Design of a Traction Motor With Tooth-Coil Windings and Embedded Magnets

Traction motor design significantly differs from industrial machine design. The starting point is the load cycle instead of the steady-state rated operation point. The speed of the motor varies from zero to very high speeds. At low speeds, heavy overloading is used for starting, and the field-weakening region also plays an important role. Finding a suitable fieldweakening point is one of the important design targets. At the lowest speeds, a high torque output is desired, and all current reserves of the supplying converter unit are used to achieve the torque. In this paper, a 110-kW 2.5-p.u. starting torque and a maximum 2.5-p.u. speed permanent-magnet traction motor will be studied. The field-weakening point is altered by varying the number of winding turns of machine. One design is selected for prototyping. Theoretical results are verified by measurements.

Unequal Teeth Widths for Torque Ripple Reduction in Permanent Magnet Synchronous Machines With Fractional-Slot Non-Overlapping Windings

Permanent magnet synchronous machines with fractional-slot non-overlapping windings (FSPMSM), also known as tooth-coil winding permanent magnet synchronous machines (TCW PMSM), have been under intensive research during the latest decade. There are many optimization routines explained and implemented in the literature in order to improve the characteristics of this machine type. This paper introduces a new technique for torque ripple minimization in TCW PMSM. The source of torque harmonics is also described. The low order torque harmonics can be harmful for a variety of applications, such as direct drive wind generators, direct drive light vehicle electrical motors, and for some high precision servo applications. The reduction of the torque ripple harmonics with the lowest orders (6th and 12th) is realized by machine geometry optimization technique using finite element analysis (FEA). The presented optimization technique includes the stator geometry adjustment in TCW PMSMs with rotor surface permanent magnets and with rotor embedded permanent magnets. Influence of the permanent magnet skewing on the torque ripple reduction and cogging torque elimination was also investigated. It was implemented separately and together with the stator optimization technique. As a result, the reduction of some torque ripple harmonics was attained.

Direct-Driven Interior Magnet Permanent Magnet Synchronous Motors for a Full Electric Sports Car

The design process of direct-driven permanent magnet synchronous machines (PMSMs) for a full electric 4 ´ 4 sports car is presented. The rotor structure of the machine consists of two permanent magnet layers embedded inside the rotor laminations thus resulting in some inverse saliency, where the q-axis inductance is larger than the d-axis one. An integer slot stator winding was selected to fully take advantage of the additional reluctance torque. The performance characteristics of the designed PMSMs were calculated by applying a twodimensional finite element method. Cross-saturation between the d- and q-axes was taken into account in the calculation of the synchronous inductances. The calculation results are validated by measurements.

Replacing Copper with New Carbon Nanomaterials in Electrical Machine Windings

Electrical machines have significant improvement potential. Nevertheless, the field is characterized by incremental innovations. Admittedly, steady improvement has been achieved, but no breakthrough development. Radical development in the field would require the introduction of new elements, such that may change the whole electrical machine industry system. Recent technological advancements in nanomaterials have opened up new horizons for the macroscopic application of carbon nanotube (CNT) fibres. With values of 100 MS/m measured on individual CNTs, CNT fibre materials hold promise for conductivities far beyond those of metals. Highly conductive, lightweight and strong CNT yarn is finally within reach; it could replace copper as a potentially better winding material. Although not yet providing low resistivity, the newest CNT yarn offers attractive perspectives for accelerated efficiency improvement of electrical machines. In this article, the potential for using new CNT materials to replace copper in machine windings is introduced. It does so, firstly, by describing the environment for a change that could revolutionize the industry and, secondly, by presenting the breakthrough results of a prototype construction. In the test motor, which is to our knowledge the first in its kind, the presently most electrically conductive carbon nanotube yarn replaces usual copper in the windings.

Agent-based management systems for many-core platforms : rigorous design and efficient implementation

