Non-Linear Analysis and Design of Synchronous Bearingless Multiphase Permanent Magnet Machines and Drives

A two-dimensional model to analyze the distribution of magnetic fields in the airgap of a PM electrical machines is studied. A numerical algorithm for non-linear magnetic analysis of multiphase surface-mounted PM machines with semi-closed slots is developed, based on the equivalent magnetic circuit method. By using a modular structure geometry, whose the basic element can be duplicated, it allows to design whatever typology of windings distribution. In comparison to a FEA, permits a reduction in computing time and to directly changing the values of the parameters in a user interface, without re-designing the model. Output torque and radial forces acting on the moving part of the machine can be calculated. In addition, an analytical model for radial forces calculation in multiphase bearingless Surface-Mounted Permanent Magnet Synchronous Motors (SPMSM) is presented. It allows to predict amplitude and direction of the force, depending on the values of torque current, of levitation current and of rotor position. It is based on the space vectors method, letting the analysis of the machine also during transients. The calculations are conducted by developing the analytical functions in Fourier series, taking all the possible interactions between stator and rotor mmf harmonic components into account and allowing to analyze the effects of electrical and geometrical quantities of the machine, being parametrized. The model is implemented in the design of a control system for bearingless machines, as an accurate electromagnetic model integrated in a three-dimensional mechanical model, where one end of the motor shaft is constrained to simulate the presence of a mechanical bearing, while the other is free, only supported by the radial forces developed in the interactions between magnetic fields, to realize a bearingless system with three degrees of freedom. The complete model represents the design of the experimental system to be realized in the laboratory.

An adjustable focusing system for a 2 MeV H- ion beam line based on permanent magnet quadrupoles

A compact adjustable focusing system for a 2 MeV H- RFQ Linac is designed, constructed and tested based on four permanent magnet quadrupoles (PMQ). A PMQ model is realised using finite element simulations, providing an integrated field gradient of 2.35 T with a maximal field gradient of 57 T/m. A prototype is constructed and the magnetic field is measured, demonstrating good agreement with the simulation. Particle track simulations provide initial values for the quadrupole positions. Accordingly, four PMQs are constructed and assembled on the beam line, their positions are then tuned to obtain a minimal beam spot size of (1.2 x 2.2) mm^2 on target. This paper describes an adjustable PMQ beam line for an external ion beam. The novel compact design based on commercially available NdFeB magnets allows high flexibility for ion beam applications.

Design optimization of short-stroke single-phase tubular permanent-magnet motor for refrigeration applications

This paper describes a design methodology to achieve optimal performance for a short-stroke single-phase tubular permanent-magnet motor which drives a reciprocating vapor compressor. The steady-state characteristic of the direct-drive linear-motor compressor system is analyzed, an analytical formula for predicting iron loss is presented, and a motor-design procedure which takes into account the effect of compressor loads under nominal operating condition is formulated. It is shown that the motor efficiency can be optimized with respect to two leading dimensional ratios. Experimental results validate the proposed design methodology. Copyright © 2010 IEEE.

Electromagnetic design and loss calculations of a 1.12-MW high-speed permanent-magnet motor for compressor applications

Electromagnetic design of a 1.12-MW, 18 000-r/min high-speed permanent-magnet motor (HSPMM) is carried out based on the analysis of pole number, stator slot number, rotor outer diameter, air-gap length, permanent magnet material, thickness, and pole arc. The no-load and full-load performance of the HSPMM is investigated in this paper by using 2-D finite element method (FEM). In addition, the power losses in the HSPMM including core loss, winding loss, rotor eddy current loss, and air friction loss are predicted. Based on the analysis, a prototype motor is manufactured and experimentally tested to verify the machine design.

Evaluation of applying retaining shield rotor for high-speed interior permanent magnet motors

This paper proposes a novel rotor structure for high-speed interior permanent magnet motors to overcome huge centrifugal forces under high-speed operation. Instead of the conventional axial stacking of silicon-steel laminations, the retaining shield rotor is inter-stacked by high-strength stainless-steel plates to enhance the rotor strength against the huge centrifugal force. Both mechanical characteristics and electromagnetic behaviors of the retaining shield rotor are analyzed using finite-element method in this paper. Prototypes and experimental results are demonstrated to evaluate the performance. The analysis and test results show that the proposed retaining shield rotor could effectively enhance the rotor strength without a significant impact on the electromagnetic performance, while some design constraints should be compromised.

