Permanent magnet synchronous motor for industrial inverter applications - analysis and design

During the latest few years the need for new motor types has grown, since both high efficiency and an accurate dynamic performance are demanded in industrial applications. For this reason, new effective control systems such as direct torque control (DTC) have been developed. Permanent magnet synchronous motors (PMSM) are well suitable for new adjustable speed AC inverter drives, because their efficiency and power factor are not depending on the pole pair number and speed to the same extent as it is the case in induction motors. Therefore, an induction motor (IM) with a mechanical gearbox can often be replaced with a direct PM motor drive. Space as well as costs will be saved, because the efficiency increases and the cost of maintenance decreases as well. This thesis deals with design criterion, analytical calculation and analysis of the permanent magnet synchronous motor for both sinusoidal air-gap flux density and rectangular air-gapflux density. It is examined how the air-gap flux, flux densities, inductances and torque can be estimated analytically for salient pole and non-salient pole motors. It has been sought by means of analytical calculations for the ultimate construction for machines rotating at relative low 300 rpm to 600 rpm speeds, which are suitable speeds e.g. in Pulp&Paper industry. The calculations are verified by using Finite Element calculations and by measuring of prototype motor. The prototype motor is a 45 kW, 600 rpm PMSM with buried V-magnets, which is a very appropriate construction for high torque motors with a high performance. With the purposebuilt prototype machine it is possible not only to verify the analytical calculations but also to show whether the 600 rpm PMSM can replace the 1500 rpm IM with a gear. It can also be tested if the outer dimensions of the PMSM may be the same as for the IM and if the PMSM in this case can produce a 2.5 fold torque, in consequence of which it may be possible to achieve the same power. The thesis also considers the question how to design a permanent magnet synchronous motor for relatively low speed applications that require a high motor torqueand efficiency as well as bearable costs of permanent magnet materials. It is shown how a selection of different parameters affects the motor properties. Key words: Permanent magnet synchronous motor, PMSM, surface magnets, buried magnets

Torque vibration model of axial-flux surface-mounted permanent magnet synchronous machine

In order that the radius and thus ununiform structure of the teeth and otherelectrical and magnetic parts of the machine may be taken into consideration the calculation of an axial flux permanent magnet machine is, conventionally, doneby means of 3D FEM-methods. This calculation procedure, however, requires a lotof time and computer recourses. This study proves that also analytical methods can be applied to perform the calculation successfully. The procedure of the analytical calculation can be summarized into following steps: first the magnet is divided into slices, which makes the calculation for each section individually, and then the parts are submitted to calculation of the final results. It is obvious that using this method can save a lot of designing and calculating time. Thecalculation program is designed to model the magnetic and electrical circuits of surface mounted axial flux permanent magnet synchronous machines in such a way, that it takes into account possible magnetic saturation of the iron parts. Theresult of the calculation is the torque of the motor including the vibrations. The motor geometry and the materials and either the torque or pole angle are defined and the motor can be fed with an arbitrary shape and amplitude of three-phase currents. There are no limits for the size and number of the pole pairs nor for many other factors. The calculation steps and the number of different sections of the magnet are selectable, but the calculation time is strongly depending on this. The results are compared to the measurements of real prototypes. The permanent magnet creates part of the flux in the magnetic circuit. The form and amplitude of the flux density in the air-gap depends on the geometry and material of the magnetic circuit, on the length of the air-gap and remanence flux density of the magnet. Slotting is taken into account by using the Carter factor in the slot opening area. The calculation is simple and fast if the shape of the magnetis a square and has no skew in relation to the stator slots. With a more complicated magnet shape the calculation has to be done in several sections. It is clear that according to the increasing number of sections also the result will become more accurate. In a radial flux motor all sections of the magnets create force with a same radius. In the case of an axial flux motor, each radial section creates force with a different radius and the torque is the sum of these. The magnetic circuit of the motor, consisting of the stator iron, rotor iron, air-gap, magnet and the slot, is modelled with a reluctance net, which considers the saturation of the iron. This means, that several iterations, in which the permeability is updated, has to be done in order to get final results. The motor torque is calculated using the instantaneous linkage flux and stator currents. Flux linkage is called the part of the flux that is created by the permanent magnets and the stator currents passing through the coils in stator teeth. The angle between this flux and the phase currents define the torque created by the magnetic circuit. Due to the winding structure of the stator and in order to limit the leakage flux the slot openings of the stator are normally not made of ferromagnetic material even though, in some cases, semimagnetic slot wedges are used. In the slot opening faces the flux enters the iron almost normally (tangentially with respect to the rotor flux) creating tangential forces in the rotor. This phenomenon iscalled cogging. The flux in the slot opening area on the different sides of theopening and in the different slot openings is not equal and so these forces do not compensate each other. In the calculation it is assumed that the flux entering the left side of the opening is the component left from the geometrical centre of the slot. This torque component together with the torque component calculated using the Lorenz force make the total torque of the motor. It is easy to assume that when all the magnet edges, where the derivative component of the magnet flux density is at its highest, enter the slot openings at the same time, this will have as a result a considerable cogging torque. To reduce the cogging torquethe magnet edges can be shaped so that they are not parallel to the stator slots, which is the common way to solve the problem. In doing so, the edge may be spread along the whole slot pitch and thus also the high derivative component willbe spread to occur equally along the rotation. Besides forming the magnets theymay also be placed somewhat asymmetric on the rotor surface. The asymmetric distribution can be made in many different ways. All the magnets may have a different deflection of the symmetrical centre point or they can be for example shiftedin pairs. There are some factors that limit the deflection. The first is that the magnets cannot overlap. The magnet shape and the relative width compared to the pole define the deflection in this case. The other factor is that a shifting of the poles limits the maximum torque of the motor. If the edges of adjacent magnets are very close to each other the leakage flux from one pole to the other increases reducing thus the air-gap magnetization. The asymmetric model needs some assumptions and simplifications in order to limit the size of the model and calculation time. The reluctance net is made for symmetric distribution. If the magnets are distributed asymmetrically the flux in the different pole pairs will not be exactly the same. Therefore, the assumption that the flux flows from the edges of the model to the next pole pairs, in the calculation model from one edgeto the other, is not correct. If it were wished for that this fact should be considered in multi-pole pair machines, this would mean that all the poles, in other words the whole machine, should be modelled in reluctance net. The error resulting from this wrong assumption is, nevertheless, irrelevant.