Due to various advantages such as flexibility, scalability and updatability, software intensive systems are increasingly embedded in everyday life. The constantly growing number of functions executed by these systems requires a high level of performance from the underlying platform. The main approach to incrementing performance has been the increase of operating frequency of a chip. However, this has led to the problem of power dissipation, which has shifted the focus of research to parallel and distributed computing. Parallel many-core platforms can provide the required level of computational power along with low power consumption. On the one hand, this enables parallel execution of highly intensive applications. With their computational power, these platforms are likely to be used in various application domains: from home use electronics (e.g., video processing) to complex critical control systems. On the other hand, the utilization of the resources has to be efficient in terms of performance and power consumption. However, the high level of on-chip integration results in the increase of the probability of various faults and creation of hotspots leading to thermal problems. Additionally, radiation, which is frequent in space but becomes an issue also at the ground level, can cause transient faults. This can eventually induce a faulty execution of applications. Therefore, it is crucial to develop methods that enable efficient as well as resilient execution of applications. The main objective of the thesis is to propose an approach to design agentbased systems for many-core platforms in a rigorous manner. When designing such a system, we explore and integrate various dynamic reconfiguration mechanisms into agents functionality. The use of these mechanisms enhances resilience of the underlying platform whilst maintaining performance at an acceptable level. The design of the system proceeds according to a formal refinement approach which allows us to ensure correct behaviour of the system with respect to postulated properties. To enable analysis of the proposed system in terms of area overhead as well as performance, we explore an approach, where the developed rigorous models are transformed into a high-level implementation language. Specifically, we investigate methods for deriving fault-free implementations from these models into, e.g., a hardware description language, namely VHDL.

Cost Reduction of Permanent Magnet Synchronous Machines

Electrical machine drives are the most electrical energy-consuming systems worldwide. The largest proportion of drives is found in industrial applications. There are, however many other applications that are also based on the use of electrical machines, because they have a relatively high efficiency, a low noise level, and do not produce local pollution. Electrical machines can be classified into several categories. One of the most commonly used electrical machine types (especially in the industry) is induction motors, also known as asynchronous machines. They have a mature production process and a robust rotor construction. However, in the world pursuing higher energy efficiency with reasonable investments not every application receives the advantage of using this type of motor drives. The main drawback of induction motors is the fact that they need slipcaused and thus loss-generating current in the rotor, and additional stator current for magnetic field production along with the torque-producing current. This can reduce the electric motor drive efficiency, especially in low-speed, low-power applications. Often, when high torque density is required together with low losses, it is desirable to apply permanent magnet technology, because in this case there is no need to use current to produce the basic excitation of the machine. This promotes the effectiveness of copper use in the stator, and further, there is no rotor current in these machines. Again, if permanent magnets with a high remanent flux density are used, the air gap flux density can be higher than in conventional induction motors. These advantages have raised the popularity of PMSMs in some challenging applications, such as hybrid electric vehicles (HEV), wind turbines, and home appliances. Usually, a correctly designed PMSM has a higher efficiency and consequently lower losses than its induction machine counterparts. Therefore, the use of these electrical machines reduces the energy consumption of the whole system to some extent, which can provide good motivation to apply permanent magnet technology to electrical machines. However, the cost of high performance rare earth permanent magnets in these machines may not be affordable in many industrial applications, because the tight competition between the manufacturers dictates the rules of low-cost and highly robust solutions, where asynchronous machines seem to be more feasible at the moment. Two main electromagnetic components of an electrical machine are the stator and the rotor. In the case of a conventional radial flux PMSM, the stator contains magnetic circuit lamination and stator winding, and the rotor consists of rotor steel (laminated or solid) and permanent magnets. The lamination itself does not significantly influence the total cost of the machine, even though it can considerably increase the construction complexity, as it requires a special assembly arrangement. However, thin metal sheet processing methods are very effective and economically feasible. Therefore, the cost of the machine is mainly affected by the stator winding and the permanent magnets. The work proposed in this doctoral dissertation comprises a description and analysis of two approaches of PMSM cost reduction: one on the rotor side and the other on the stator side. The first approach on the rotor side includes the use of low-cost and abundant ferrite magnets together with a tooth-coil winding topology and an outer rotor construction. The second approach on the stator side exploits the use of a modular stator structure instead of a monolithic one. PMSMs with the proposed structures were thoroughly analysed by finite element method based tools (FEM). It was found out that by implementing the described principles, some favourable characteristics of the machine (mainly concerning the machine size) will inevitable be compromised. However, the main target of the proposed approaches is not to compete with conventional rare earth PMSMs, but to reduce the price at which they can be implemented in industrial applications, keeping their dimensions at the same level or lower than those of a typical electrical machine used in the industry at the moment. The measurement results of the prototypes show that the main performance characteristics of these machines are at an acceptable level. It is shown that with certain specific actions it is possible to achieve a desirable efficiency level of the machine with the proposed cost reduction methods.

