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11 pages, 4638 KiB

Open AccessArticle

Eddy Current Loss Reduction in Axial-Flux Motors Using 3D Printing

by Hyun-Jo Pyo, Kangbeen Lee, Jeong-Yeon Min, Min-Ki Hong and Won-Ho Kim

Energies 2023, 16(3), 1318; https://doi.org/10.3390/en16031318 - 26 Jan 2023

Cited by 1 | Viewed by 1711

Abstract

As more electrification and emission-free transportation trends receive more attention, electrical systems applied in the aircraft and automotive industries are changing from fossil fuel and hydraulic systems to electric AC machine drive systems. Three-dimensional printing technology has been contributing to a new design [...] Read more.

As more electrification and emission-free transportation trends receive more attention, electrical systems applied in the aircraft and automotive industries are changing from fossil fuel and hydraulic systems to electric AC machine drive systems. Three-dimensional printing technology has been contributing to a new design of machines, because it provides many opportunities without limitation compared to the conventional manufacturing system. Although 3D printing technology opened a door for increasing the efficiency and power density of AC machine drives with low conduction loss, an optimal design process for eddy current loss reduction is required, because eddy current loss is affected by the design structure of the machine. The slit structure at the stator shoe is proposed to reduce eddy current loss. With the three variables, the number of slits, the thickness of slits, and the length of ribs, a parametric analysis was conducted to find an optimal design with eddy current loss reduction without a significant performance dip. The optimal design provides an 18.75% decrease in eddy current loss. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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14 pages, 19256 KiB

Open AccessArticle

Predictive Current Control of Sensorless Linear Permanent Magnet Synchronous Motor

by He Wang, Tao Wu, Youguang Guo, Gang Lei and Xinmei Wang

Energies 2023, 16(2), 628; https://doi.org/10.3390/en16020628 - 04 Jan 2023

Cited by 2 | Viewed by 947

Abstract

In the vector control system of a tubular oscillating permanent magnet synchronous linear motor, it is difficult to obtain accurate feedback information from the conventional mechanical sensors under bad and complex working conditions. This paper presents a new predictive current control designed to [...] Read more.

In the vector control system of a tubular oscillating permanent magnet synchronous linear motor, it is difficult to obtain accurate feedback information from the conventional mechanical sensors under bad and complex working conditions. This paper presents a new predictive current control designed to estimate the speed of the tubular oscillation permanent magnet synchronous linear motor. It implements two control techniques: The first technique is using the sliding-mode observer’s speed observer for speed estimation. The second is to design a deadbeat predictive current control to replace the PI regulator in the conventional current loop; it solves the difficulties of global optimization and PI parameter setting. The simulation and experimental results show that this method gives a good dynamic performance. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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15 pages, 3212 KiB

Open AccessArticle

Steady-State Thermal Modeling of Salient Pole Synchronous Generator

by Payam Shams Ghahfarokhi, Andrejs Podgornovs, Ants Kallaste, Antonio J. Marques Cardoso, Anouar Belahcen, Toomas Vaimann, Oleg Kudrjavtsev, Bilal Asad and Muhammad Naveed Iqbal

Energies 2022, 15(24), 9460; https://doi.org/10.3390/en15249460 - 13 Dec 2022

Viewed by 1456

Abstract

This paper presents a practical thermal model of a synchronous generator for high-power applications. This model couples the lumped parameter thermal network and coolant network together to utilize the impact of the coolant’s temperature rising over the machine. Furthermore, the advanced multi-planes technique [...] Read more.