Design and flux-weakening control of an interior permanent magnet synchronous motor for electric vehicles

Permanent magnet synchronous motors (PMSMs) provide a competitive technology for EV traction drives owing to their high power density and high efficiency. In this paper, three types of interior PMSMs with different PM arrangements are modeled by the finite element method (FEM). For a given amount of permanent magnet materials, the V shape interior PMSM is found better than the U-shape and the conventional rotor topologies for EV traction drives. Then the V shape interior PMSM is further analyzed with the effects of stator slot opening and the permanent magnet pole chamfering on cogging torque and output torque performance. A vector-controlled flux-weakening method is developed and simulated in matlab to expand the motor speed range for EV drive system. The results show good dynamic and steady-state performance with a capability of expanding speed up to 4 times of the rated. A prototype of the V shape interior PMSM is also manufactured and tested to validate the numerical models built by the finite element method.

Parameter optimization for noise and vibration reduction associated with position and speed sensorless control of permanent magnet machines at low speed

With the advantages and popularity of Permanent Magnet (PM) motors due to their high power density, there is an increasing incentive to use them in variety of applications including electric actuation. These applications have strict noise emission standards. The generation of audible noise and associated vibration modes are characteristics of all electric motors, it is especially problematic in low speed sensorless control rotary actuation applications using high frequency voltage injection technique. This dissertation is aimed at solving the problem of optimizing the sensorless control algorithm for low noise and vibration while achieving at least 12 bit absolute accuracy for speed and position control. The low speed sensorless algorithm is simulated using an improved Phase Variable Model, developed and implemented in a hardware-in-the-loop prototyping environment. Two experimental testbeds were developed and built to test and verify the algorithm in real time.^ A neural network based modeling approach was used to predict the audible noise due to the high frequency injected carrier signal. This model was created based on noise measurements in an especially built chamber. The developed noise model is then integrated into the high frequency based sensorless control scheme so that appropriate tradeoffs and mitigation techniques can be devised. This will improve the position estimation and control performance while keeping the noise below a certain level. Genetic algorithms were used for including the noise optimization parameters into the developed control algorithm.^ A novel wavelet based filtering approach was proposed in this dissertation for the sensorless control algorithm at low speed. This novel filter was capable of extracting the position information at low values of injection voltage where conventional filters fail. This filtering approach can be used in practice to reduce the injected voltage in sensorless control algorithm resulting in significant reduction of noise and vibration.^ Online optimization of sensorless position estimation algorithm was performed to reduce vibration and to improve the position estimation performance. The results obtained are important and represent original contributions that can be helpful in choosing optimal parameters for sensorless control algorithm in many practical applications.^

Design and Flux-Weakening Control of an Interior Permanent Magnet Synchronous Motor for Electric Vehicles

Permanent magnet synchronous motors (PMSMs) provide a competitive technology for EV traction drives owing to their high power density and high efficiency. In this paper, three types of interior PMSMs with different PM arrangements are modeled by the finite element method (FEM). For a given amount of permanent magnet materials, the V-shape interior PMSM is found better than the U-shape and the conventional rotor topologies for EV traction drives. Then the V-shape interior PMSM is further analyzed with the effects of stator slot opening and the permanent magnet pole chamfering on cogging torque and output torque performance. A vector-controlled flux-weakening method is developed and simulated in Matlab to expand the motor speed range for EV drive system. The results show good dynamic and steady-state performance with a capability of expanding speed up to four times of the rated. A prototype of the V-shape interior PMSM is also manufactured and tested to validate the numerical models built by the FEM.

Fifth harmonic and sag impact on PMSG wind turbines with a balancing new strategy for capacitor voltages

This paper deals with the computing simulation of the impact on permanent magnet synchronous generator wind turbines due to fifth harmonic content and grid voltage decrease. Power converter topologies considered in the simulations are the two-level and the three-level ones. The three-level converters are limited by unbalance voltages in the DC-link capacitors. In order to lessen this limitation, a new control strategy for the selection of the output voltage vectors is proposed. Controller strategies considered in the simulation are respectively based on proportional integral and fractional-order controllers. Finally, a comparison between the results of the simulations with the two controller strategies is presented in order to show the main advantage of the proposed strategy. (C) 2014 Elsevier Ltd. All rights reserved.