Sähköisen lineaariservomoottorijärjestelmän dynamiikan simulointi

Työssä johdettiin sähköisen lineaariservomoottorijärjestelmän dynaaminen malli. Lineaarimoottori on keksintönä vanha, mutta vasta viimeaikoina kestomagneettimateriaalien kehittyessä ja halvetessa lineaarimoottorista on tullut varteenotettava vaihtoehto pyörivän moottorin ja lineaarisen liikkeen toteuttavan mekanismin yhdistelmälle. Kestomagnetoituja lineaarimoottoreita käytetään sovelluksissa, joissa tarvitaan tarkkaa paikoitusta ja nopeudella ja kiihtyvyydellä on suuret vaatimukset. Moottorimalli toteutettiin vuorovaikutteisena simulointimallina. Moottorimalli, josta saatiin moottorin voima, rakennettiin MatLabâ 6.0/Simulinkâ –ohjelmalle ja moottoriin kiinnitetyn mekaniikan malli ADAMS 10.0 –ohjelmalle. Mallit on liitetty tämän jälkeen vuorovaikutteiseksi simulointimalliksi. Simuloinnista saatuja tuloksia on verrattu koneautomaation laboratorioon hankitun lineaarimoottorijärjestelmän mitattuihin vasteisiin.

Electrical machine in a Hybrid Electrical Vehicle

Hybrid electric vehicles (HEV) have attracted very much attention during the latest years. Increasing environmental concern and an increase in fuel prices are key factors for the growing interest towards the HEV. In a hybrid electric vehicle the power train consists of both a mechanical power system and an electric power transmission system. The major subsystems in the mechanical power system are the internal combustion engine which powers the vehicle; electric power transmission including an energy storage, power electronic inverter, hybrid control system; the electric motor drive that runs either in the generating mode or in the motoring mode to process the power flow between the energy storage and the electrical machine. This research includes two advanced electric motors for a parallel hybrid: induction machine and permanent magnets synchronous machine. In the thesis an induction motor and a permanent magnet motor are compared as propulsion motors. Electric energy storages are also studied.

Transporte de carga em compósitos de polianilina/V2O5

In this work, composites formed from a mixture of V2O5 and polyaniline (PANI) were investigated, for applications as cathode materials for secondary lithium batteries. Electrochemical quartz crystal microbalance (EQCM) data show that charge compensation in the [PANI]0.3V2O5 nanocomposite is achieved predominantly by Li+ migration. However, the charge compensation in the [PANI]V2O5 microcomposite occurs by Li+ and ClO4- transport. Electrochemical Impedance Spectroscopy (EIS) measurements reveal several benefits of nanohybrid formation, including the achievement of shorter ionic diffusion pathways, the higher diffusion rate of the lithium ion and also the higher electronic conductivity, which are responsible for a synergetic effect of the energy storage properties.