This paper presents a practical thermal model of a synchronous generator for high-power applications. This model couples the lumped parameter thermal network and coolant network together to utilize the impact of the coolant’s temperature rising over the machine. Furthermore, the advanced multi-planes technique provides a more precise and higher resolution temperature distribution of various machine sections. Therefore, the machines are divided into five planes; three belong to the active part, and two are added to model the machine’s drive and non-drive end-regions. Furthermore, the paper pays special attention to describing the challenges and providing solutions to them during the heat transfer modeling and analysis. Finally, the analytical model is verified using experimental results on a synchronous generator with a salient pole rotor and an open self-ventilation (OSV) cooling system by comparing the analytical and experimental results. As a result, good correspondence between the estimated and measurement results is achieved. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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23 pages, 5390 KiB

Open AccessArticle

Implementation and Experimental Validation of Efficiency Improvement in PM Synchronous Hub Motors for Light Electric Vehicles

by İrfan Güven Çömezoğlu and Sibel Zorlu Partal

Energies 2022, 15(21), 7953; https://doi.org/10.3390/en15217953 - 26 Oct 2022

Cited by 1 | Viewed by 1617

Abstract

The efficiency of permanent magnet synchronous hub motors (PMSHM) used in light electric vehicles (EVs) is lower than that used in commercial EVs. Therefore, in this study a high-efficiency radial-flux outer-rotor PMSHM was designed for light EVs. The high-efficiency motor will contribute to [...] Read more.

The efficiency of permanent magnet synchronous hub motors (PMSHM) used in light electric vehicles (EVs) is lower than that used in commercial EVs. Therefore, in this study a high-efficiency radial-flux outer-rotor PMSHM was designed for light EVs. The high-efficiency motor will contribute to the reduction of the power consumption demand from the batteries of EVs, the longer life of the batteries and the longer uninterrupted operation of the system. The optimization objectives, such as motor sizing, number of slots and poles, air gap length, material selection, stator winding structure, stator slot shape, magnet thickness, and cutting method for stator sheets were considered to ensure high efficiency and low cogging torque. In this study, three validation stages were followed; electromagnetic analyzes with FEM, analytical calculations, and finally experimental validation. First, the design parameters of the motor were determined based on the analyses results obtained using ANSYS Maxwell software, and then validated both with the analytical calculations and experimental results. The comparison results show that the design data of the motor at the rated speed agree well with the analytical calculations and test results. After obtaining the optimized motor design, the motor was installed on a prototype electric car for the road test. During the test drive, the motor performed successfully and operated compatibly with the rest of the electric vehicle systems such as the motor driver and the battery. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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15 pages, 8411 KiB

Open AccessArticle

A Design Methodology for Dual-Mode Electro-Mechanical Transmission Scheme Based on Jointing Characteristics

by Xueliang Li, Xinyu Kang, Xin Ba, Zengxiong Peng, Shujun Yang and Zhifu Zhao

Energies 2022, 15(15), 5482; https://doi.org/10.3390/en15155482 - 28 Jul 2022

Cited by 1 | Viewed by 1059

Abstract

Electro-mechanical transmission is the best choice for the transmission system of military, engineering and other heavy special vehicles. The scheme design is fundamental and key to realize the original innovation of the electro-mechanical transmission. Therefore, a novel design method of a planetary-gear scheme [...] Read more.

Electro-mechanical transmission is the best choice for the transmission system of military, engineering and other heavy special vehicles. The scheme design is fundamental and key to realize the original innovation of the electro-mechanical transmission. Therefore, a novel design method of a planetary-gear scheme is proposed for electro-mechanical transmission. According to the distribution of mechanical points and the speed continuous condition of mode switching, the mode combination law of a dual-mode electro-mechanical transmission is obtained, i.e., the input split mode based on the scheme of three-degree-of-freedom (3-DOF) and the compound split mode based on the scheme of 2-DOF. Moreover, a design method for an electro-mechanical transmission scheme is proposed based on the mode combination law. Two single-mode schemes are combined to form a dual-mode scheme, and then mode jointing, control logic, isomorphism and other screening conditions are in turn used to screen schemes; therefore, two optimized schemes are obtained ultimately. Lastly, by analyzing the characteristics of speed, torque and the power split of the optimized schemes, the accuracy of the proposed design method in this paper is verified. The proposed design method can provide new ideas of designing multi-mode and multi-output electro-mechanical transmission schemes. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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24 pages, 5860 KiB