Melo generaattori 1 kuntokartoitus

Työn tarkoitus on arvioida ja selvittää, milloin generaattorin uusinta on optimaalista tehdä vesivoimalaitoksella teknisen kunnon suhteen. Melon generaattori otettiin käyttöön vuonna 1971 ja se on peruskunnostettiin 1998. Vuonna 2009 tehdyn kuntokartoituksen mukaan koneelle annettiin laskelmien 20 vuotta elinikään. Alkuperäisessä generaattorissa on ollut ongelmia alusta asti. Alkuperäiset ongelmat pohjautuvat väärään uralukuun, joka aiheutti värinöitä koneeseen. Värinät saatiin korjattua staattorin käämitystä muuttamalla 1973 ja muutos rajoitti generaattorin tehon 33 MW:iin. Myöhemmin konetta on ajettu yli 33 MW:n teholla, joka aiheutti staattorin levypaketin aaltoilun. Aaltoilu olisi voinut aiheuttaa vakan vaurion generaattoriin. Vuonna 2014 tehdyn revision yhteydessä edellä mainitut ongelmat poistuivat. Ottaen huomioon generaattori 2 ongelmat (käyttöönotettu 1971), niin voidaan todeta, että revisio tehtiin täysin optimaaliseen aikaan.

Influence of Travelling Current Linkage Harmonics on Inductance Variation, Torque Ripple and Sensorless Capability of Tooth-Coil Permanent-Magnet Synchronous Machines

This paper introduces an important source of torque ripple in PMSMs with tooth-coil windings (TC-PMSMs). It is theoretically proven that saturation and cross-saturation phenomena caused by the non-synchronous harmonics of the stator current linkage cause a synchronous inductance variation with a particular periodicity. This, in turn, determines the magnitude of the torque ripple and can also deteriorate the performance of signal-injection-based rotor position estimation algorithms. An improved dq- inductance model is proposed. It can be used in torque ripple reduction control schemes and can enhance the self-sensing capabilities of TC-PMSMs

Permanent magnet synchronous generator design solution for large directdrive wind turbines: Thermal behavior of the LC DD-PMSG

Wind is one of the most compelling forms of indirect solar energy. Available now, the conversion of wind power into electricity is and will continue to be an important element of energy self-sufficiency planning. This paper is one in a series intended to report on the development of a new type of generator for wind energy; a compact, high-power, direct-drive permanent magnet synchronous generator (DD-PMSG) that uses direct liquid cooling (LC) of the stator windings to manage Joule heating losses. The main param-eters of the subject LC DD-PMSG are 8 MW, 3.3 kV, and 11 Hz. The stator winding is cooled directly by deionized water, which flows through the continuous hollow conductor of each stator tooth-coil winding. The design of the machine is to a large degree subordinate to the use of these solid-copper tooth-coils. Both steady-state and timedependent temperature distributions for LC DD-PMSG were examined with calculations based on a lumpedparameter thermal model, which makes it possible to account for uneven heat loss distribution in the stator conductors and the conductor cooling system. Transient calculations reveal the copper winding temperature distribution for an example duty cycle during variable-speed wind turbine operation. The cooling performance of the liquid cooled tooth-coil design was predicted via finite element analysis. An instrumented cooling loop featuring a pair of LC tooth-coils embedded in a lamination stack was built and laboratory tested to verify the analytical model. Predicted and measured results were in agreement, confirming the predicted satisfactory operation of the LC DD-PMSG cooling technology approach as a whole.