Síntese e caracterização de nanocompósitos Ni: SiO2 processados na forma de filmes finos

We have produced nanocomposite films of Ni:SiO2 by an alternative polymeric precursor route. Films, with thickness of ~ 1000 nm, were characterized by several techniques including X-ray diffraction, scanning electron microscopy, atomic force microscopy, flame absorption atomic spectrometry, and dc magnetization. Results from the microstructural characterizations indicated that metallic Ni-nanoparticles with average diameter of ~ 3 nm are homogeneously distributed in an amorphous SiO2 matrix. Magnetization measurements revealed a blocking temperature T B ~ 7 K for the most diluted sample and the absence of an exchange bias suggesting that Ni nanoparticles are free from an oxide layer.

Concentrated Winding Multiphase Permanent Magnet Machine Design and Electromagnetic Properties – Case Axial Flux Machine

Concentrated winding permanent magnet machines and their electromagnetic properties are studied in this doctoral thesis. The thesis includes a number of main tasks related to the application of permanent magnets in concentrated winding open slot machines. Suitable analytical methods are required for the first design calculations of a new machine. Concentrated winding machines differ from conventional integral slot winding machines in such a way that adapted analytical calculation methods are needed. A simple analytical model for calculating the concentrated winding axial flux machines is provided. The next three main design tasks are discussed in more detail in the thesis. The magnetic length of the rotor surface magnet machines is studied, and it is shown that the traditional methods have to be modified also in this respect. An important topic in this study has been to evaluate and minimize the rotor permanent magnet Joule losses by using segmented magnets in the calculations and experiments. Determination of the magnetizing and leakage inductances for a concentrated winding machine and the torque production capability of concentrated winding machines with different pole pair numbers are studied, and the results are compared with the corresponding properties of integral slot winding machines. The thesis introduces a new practical permanent magnet motor type for industrial use. The special features of the machine are based on the option of using concentrated winding open slot constructions of permanent magnet synchronous machines in the normal speed ranges of industrial motors, for instance up to 3000 min-1, without excessive rotor losses. By applying the analytical equations and methods introduced in the thesis, a 37 kW 2400 min-1 12-slot 10-pole axial flux machine with rotor-surfacemounted magnets is designed. The performance of the designed motor is determined by experimental measurements and finite element calculations.

Nanocompósitos cerâmicos a partir do processo de moagem mecânica de alta energia

Pb/Ti, Sn and Mg-based nanocomposite materials were prepared by the high-energy mechanical milling of commercial powders. The surface of these ceramic compounds was strongly influenced by the doping, diameter of the milling spheres and time of the mechanical milling (amorphization process). Such milling leads to the formation of nanocrystalline materials. The mechanical processing parameters of these compounds were investigated through Brunauer, Emmett and Teller isotherms, wide angle X-ray diffraction, transmission electron microscopy and CO2 adsorption.

Tuulivoimalan generaattorin roottorin valmistuksen ja valmistuskustannusten arviointi

Diplomityössä on käsitelty tuulivoimalan generaattorin roottorin valmistusta ja magneettien kiinnitystä. Työ on osa projektia, jonka tarkoituksena on ollut tuottaa kohdeyritykselle vaihtoehtoinen tuulivoimalan generaattorin roottorirakenne. Työhön on koottu projektissa käsitellyt asiat roottorin valmistustekniikan osalta. Työssä on selvitetty kustannuksien kannalta paras vaihtoehto roottorin valmistamiseksi sisältäen kuljetukset ja magneettien kokoonpanon. Valmistusmenetelminä on vertailtu hitsausta ja valamista. Magneettien osalta tarkasteltiin uuden vaihtoehtoisen kiinnitysmenetelmän tuomia säästöjä nykyiseen ratkaisuun verrattuna. Uusien roottorien kustannuksia on verrattu nykyiseen rakenteeseen. Tutkimusmenetelminä on käytetty projektiryhmän palavereja, haastatteluja ja kirjallisuusselvityksiä. Lopputuloksena kohdeyritykselle luotiin uusi roottorikonsepti, jossa yhdistyvät edullisempi roottorin valmistus ja magneettien kiinnitys. Roottorin valmistaminen valamalla osoittautui selvästi edullisemmaksi kuin hitsaaminen levyistä. Magneettien kiinnitystä yksinkertaistettiin käyttämällä seostettuja magneetteja ja magneettikehyksiä. Roottorin konstruktiomuutoksien avulla mahdollistettiin suurempi magneettien määrä, joka mahdollistaa suuremman tehontuoton.