Open AccessArticle

Implementation of an Improved Motor Control for Electric Vehicles

by Xiaojin Men, Youguang Guo, Gang Wu, Shuangwu Chen and Chun Shi

Energies 2022, 15(13), 4833; https://doi.org/10.3390/en15134833 - 01 Jul 2022

Cited by 9 | Viewed by 2677

Abstract

Electric vehicles are regarded as a significant way to mitigate the global energy crisis and the environmental pollution problem. Motor control is a very important part for electric vehicles. As for hardware, a motor controller usually has components such as a power module, [...] Read more.

Electric vehicles are regarded as a significant way to mitigate the global energy crisis and the environmental pollution problem. Motor control is a very important part for electric vehicles. As for hardware, a motor controller usually has components such as a power module, microprocessor unit, IGBT driver, sensors, and resolver-to-digital convertor. As for software, a field-oriented control (FOC) with space vector pulse width modulation (SVPWM) is a popular method, while model predictive control (MPC) has recently shown great potential in motor drives. In this paper, both FOC and MPC are discussed and the performances are compared based on experiments. As the implementation is on a digital processor, the discretization and normalization are addressed, and the flux observer and speed estimation are discussed. Some practical issues for implementation are also talked about, such as field weakening control, overmodulation, etc. This paper focuses on how to implement the improved motor control for electric vehicles as industrial applications. The steady-state torque performances of this motor controller are verified by motor test-bench experiments. MPC shows as good performance as FOC in these experiments. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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16 pages, 1191 KiB

Open AccessArticle

Normalized Model Reference Adaptive Control Applied to High Starting Torque Scalar Control Scheme for Induction Motors

by Juan Carlos Travieso-Torres and Manuel A. Duarte-Mermoud

Energies 2022, 15(10), 3606; https://doi.org/10.3390/en15103606 - 14 May 2022

Cited by 5 | Viewed by 1803

Abstract

Recently, a novel high-starting torque scalar control scheme (HST-SCS) for induction motor(s) (IM) emerged. It expands the scalar control application field beyond centrifugal pumps, blowers, and fans, moving, for instance, some conveyor belts with nominal torque loading. This paper proposes a normalized model [...] Read more.

Recently, a novel high-starting torque scalar control scheme (HST-SCS) for induction motor(s) (IM) emerged. It expands the scalar control application field beyond centrifugal pumps, blowers, and fans, moving, for instance, some conveyor belts with nominal torque loading. This paper proposes a normalized model reference adaptive control (N-MRAC) applied to HST-SCS for IM. First, the proposal extends the MRAC, resulting inn a class of nonlinear systems encompassing the IM dynamical model. It uses a normalized information vector, jointly with a direct control approach, reducing the trial and error adaptive controller tuning. Second, a properly designed N-MRAC is applied to regulate the starting stator current within the variable speed drive under investigation. As a result, the proposed methodology keeps the HST-SCS as a simple control scheme without needing variable observers or parameter estimators and employing tuning information only from the motor nameplate and datasheet. Test bench experiments with a 10 HP motor validate the proposal effectiveness. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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17 pages, 10398 KiB

Open AccessArticle

Reduction in the Cogging Torques in the DCEFSM Motor by Changing the Geometry of the Rotor Teeth

by Andrzej Bień, Tomasz Drabek, Dawid Kara and Tomasz Kołacz

Energies 2022, 15(7), 2455; https://doi.org/10.3390/en15072455 - 27 Mar 2022

Cited by 4 | Viewed by 1492

Abstract

The paper presents the results of FEM 2D computational studies of a three-phase Direct Current Excited Flux Switching Machine (DCEFSM) electric motor with 15 rotor teeth and 36 stator teeth. The aim of the research was to minimize the cogging torque of the [...] Read more.