Energy Harvesting for Autonomous Underwater Vehicles

In this study, energy production for autonomous underwater vehicles is investigated. This project is part of a bigger project called TURTLE. The autonomous vehicles perform oceanic researches at seabed for which they are intended to be kept operational underwater for several months. In order to ful l a long-term underwater condition, powerful batteries are combined with \micro- scale" energy production on the spot. This work tends to develop a system that generates power up to a maximum of 30 W. Latter energy harvesting structure consists basically of a turbine combined with a generator and low-power electronics to adjust the achieved voltage to a required battery charger voltage. Every component is examined separately hence an optimum can be de ned for all, and subsequently also an overall optimum. Di erent design parameters as e.g. number of blades, solidity ratio and cross-section area are compared for di erent turbines, in order to see what is the most feasible type. Further, a generator is chosen by studying how ux distributions might be adjusted to low velocities, and how cogging torque can be excluded by adapted designs. Low-power electronics are con gured in order to convert and stabilize heavily varying three-phase voltages to a constant, recti ed voltage which is usable for battery storage. Clearly, di erent component parameters as maximum power and torque are matched here to increase the overall power generation. Furthermore an overall maximum power is set up for achieving a maximum power ow at load side. Due to among others typical low velocities of about 0.1 to 0.5 m/s, and constructing limits of the prototype, the vast range of components is restricted to only a few that could be used. Hence, a helical turbine is combined in a direct drive mode to a coreless-stator axial- ux permanent-magnet generator, from which the output voltage is adjusted subsequently by a recti er, impedance matching unit, upconverter circuit and an overall control unit to regulate di erent component parameters. All these electronics are combined in a closed-loop design to involve positive feedback signals. Furthermore a theoretical con guration for the TURTLE vehicle is described in this work and a solution is proposed that might be implemented, for which several design tests are performable in a future study.

Kestomagneettigeneraattorin staattorin mekaanisen rakenteen analysointi ja kehitys

Työssä tutkittiin kestomagneettigeneraattorin staattoriytimen aksiaalisen puristamisen ja lämpötilan vaikutuksia staattorin jännityksiin ja muodonmuutoksiin. Lisäksi tutkittiin aksiaalisen puristusjännityksen vaikutusta staattorin aksiaalisuuntaisen ominaismuodon taajuuteen. Rakenteesta tehtiin elementtimalli, jonka avulla laskettiin rakenteen siirtymät, jännitykset ja ominaistaajuudet. Rakenteen jännityksiä ja siirtymiä tutkittiin myös yksinkertaisella jousikuvauksella, jonka tuloksia verrattiin elementtimallilla saatuihin tuloksiin. Työn tavoitteena oli kehittää uusi staattorirakenne. Elementtimenetelmän tulosten perusteella staattorirakennetta voidaan yksinkertaistaa poistamalla nyt käytetty puristusrengas, jolloin rakenteesta tulee yksinkertaisempi ja kustannustehokkaampi.

Kestomagneettigeneraattorin lämmönsiirron mallinnus tuulivoimakäytössä

Pyörivien sähkökoneiden suunnittelussa terminen suunnittelu on yhtä tärkeää kuin sähköinen ja mekaaninen suunnittelukin. Tässä diplomityössä tarkoituksena on kehittää ilmajäähdytteisten kestomagneettigeneraattorien laskentaan soveltuva lämmönsiirtymismalli, jolla staattorin lämpötilajakauma voitaisiin selvittää. Kehitetty lämmönsiirtymismalli perustuu kolmiulotteiseen äärellisen erotuksen (finite difference) menetelmään. Malli ottaa huomioon lämmönjohtumisen staattorin aktiiviosissa ja konvektion jäähdytysilmavirtaan. Mallissa on myös yksinkertainen painehäviölaskenta jäähdytysjärjestelmän komponenttien mitoittamista varten. Laskentamallilla lasketaan esimerkkitapauksena 4,3 MW:n kestomagneettigeneraattorin jäähdytystä eri toimintapisteissä. Tuloksia verrataan CFD-mallinnuksen antamiin tuloksiin sekä kokeellisten mittausten antamiin tuloksiin.

