such faults for applying corrective actions at the precise time once the fault has been diagnosed

Scanning electron microscope studies of boron implanted silicon

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Magnet shape influence on the performance of AFPMM with demagnetization

In this paper the effect of the magnets shape on the AFPMM performance under a demagnetization fault has been analyzed by means of 3D-FEM simulations. Demagnetization faults in permanent magnet synchronous motors (PMSMs) may generate specific fault harmonic frequencies in the stator currents, output torque and the zero-sequence voltage component (ZSVC) spectra the ones can affect motor behavior, and so these parameters have been studied and compared, for each magnet configuration in each condition. These analyses are carried out to find out the more suitable geometry for an operation under healthy and faulty condition

Inter-turn fault detection in five-phase PMSMs. Effects of the fault severity

This paper deals with the effects of inter-turn short circuit faults in five-phase permanent magnet synchronous motors (PMSMs). For this purpose a finiteelements model (FEM) of a faulty machine with 1, 2 and 4 inter-turns in short circuit is analyzed. From the results of this model the effects of these fault severities in the stator currents and zero-sequence voltage components (ZSVC) harmonics is analyzed and the possibility of developing a fault diagnosis scheme based on the changes in their spectral content is exposed. Moreover, the effect of the fault severity on the total power losses in the machine is presented. Inter-turn faults generate large circulating currents which may lead to catastrophic failures. Therefore it is very important to know the increase in power losses in the machine due to the occurrence of such faults for applying corrective actions at the precise time once the fault has been diagnosed.Postprint (published version

Optimal design of a three-phase AFPM for in-wheel electrical traction

Sinusoidally fed permanent magnet synchronous motors (PMSM) fulfill the special features required for traction motors to be applied in electric vehicles (EV). Among them, axial flux permanent magnet (AFPM) synchronous motors are especially suited for in-wheel applications. Electric motors used in such applications must meet two main requirements, i.e. high power density and fault tolerance. This paper deals with the optimal design of an AFPM for in-wheel applications used to drive an electrical scooter. The single-objective optimization process carried out in this paper is based on designing the AFPM to obtain an optimized power density while ensuring appropriate fault tolerance requirements. For this purpose a set of analytical equations are applied to obtain the geometrical, electric and mechanical parameters of the optimized AFPM and several design restrictions are applied to ensure fault tolerance capability. The optimization process is based on a genetic algorithm and two more constrained nonlinear optimization algorithms in which the objective function is the power density. Comparisons with available data found in the technical bibliography show the appropriateness of the approach developed in this work