The paper presents the results of FEM 2D computational studies of a three-phase Direct Current Excited Flux Switching Machine (DCEFSM) electric motor with 15 rotor teeth and 36 stator teeth. The aim of the research was to minimize the cogging torque of the machine by changing the geometry of the rotor teeth and the size of the air gap between the stator and the rotor, with the operating torques unchanged. Computational studies were carried out on the influence of the width of the rotor teeth, the radius of the rounding of their corners, and the size of the air gap on the cogging torque and machine operating torques. The results of the calculations made it possible to select the dimensions of the rotor and the air gap in such a way that the maximum cogging torque was reduced more than six-fold, with the machine operating torques being unchanged. The calculations also showed that it is not possible to increase the value of the operational torques by further changes in the geometry of the rotor teeth and the size of the air gap of the machine. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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13 pages, 22016 KiB

Open AccessArticle

Robust Sliding Mode Control of the Permanent Magnet Synchronous Motor with an Improved Power Reaching Law

by Zhenjie Gong, Xin Ba, Chengning Zhang and Youguang Guo

Energies 2022, 15(5), 1935; https://doi.org/10.3390/en15051935 - 07 Mar 2022

Cited by 4 | Viewed by 2165

Abstract

To improve the suppression ability of uncertain disturbance of the sliding mode control driving system of the surface-mounted permanent magnet synchronous motor (SPMSM) and to reduce the chattering of the control output, a robust sliding mode control strategy with an improved power reaching [...] Read more.

To improve the suppression ability of uncertain disturbance of the sliding mode control driving system of the surface-mounted permanent magnet synchronous motor (SPMSM) and to reduce the chattering of the control output, a robust sliding mode control strategy with an improved power reaching law (IPRL) is proposed in this paper. Compared with the traditional fast power reaching law (FPRL), the IPRL incorporates the sum of the power terms of the system state variables into the conventional power terms, and uses hyperbolic tangent saturation function to replace the piecewise function, which can effectively suppress the sliding mode chattering and improve the convergence speed of the system state to the sliding mode surface. Furthermore, the robust sliding mode speed controller and sliding mode current controller of the SPMSM are designed separately with the IPRL, and detailed simulation verification is carried out to reveal the effectiveness of the IPRL. Simulation and experimental results show that compared with the FPRL, the proposed IPRL can reduce the inherent chattering phenomenon in sliding mode control, and the IPRL-based speed and current control strategy can effectively improve the dynamic performance and robustness of the system. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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13 pages, 7193 KiB

Open AccessArticle

Analysis and Cogging Torque Minimization of a Novel Flux Reversal Claw Pole Machine with Soft Magnetic Composite Cores

by Bin Li, Xue Li, Shaopeng Wang, Rongmei Liu, Youhua Wang and Zhiwei Lin

Energies 2022, 15(4), 1285; https://doi.org/10.3390/en15041285 - 10 Feb 2022

Cited by 4 | Viewed by 1234

Abstract

The performances of a novel flux reversal claw pole machine (FRCPM) using soft magnetic composite (SMC) cores is analyzed in detail. The developed FRCPM uses both a flux reversal permanent magnet machine (FRPMM) and claw pole machine (CPM). In this paper, the main [...] Read more.

The performances of a novel flux reversal claw pole machine (FRCPM) using soft magnetic composite (SMC) cores is analyzed in detail. The developed FRCPM uses both a flux reversal permanent magnet machine (FRPMM) and claw pole machine (CPM). In this paper, the main dimensions are optimized to ensure that the FRCPM can achieve maximum torque. In addition, the rotor skewing technology applied in the paper leads to a reduction in cogging torque and torque ripple of the machine. The main electromagnetic parameters and performance are obtained using the 3D finite element method. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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17 pages, 6630 KiB

Open AccessArticle

A Position Sensorless Closed-Loop Control Mode of a Three-Phase Hybrid Stepper Motor

by Zhen Peng and Chao Bi

Energies 2022, 15(3), 804; https://doi.org/10.3390/en15030804 - 22 Jan 2022

Viewed by 2532

Abstract

The demand for the high-performance and low-cost position control actuators in many applications promotes the development of three-phase hybrid stepper motors. The torque ripple, loss, and pullout torque of the motor are the key factors to be considered in the motor application. In [...] Read more.