Tuulivoimageneraattorin konseptisuunnittelu

Tämä diplomityö käsittelee tuulivoimageneraattorin konseptisuunnittelua. Työssä käydään läpi tuulivoimateollisuuden, -markkinoiden ja -turbiinien historiaa, nykyhetkeä ja tulevaisuuden ennusteita. Tuulivoimaturbiineista esitellään yleisimmät tyypit ja teknologiat, joita vertaillaan keskenään. Lisäksi selvitetään tarkemmin suoravetoisten tuuliturbiinigeneraattoreiden teknologiaa ja teknisiä rakenteita joita myös vertaillaan keskenään. Työn pääasiallisena tarkoituksena on luoda selkeä konseptisuunnitteluprojektin toimintamalli, jota noudattamalla projekti voidaan hoitaa johdonmukaisesti läpi. Lopuksi työssä vielä käydään läpi suoravetoisen kestomagneettigeneraattorin todellinen konseptisuunnitteluprojekti, jossa ei ole ollut käytössä selkeää toimintamallia.

Vibrations in Rotating Machinery Arising from Minor Imperfections in Component Geometries

Vibrations in machines can cause noise, decrease the performance, or even damage the machine. Vibrations appear if there is a source of vibration that excites the system. In the worst case scenario, the excitation frequency coincides with the natural frequency of the machine causing resonance. Rotating machines are a machine type, where the excitation arises from the machine itself. The excitation originates from the mass imbalance in the rotating shaft, which always exists in machines that are manufactured using conventional methods. The excitation has a frequency that is dependent on the rotational speed of the machine. The rotating machines in industrial use are usually designed to rotate at a constant rotational speed, the case where the resonances can be easily avoided. However, the machines that have a varying operational speed are more problematic due to a wider range of frequencies that have to be avoided. Vibrations, which frequencies equal to rotational speed frequency of the machine are widely studied and considered in the typical machine design process. This study concentrates on vibrations, which arise from the excitations having frequencies that are multiples of the rotational speed frequency. These vibrations take place when there are two or more excitation components in a revolution of a rotating shaft. The dissertation introduces four studies where three kinds of machines are experiencing vibrations caused by different excitations. The first studied case is a directly driven permanent magnet generator used in a wind power plant. The electromagnetic properties of the generator cause harmonic excitations in the system. The dynamic responses of the generator are studied using the multibody dynamics formulation. In another study, the finite element method is used to study the vibrations of a magnetic gear due to excitations, which frequencies equal to the rotational speed frequency. The objective is to study the effects of manufacturing and assembling inaccuracies. Particularly, the eccentricity of the rotating part with respect to non-rotating part is studied since the eccentric operation causes a force component in the direction of the shortest air gap. The third machine type is a tube roll of a paper machine, which is studied while the tube roll is supported using two different structures. These cases are studied using different formulations. In the first case, the tube roll is supported by spherical roller bearings, which have some wavinesses on the rolling surfaces. Wavinesses cause excitations to the tube roll, which starts to resonate at the frequency that is a half of the first natural frequency. The frequency is in the range where the machine normally operates. The tube roll is modeled using the finite element method and the bearings are modeled as nonlinear forces between the tube roll and the pedestals. In the second case studied, the tube roll is supported by freely rotating discs, which wavinesses are also measured. The above described phenomenon is captured as well in this case, but the simulation methodology is based on the flexible multibody dynamics formulation. The simulation models that are used in both of the last two cases studied are verified by measuring the actual devices and comparing the simulated and measured results. The results show good agreement.

Conversor CA-CA de elevado fator de potência para aplicações com geradores de Ímã permanente

This paper proposes and describes a high power factor AC-AC converter for naval applications using Permanent Magnet Generator (PMG). The three-phase output voltages of the PMG vary from 260 Vrms (220 Hz) to 380 Vrms (360 Hz), depending on load conditions. The proposed converter consists of a Y-/ΔY power transformer, which provides electrical isolation between the PMG and remaining stages, and a twelve-pulse uncontrolled rectifier stage directly connected to a single-phase inverter stage, without the use of an intermediary DC-DC topology. This proposal results in more simplicity for the overall circuitry, assuring robustness, reliability and reduced costs. Furthermore, the multipulse rectifier stage is capable to provide high power factor and low total harmonic distortion for the input currents of the converter. The single-phase inverter stage was designed to operate with wide range of DC bus voltage, maintaining 120 Vrms, 60 Hz output. The control philosophy, implemented in a digital signal processor (DSP) which also contains protection routines, alows series connections between two identical converters, achieving 240 Vrms, 60 Hz total output voltage. Measured total harmonic distortion for the AC output voltage is lower than 2% and the input power factor is 0.93 at 3.6kW nominal load. © 2010 IEEE.