Design and market considerations for axial flux superconducting electric machine design

In this paper, the authors investigate a number of design and market considerations for an axial flux superconducting electric machine design that uses high temperature superconductors. The axial flux machine design is assumed to utilise high temperature superconductors in both wire (stator winding) and bulk (rotor field) forms, to operate over a temperature range of 65-77 K, and to have a power output in the range from 10s of kW up to 1 MW (typical for axial flux machines), with approximately 2-3 T as the peak trapped field in the bulk superconductors. The authors firstly investigate the applicability of this type of machine as a generator in small- and medium-sized wind turbines, including the current and forecasted market and pricing for conventional turbines. Next, a study is also carried out on the machine's applicability as an in-wheel hub motor for electric vehicles. Some recommendations for future applications are made based on the outcome of these two studies. Finally, the cost of YBCO-based superconducting (2G HTS) wire is analysed with respect to competing wire technologies and compared with current conventional material costs and current wire costs for both 1G and 2G HTS are still too great to be economically feasible for such superconducting devices.

Design and Performance Analysis of a 2.5 MW-Class HTS Synchronous Motor for Ship Propulsion

The development of cryogenic technology and high temperature superconducting (HTS) materials has seen continued interest worldwide in the development of HTS machines since the late 1980s. In this paper, the authors present a conceptual design of a 2.5 MW class synchronous motor. The structure of the motor is specified and the motor performance is analyzed via a three-dimensional model using the finite element method (FEM). Rotor optimization is carried out to decrease the harmonic components in the air gap field generated by HTS tapes. Based on the results of this 3D simulation, the determination of the operating conditions and load angle is discussed with consideration to the HTS material properties. The economic viability of air-core and iron-core designs is compared. The results show that this type of HTS machine has the potential to achieve an economic, efficient and effective machine design, which operates at a low load angle, and this design process provides a practical way to simulate and analyze the performance of such machines.

Flexible asymmetric spinning

Metal spinning is used to form shell components, but is constrained by two features: it can only produce axisymmetric shapes; it requires a dedicated mandrel for each product. Examination of pressures between product and mandrel revealed that contact is limited to three well defined areas. This suggested that the full mandrel could be replaced by three rollers. Furthermore, if these rollers could be controlled, they could represent any symmetric or asymmetric mandrel. A seven-axis machine has been designed, manufactured, and used to spin trial parts. The machine design is described, and preliminary results give an indicator of process capability. © 2011 CIRP.

AC loss estimation of HTS armature windings for electric machines

This paper studies 2G high-temperature superconducting (HTS) coils for electric machine armature windings, using finite element method (FEM) and H formulation. A FEM model for 2G HTS racetrack coil is built in COMSOL, and is well validated by comparing calculated ac loss with experimental measurements. The FEM model is used to calculate transport loss in HTS armature windings, using air-cored design. We find that distributed winding used in conventional machine design is an effective way to reduce transport loss of HTS armature winding, in terms of air-cored design. Based on our study, we give suggestions on the design of low loss HTS armature winding. © 2002-2011 IEEE.

Design methodology of HTS bulk machine for direct-driven wind generation

This paper introduces the design methodology of HTS bulk generator for direct-driven wind turbine. The trap field capability of HTS bulks offer the potential of maintaining similar or even higher magnetic loading level without the iron circuit in the generator. This so-called air-cored design can reduce the weight and increase the power outing per volume of the machine. The detailed design method of the air-cored HTS bulk machine is presented; 3D modeling is applied to consider the total trapped field of bulk arrays; a case study is performed to demonstrate the advantages of air-cored HTS bulk machine over conventional permanent magnet machine. Our results show that the air-cored HTS bulk machine has the potential to maintain the same magnetic loading level as that of the conventional permanent magnet machine. More importantly, it can reduce the total machine weight by 30%. © 2002-2011 IEEE.

A general design method for electric machines using magnetic circuit model considering the flux saturation problem

This paper proposes an analytical approach that is generalized for the design of various types of electric machines based on a physical magnetic circuit model. Conventional approaches have been used to predict the behavior of electric machines but have limitations in accurate flux saturation analysis and hence machine dimensioning at the initial design stage. In particular, magnetic saturation is generally ignored or compensated by correction factors in simplified models since it is difficult to determine the flux in each stator tooth for machines with any slot-pole combinations. In this paper, the flux produced by stator winding currents can be calculated accurately and rapidly for each stator tooth using the developed model, taking saturation into account. This aids machine dimensioning without the need for a computationally expensive finite element analysis (FEA). A 48-slot machine operated in induction and doubly-fed modes is used to demonstrate the proposed model. FEA is employed for verification.