The demand for the high-performance and low-cost position control actuators in many applications promotes the development of three-phase hybrid stepper motors. The torque ripple, loss, and pullout torque of the motor are the key factors to be considered in the motor application. In order to solve the problems of the open-loop control mode, this paper proposes a new “sensorless closed-loop” control mode to significantly improve the performance of three-phase hybrid stepper motors. This control mode is developed by estimating the rotor position with the Extended Kalman filter observer, thereby realizing the closed-loop control of the motor with sensorless technology. This paper illustrates the effects of this control mode by analyzing motor noise, losses, and pullout-torque. The results show that the use of the “sensorless closed-loop” control mode presented can effectively improve the performance of the stepper motor while maintaining the advantages of the motor in terms of cost and size. These results have positive significance for the development, application, and promotion of high-performance three-phase hybrid stepper motor systems. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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18 pages, 6712 KiB

Open AccessArticle

The Effects of Permanent Magnet Segmentations on Electromagnetic Performance in Ironless Brushless DC Motors

by Fugang Zhai, Liu Yang, Wenqi Fu, Haisheng Tong and Tianyu Zhao

Energies 2022, 15(2), 621; https://doi.org/10.3390/en15020621 - 16 Jan 2022

Cited by 2 | Viewed by 1341

Abstract

This paper investigates the electromagnetic torque by considering back electromagnetic force (back-EMF) trapezoidal degrees of ironless brushless DC (BLDC) motors through the two-dimensional finite element method (2-D FEM). First, the change percentages of the electromagnetic torque with back-EMF trapezoidal degrees, relative to those [...] Read more.

This paper investigates the electromagnetic torque by considering back electromagnetic force (back-EMF) trapezoidal degrees of ironless brushless DC (BLDC) motors through the two-dimensional finite element method (2-D FEM). First, the change percentages of the electromagnetic torque with back-EMF trapezoidal degrees, relative to those of PMs without segments, are investigated on the premise of the same back-EMF amplitude. It is found that both PM symmetrically and asymmetrically segmented types influence back-EMF trapezoidal degrees. Second, the corresponding electromagnetic torque, relative to that of PMs without segments, is studied in detail. The results show that the electromagnetic torque can be improved or deteriorated depending on whether the back-EMF trapezoidal degree is lower or higher than that of PMs without segments. Additionally, the electromagnetic torque can easily be improved by increasing the number of PMs’ symmetrical segments. In addition, the electromagnetic torque in PMs with asymmetrical segments is always higher than that of PMs without segments. Finally, two ironless PM BLDC motors with PMs symmetrically segmented into three segments and without segments are manufactured and tested. The experimental results show good agreement with those of the 2-D FEM method. This approach provides significant guidelines to electromagnetic torque improvement without much increase in manufacturing costs and process complexity. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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19 pages, 5383 KiB

Open AccessArticle

Challenges in the Electromagnetic Design of Multiphase Machines: Winding and Equivalent Circuit Parameters

by Jan Laksar, Radek Cermak and Karel Hruska

Energies 2021, 14(21), 7335; https://doi.org/10.3390/en14217335 - 04 Nov 2021

Cited by 8 | Viewed by 1722

Abstract

The usage of multiphase electrical drives expands the operation possibilities of electrical machines and opens new directions of research on inverter-fed electrical machines. With an increasing number of phases, the standard approach of the electromagnetic design of machines has to be generalized to [...] Read more.