Nanocompósitos semicondutores ZnO/TiO2: testes fotocatalíticos

Titanium dioxide is an efficient photocatalist, being possible to improve its efficiency with better charge separation which occurs when it is coupled with other semiconductors. Nanometric particles of ZnO were used to impregnate TiO2 P25 in order to optimize its photocatalytic properties. ZnO/TiO2 composites were obtained at different proportions and were characterized by X-ray diffraction (XRD), micro-Raman and diffuse reflectance spectroscopies, measurement of surface area (BET) and scanning electron microscopy (SEM). Raman spectroscopy data revealed a change on the TiO2 surface due the presence of ZnO which was observed by an enlargement of TiO2 peaks and a change on the relation rate between anatase and rutile phases of the composites. The photodegradation of azo-dye Drimaren red revealed better efficiency for ZnO/TiO2 3% nanocomposite and for ZnO pure.

Fotoeletrodegradação do corante AO7 utilizando filmes de nanocompósitos de ZnO-TiO2

The Zn-TiO2nanocomposite films were prepared by electrodeposition, using an acidic zinc sulphate solution with TiO2 nanoparticles in suspension. The as-deposited samples have been heated in air at 450 ºC for 6 h. The XRD and SEM analyses pointed out to the metal matrix conversion from Zn to ZnO and a rich morphology of needles-shaped grains. These materials were used on the photoelectrochemical degradation of AO7, which was efficiently degraded, with 40% of color removal, after 2 h period at 1.0 V, under white light irradiation. The apparent first order rate constant of the photoelectrodegradation reaction was 4.12 x 10-3 min-1.

Síntese e caracterização de nanocompósitos de poliestireno/hidroxissal lamelar

Polystyrene/layered hydroxide salt (LHS) modified with sodium dodecyl sulfate was synthesized by in situ polymerization. The materials synthesized were characterized by gravimetry, X-ray diffraction (XRD), thermogravimetry analyses (TGA), differential scanning calorimetry (DSC) and the flammability test (FT). XRD demonstrated that synthesized nanocomposites in all compositions studied showed poor global dispersion of LHS in polystyrene. TGA showed a slight decrease in thermal stability. DSC curves showed that the glass transition temperature of polystyrene and nanocomposites were similar. The FT showed that the nanocomposite with low load of LHS exhibited good results.

Nanocompósito de polpa de mamão e nanopartículas de quitosana para aplicação em embalagens

Nanocomposite materials have been incorporated into biopolymers, (e.g. hydroxypropyl methylcellulose), to improve their physical and chemical properties and enable them to be applied in food packaging, especially for their biodegradable and renewable properties. With this addition, fruit puree has been incorporated into the films to confer nutritional properties besides color and flavor. Chitosan is of interest in the packaging field since it is a biodegradable, bioabsorbable, antimicrobial agent. Furthermore, chitosan nanoparticles have been widely explored for their interesting properties and potential applications in food packaging. This work was divided into two stages: (1) chitosan nanoparticle synthesis; (2) addition of nanoparticles into HPMC and papaya puree films. Addition of chitosan nanoparticles to HPMC and papaya puree films improved film properties: mechanical, thermal and water vapor barrier. We have developed a novel nanomaterial with great potential for application in packaging to prolong the shelf life of food.

Nanocompósitos entre nanotubos de carbono e nanopartículas de platina: preparação, caracterização e aplicação em eletro-oxidação de álcoois

The synthesis and characterization of different platinum nanoparticle/carbon nanotube nanocomposite samples are described along with the application of these nanocomposites as electrocatalysts for alcohol oxidation. Samples were prepared by a biphasic system in which platinum nanoparticles (Pt-NPs) are synthesized in situ in contact with a carbon nanotube (CNT) dispersion. Variables including platinum precursor/CNT ratio, previous chemical treatment of carbon nanotubes, and presence or absence of a capping agent were evaluated and correlated with the characteristic of the synthesized materials. Samples were characterized by Raman spectroscopy, X-ray diffraction, thermogravimetric analysis and transmission electron microscopy. Glassy carbon electrodes were modified by the nanocomposite samples and evaluated as electrocatalysts for alcohol oxidation. Current densities of 56.1 and 79.8/104.7 mA cm-2 were determined for the oxidation of methanol and ethanol, respectively.

INFLUÊNCIA DO TRATAMENTO TÉRMICO NO NANOCOMPÓSITO FOTOCATALISADOR ZnO/TiO2

ZnO/TiO2 nanocomposites were prepared by impregnating zinc acetate dihydrate on the surface of titanium dioxide P25, followed by thermal treatment at 350, 600, 750, and 900 °C, in order to investigate the TiO2 phase and titanate formation and the role of the latter in the photocatalytic activity of the nanocomposite. In the nanocomposites, the anatase-to-rutile transition is favored due to the presence of Zn2+, and the conversion is nearly complete at 750 °C. The presence of zinc metatitanate in the sample heated at 600 °C had no significant effect on the nanocomposite photocatalytic activity.