Rotor retaining sleeve design for a 1.12-MW high-speed PM machine

Permanent-magnet (PM) synchronous machines (PMSMs) can provide excellent performance in terms of torque density, energy efficiency, and controllability. However, PMs on the rotor are prone to centrifugal force, which may break their physical integrity, particularly at high-speed operation. Typically, PMs are bound with carbon fiber or retained by alloy sleeves on the rotor surface. This paper is concerned with the design of a rotor retaining sleeve for a 1.12-MW 18-kr/min PM machine; its electromagnetic performance is investigated by the 2-D finite-element method (FEM). Theoretical and numerical analyses of the rotor stress are carried out. For the carbon fiber protective measure, the stresses of three PM configurations and three pole filler materials are compared in terms of operating temperature, rotor speed, retaining sleeve thickness, and interference fit. Then, a new hybrid protective measure is proposed and analyzed by the 2-D FEM for operational speeds up to 22 kr/min (1.2 times the rated speed). The rotor losses and machine temperatures with the carbon fiber retaining sleeve and the hybrid retaining sleeve are compared, and the sleeve design is refined. Two rotors using both designs are prototyped and experimentally tested to validate the effectiveness of the developed techniques for PM machines. The developed retaining sleeve makes it possible to operate megawatt PM machines at high speeds of 22 kr/min. This opens doors for many high-power high-speed applications such as turbo-generator, aerospace, and submarine motor drives.

In-fibre Bragg grating temperature sensor system for medical applications

A novel quasidistributed in-fiber Bragg grating (FBG) temperature sensor system has been developed for temperature proving in vivo in the human body for medical applications, e.g., hyperthermia treatment. This paper provides the operating principle of FBG temperature sensors and then the design of the sensor head. High-resolution detection of the wavelength-shifts induced by temperature changes are achieved using drift-compensated interferometric detection while the return signals from the FBG sensor array are demultiplexed with a simple monochromator which offers crosstalk-free wavelength-division-multiplexing (WDM). A “strain-free” probe is designed by enclosing the FBG sensor array in a protection sleeve. A four FBG sensor system is demonstrated and the experimental results are in good agreement with those obtained by traditional electrical thermocouple sensors. A resolution of 0.1°C and an accuracy of ±0.2°C over a temperature range of 30-60°C have been achieved, which meet established medical requirements.

In-fibre Bragg grating temperature sensor system for medical applications

A novel quasidistributed in-flber Bragg grating (FBG) temperature sensor system has been developed for temperature profiling in vivo in the human body for medical applications, e.g., hyperthermia treatment. This paper provides the operating principle of FBG temperature sensors and then the design of the sensor head. High-resolution detection of the wavelength-shifts induced by temperature changes are achieved using drift-compensated interferometric detection while the return signals from the FBG sensor array are demultiplexed with a simple monochromator which offers crosstalk-free wavelength-division-multiplexing (WDM). A "strain-free" probe is designed by enclosing the FBG sensor array in a protection sleeve. A four FBG sensor system is demonstrated and the experimental results are in good agreement with those obtained by traditional electrical thermocouple sensors. A resolution of 0.1°C and an accuracy of ±0.2°C over a temperature range of 30-60°C have been achieved, which meet established medical requirements.

Reliability modelling and verification of manufacturing processes based on process knowledge management

Reliability modelling and verification is indispensable in modern manufacturing, especially for product development risk reduction. Based on the discussion of the deficiencies of traditional reliability modelling methods for process reliability, a novel modelling method is presented herein that draws upon a knowledge network of process scenarios based on the analytic network process (ANP). An integration framework of manufacturing process reliability and product quality is presented together with a product development and reliability verification process. According to the roles of key characteristics (KCs) in manufacturing processes, KCs are organised into four clusters, that is, product KCs, material KCs, operation KCs and equipment KCs, which represent the process knowledge network of manufacturing processes. A mathematical model and algorithm is developed for calculating the reliability requirements of KCs with respect to different manufacturing process scenarios. A case study on valve-sleeve component manufacturing is provided as an application example of the new reliability modelling and verification procedure. This methodology is applied in the valve-sleeve component manufacturing processes to manage and deploy production resources.