The usage of multiphase electrical drives expands the operation possibilities of electrical machines and opens new directions of research on inverter-fed electrical machines. With an increasing number of phases, the standard approach of the electromagnetic design of machines has to be generalized to m-phase systems, which is not usually respected in the literature focused on electric machine design, and it is rarely published. This paper summarizes the specific problems linked with the design of machines with different numbers of phases, focusing on the winding design and the calculation of equivalent circuit parameters. In addition to the direct effect of different numbers of phases, the impact of injecting higher order time harmonic components on the electromagnetic design of electric machines is analyzed. The obtained analytical results are verified by the measurement of a nine-phase experimental induction motor. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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Review

Jump to: Research

18 pages, 2584 KiB

Open AccessReview

Characterization of Rotational Magnetic Properties of Amorphous Metal Materials for Advanced Electrical Machine Design and Analysis

by Youguang Guo, Lin Liu, Xin Ba, Haiyan Lu, Gang Lei, Pejush Sarker and Jianguo Zhu

Energies 2022, 15(20), 7798; https://doi.org/10.3390/en15207798 - 21 Oct 2022

Cited by 7 | Viewed by 1660

Abstract

Amorphous metal (AM), specifically amorphous ferromagnetic metal, is considered as a satisfactory magnetic material for exploring electromagnetic devices with high-efficiency and high-power density, such as electrical machines and transformers, benefits from its various advantages, such as reasonably low power loss and very high [...] Read more.

Amorphous metal (AM), specifically amorphous ferromagnetic metal, is considered as a satisfactory magnetic material for exploring electromagnetic devices with high-efficiency and high-power density, such as electrical machines and transformers, benefits from its various advantages, such as reasonably low power loss and very high permeability in medium to high frequency. However, the characteristics of these materials have not been investigated comprehensively, which limits its application prospects to good-performance electrical machines that have the magnetic flux density with generally rotational and non-sinusoidal features. The appropriate characterization of AMs under different magnetizations is among the fundamentals for utilizing these materials in electrical machines. This paper aims to extensively overview AM property measurement techniques in the presence of various magnetization patterns, particularly rotational magnetizations, and AM property modeling methods for advanced electrical machine design and analysis. Possible future research tasks are also discussed for further improving AM applications. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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18 pages, 3653 KiB

Open AccessReview

The Review of Electromagnetic Field Modeling Methods for Permanent-Magnet Linear Motors

by Xinmei Wang, Yifei Wang and Tao Wu

Energies 2022, 15(10), 3595; https://doi.org/10.3390/en15103595 - 13 May 2022

Cited by 6 | Viewed by 2496

Abstract

Permanent-magnet linear motors (PMLMs) are widely used in various fields of industrial production, and the optimization design of the PMLM is increasingly attracting attention in order to improve the comprehensive performance of the motor. The primary problem of PMLM optimization design is the [...] Read more.

Permanent-magnet linear motors (PMLMs) are widely used in various fields of industrial production, and the optimization design of the PMLM is increasingly attracting attention in order to improve the comprehensive performance of the motor. The primary problem of PMLM optimization design is the establishment of a motor model, and this paper summarizes the modeling of the PMLM electromagnetic field. First, PMLM parametric modeling methods (model-driven methods) such as the equivalent circuit method, analytical method, and finite element method, are introduced, and then non-parametric modeling methods (data-driven methods) such as the surrogate model and machine learning are introduced. Non-parametric modeling methods have the characteristics of higher accuracy and faster computation, and are the mainstream approach to motor modeling at present. However, surrogate models and traditional machine learning models such as support vector machine (SVM) and extreme learning machine (ELM) approaches have shortcomings in dealing with the high-dimensional data of motors, and some machine learning methods such as random forest (RF) require a large number of samples to obtain better modeling accuracy. Considering the modeling problem in the case of the high-dimensional electromagnetic field of the motor under the condition of a limited number of samples, this paper introduces the generative adversarial network (GAN) model and the application of the GAN in the electromagnetic field modeling of PMLM, and compares it with the mainstream machine learning models. Finally, the development of motor modeling that combines model-driven and data-driven methods is proposed. Full article

(This article belongs to the Special Issue Advanced Electrical Machine Design and Optimization)

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