Model-based testing of software systems : functionality and performance

Software is a key component in many of our devices and products that we use every day. Most customers demand not only that their devices should function as expected but also that the software should be of high quality, reliable, fault tolerant, efficient, etc. In short, it is not enough that a calculator gives the correct result of a calculation, we want the result instantly, in the right form, with minimal use of battery, etc. One of the key aspects for succeeding in today's industry is delivering high quality. In most software development projects, high-quality software is achieved by rigorous testing and good quality assurance practices. However, today, customers are asking for these high quality software products at an ever-increasing pace. This leaves the companies with less time for development. Software testing is an expensive activity, because it requires much manual work. Testing, debugging, and verification are estimated to consume 50 to 75 per cent of the total development cost of complex software projects. Further, the most expensive software defects are those which have to be fixed after the product is released. One of the main challenges in software development is reducing the associated cost and time of software testing without sacrificing the quality of the developed software. It is often not enough to only demonstrate that a piece of software is functioning correctly. Usually, many other aspects of the software, such as performance, security, scalability, usability, etc., need also to be verified. Testing these aspects of the software is traditionally referred to as nonfunctional testing. One of the major challenges with non-functional testing is that it is usually carried out at the end of the software development process when most of the functionality is implemented. This is due to the fact that non-functional aspects, such as performance or security, apply to the software as a whole. In this thesis, we study the use of model-based testing. We present approaches to automatically generate tests from behavioral models for solving some of these challenges. We show that model-based testing is not only applicable to functional testing but also to non-functional testing. In its simplest form, performance testing is performed by executing multiple test sequences at once while observing the software in terms of responsiveness and stability, rather than the output. The main contribution of the thesis is a coherent model-based testing approach for testing functional and performance related issues in software systems. We show how we go from system models, expressed in the Unified Modeling Language, to test cases and back to models again. The system requirements are traced throughout the entire testing process. Requirements traceability facilitates finding faults in the design and implementation of the software. In the research field of model-based testing, many new proposed approaches suffer from poor or the lack of tool support. Therefore, the second contribution of this thesis is proper tool support for the proposed approach that is integrated with leading industry tools. We o er independent tools, tools that are integrated with other industry leading tools, and complete tool-chains when necessary. Many model-based testing approaches proposed by the research community suffer from poor empirical validation in an industrial context. In order to demonstrate the applicability of our proposed approach, we apply our research to several systems, including industrial ones.

Toimittajien suorituskykymittariston suunnittelu ja toteutus

Tämän diplomityön tarkoituksena oli kehittää teollisuusyrityksen toimittajahallintaa suorituskykymittauksen avulla. Työssä suunnitellaan ja toteutetaan toimittajien suorituskykymittaristo teoriatiedon avulla. Projektin lopputuloksena case-yrityksellä on käytössään kokonaisvaltainen toimittajien suorituskykymittaristo ja kehittyneet toimittajahallinnan prosessit. Työn teoriaosuudessa syvennytään erilaisiin suorituskykymittariston kehittämisen viitekehyksiin. Lisäksi teoriaosuudessa käsitellään hyvän suorituskykymittariston vaatimuksia ja suositeltuja mittauksen seuranta-alueita. Työn empiriaosuudessa rakennetaan suorituskykymittaristo vaihe vaiheelta perustuen tapaustutkimukseen. Kehitettyä suorituskykymittaristoa testattiin simulaatiovaiheen aikana case-yrityksen kolmella tehtaalla. Käyttäjäpalautteen perusteella mittaristo täytti teoriaosuudessa löydetyt tärkeimmät vaatimukset suorituskykymittaristolle. Mittaristo on helppokäyttöinen, visuaalinen ja sen raportoinnista saa arvokasta informaatiota toimittajien arviointiin. Diplomityön konkreettisia hyötyjä case-yritykselle ovat olleet laatupoikkeamien kehittynyt havaitseminen ja toimittajan hintakilpailukyvyn parantunut arviointi. Kaikkein merkittävin hyöty case-yritykselle on kuitenkin ollut systemaattinen toimittaja-arviointiprosessi, minkä suorituskykymittaristo mahdollistaa.

Heat-transfer improvements in an axial-flux permanent-magnet synchronous machine

Axial-flux machines tend to have cooling difficulties since it is difficult to arrange continuous heat path between the stator stack and the frame. One important reason for this is that no shrink fitting of the stator is possible in an axial-flux machine. Using of liquid-cooled end shields does not alone solve this issue. Cooling of the rotor and the end windings may also be difficult at least in case of two-stator-single-rotor construction where air circulation in the rotor and in the end-winding areas may be difficult to arrange. If the rotor has significant losses air circulation via the rotor and behind the stator yokes should be arranged which, again, weakens the stator cooling. In this paper we study a novel way of using copper bars as extra heat transfer paths between the stator teeth and liquid cooling pools in the end shields. After this the end windings still suffer of low thermal conductivity and means for improving this by high-heat-conductance material was also studied. The design principle of each cooling system is presented in details. Thermal models based on Computational Fluid Dynamics (CFD) are used to analyse the temperature distribution in the machine. Measurement results are provided from different versions of the machine. The results show that significant improvements in the cooling can be gained by these steps.

Analogisen tunnisteanalyysin käyttö korjauspalveluissa mikropiirien ylijännitteestä aiheutuneiden vaurioiden paikantamisen

Korjauspalveluissa aikaa vieviä tapauksia ovat mikropiirien vaikeasti paikannettavat viat. Tällaista vianetsintää varten yrityksemme oli ostanut Polar Fault Locator 780 –mittalaitteen, jolla voidaan mitata mikropiirien toimintaa käyttämällä analogista tunnisteanalyysiä. Diplomityön tavoitteena oli selvittää, miten mittaustapaa voidaan käyttää korjauspalveluissa. Tutkintaa lähestyttiin joidenkin tyypillisten komponenttien näkökulmasta, mutta pääpaino oli mikropiireissä. Joitain mikropiirejä vaurioitettiin tahallisesti, jolloin mittaustulokset uusittiin ja tutkittiin miten vaurioituminen näkyy mittaustuloksissa. Tutkimusmenetelmänä oli kirjallisuus ja empiirinen kokeellisuus. Diplomityön tuloksena oli, että tätä mittaustapaa käyttämällä mikropiirien kuntoa voidaan tutkia. Ongelmiksi osoittautuivat alkuperäinen oletus mittalaitteen tuloksien tulkinnasta ja taustamateriaalin heikko saatavuus. Täten mittalaite parhaiten soveltuu tilanteisiin, joissa sen antamia tuloksia verrataan suoraan toisen toimivaksi tunnetun yksikön mittaustuloksiin. Vaurioitettaessa komponenteissa oli kuitenkin havaittavissa selvä poikkeavuus.

Integroitua päästöjen hallintamallia soveltavan öljynjalostamon normaalitoiminnan ja monitoroinnin määrittäminen

Tässä diplomityössä määritettiin Nesteen Suomen jalostamoiden normaalitoiminta ja integroidun päästöjen hallintamallin mukainen monitorointi. Työn ensimmäisenä tavoitteena oli selvittää määritelmä integroidun päästöjen hallintamallin mukaiselle normaalitoiminnalle öljynjalostamolla. Toisena tavoitteena oli löytää ratkaisut integroidun päästöjen hallintamallin monitoroinnin heikosti ohjeistettuihin kohtiin. Jalostamoiden normaalitoiminnan määrittäviä kohteita selvitettiin keskustelemalla jalostamon käyttöhenkilökunnan kanssa kriittisistä kohteista päästöjenhallinnan sekä jalostamokokonaisuuden toiminnan kannalta. Keskusteluissa esiin tulleiden kohteiden hyödyllisyyttä jalostamon normaalitoiminnan määrittämiseksi tutkittiin Nesteen jalostamoiden automaatiojärjestelmän historiatietojen perusteella. Selkeästi normaalista poikkeavaksi toiminnaksi lisääntyneiden päästöjen takia tunnistettiin polttoaineiden ja savukaasujen puhdistusprosessien häiriöt sekä Porvoon jalostamolla voimalaitoksen höyryntuotantohäiriöt. Lisäksi jalostamon normaalitoiminnan kuvaajaksi tunnistettiin toiminnassa olevien yksiköiden määrä. Monitoroinnin ohjeistuksen puutteisiin etsittiin ratkaisua olemassa olevista muiden soveltamisalojen ohjeistuksista. Integroidun päästöjen hallintamallin monitorointitarpeista tunnistettiin paljon samaa päästökaupan monitoroinnin kanssa. Monitoroinnin lisäohjeistuksena suositeltiin käyttämään päästökaupan monitorointiohjetta ja sieltä löytyviä määräyksiä. Integroidussa päästöjen hallintamallissa tunnistettiin uusia haasteita viranomaisseurannan toteuttamisessa.

Spare Part Management of Bubbling Fluidized Bed Boiler

Energy generation industry is very capital-intensive industry. Productivity and availability requirements have increased while competition and quality requirement have increased. Maintenance has a significant role that these requirements can be reached. Even maintenance is much more than repairing faults nowadays, spare parts are important part of maintenance. Large power boilers are user-specific therefore features of boilers vary from project to project. Equipment have been designed to follow the customer’s requirements therefore spare parts are mainly user-specific also. The study starts with literature review introducing maintenance, failure mechanisms, and systems and equipment of bubbling fluidized bed boiler. At the final part spare part management is discussed from boiler technology point of view. For this part of the study science publications about spare part management are utilized also some specialist from a boiler technology company and other original equipment manufacturers were interviewed. Spare part management is challenging from the boiler supplier point of view and the end user of spare parts has a responsibility of stocking items. Criticality analysis can be used for finding most critical devices of the process and spare part management shall focus to those items. Spare parts are part of risk management. Stocking spare parts is increasing costs but then high spare part availability is decreasing delay time caused by fault of item.