scholarly journals Geometrical and dimensional tolerance analysis for the radial flux type of permanent magnet generator design

2021 ◽  
Vol 12 (2) ◽  
pp. 68-80
Author(s):  
Muhammad Fathul Hikmawan ◽  
Agung Wibowo ◽  
Muhammad Kasim
Keyword(s):  
Permanent Magnet ◽  
Manufacturing Process ◽  
Cumulative Effect ◽  
Tolerance Analysis ◽  
Air Gap ◽  
Tolerance Allocation ◽  
Design Stage ◽  
Worst Case ◽  
Radial Flux ◽  
Permanent Magnet Generator

Mechanical tolerance is something that should be carefully taken into consideration and cannot be avoided in a product for manufacturing and assembly needs, especially in the design stage, to avoid excessive dimensional and geometric deviations of the components made. This paper discusses how to determine and allocate dimensional and geometric tolerances in the design of a 10 kW, 500 rpm radial flux permanent magnet generator prototype components. The electrical and mechanical design results in the form of the detailed nominal dimensions of the generator components, and the allowable air gap range are used as input parameters for tolerance analysis. The values of tolerance allocation and re-allocation process are carried out by considering the capability of the production machine and the ease level of the manufacturing process. The tolerance stack-up analysis method based on the worst case (WC) scenario is used to determine the cumulative effect on the air gap distance due to the allocated tolerance and to ensure that the cumulative effect is acceptable so as to guarantee the generator's functionality. The calculations and simulations results show that with an air gap of 1 ± 0.2 mm, the maximum air gap value obtained is 1.1785 mm, and the minimum is 0.8 mm. The smallest tolerance value allocation is 1 µm on the shaft precisely on the FSBS/SRBS feature and the rotor on the RPMS feature. In addition, the manufacturing process required to achieve the smallest tolerance allocation value is grinding, lapping, and polishing processes.

scholarly journals DESIGN OF A SINGLE-PHASE RADIAL FLUX PERMANENT MAGNET GENERATOR WITH VARIATION OF THE STATOR DIAMETER

2019 ◽  
Vol 81 (4) ◽  
Author(s):  
Hari Prasetijo ◽  
Winasis Winasis ◽  
Priswanto Priswanto ◽  
Dadan Hermawan
Keyword(s):  
Magnetic Flux ◽  
Permanent Magnet ◽  
Flux Density ◽  
Single Phase ◽  
Air Gap ◽  
Wire Diameter ◽  
Terminal Phase ◽  
Magnetic Flux Density ◽  
Phase Voltage ◽  
Radial Flux

This study aims to observe the influence of the changing stator dimension on the air gap magnetic flux density (Bg) in the design of a single-phase radial flux permanent magnet generator (RFPMG). The changes in stator dimension were carried out by using three different wire diameters as stator wire, namely, AWG 14 (d = 1.63 mm), AWG 15 (d = 1.45 mm) and AWG 16 (d = 1.29 mm). The dimension of the width of the stator teeth (Wts) was fixed such that a larger stator wire diameter will require a larger stator outside diameter (Dso). By fixing the dimensions of the rotor, permanent magnet, air gap (lg) and stator inner diameter, the magnitude of the magnetic flux density in the air gap (Bg) can be determined. This flux density was used to calculate the phase back electromotive force (Eph). The terminal phase voltage (V∅) was determined after calculating the stator wire impedance (Z) with a constant current of 3.63 A. The study method was conducted by determining the design parameters, calculating the design variables, designing the generator dimensions using AutoCad and determining the magnetic flux density using FEMM simulation.  The results show that the magnetic flux density in the air gap and the phase back emf Eph slightly decrease with increasing stator dimension because of increasing reluctance. However, the voltage drop is more dominant when the stator coil wire diameter is smaller. Thus, a larger diameter of the stator wire would allow terminal phase voltage (V∅) to become slightly larger. With a stator wire diameter of 1.29, 1.45 and 1.63 mm, the impedance values of the stator wire (Z) were 9.52746, 9.23581 and 9.06421 Ω and the terminal phase voltages (V∅) were 220.73, 221.57 and 222.80 V, respectively. Increasing the power capacity (S) in the RFPMG design by increasing the diameter (d) of the stator wire will cause a significant increase in the percentage of the stator maximum current carrying capacity wire but the decrease in stator wire impedance is not significant. Thus, it will reduce the phase terminal voltage (V∅) from its nominal value.

Process Capability Based Tolerance Allocation in Pneumatic Percussive Riveting

2020 ◽  
Author(s):  
Hua Wang ◽  
Jialei Zhang ◽  
Junyang Yu
Keyword(s):  
High Efficiency ◽  
Load Transfer ◽  
Process Capability ◽  
Tolerance Analysis ◽  
Tolerance Allocation ◽  
Hole Drilling ◽  
Case Method ◽  
Pneumatic Hammer ◽  
Worst Case ◽  
Mating Conditions

Abstract Pneumatic percussive riveting is an important way to join the sheet metals. In order to ensure the load transfer and the fatigue performance of riveted joint, the interference of the rivet/hole is strictly specified. The interference of the rivet/hole is highly correlated with the process capability of the pneumatic hammer and the diameter of the pre-hole. It is a critical step to choose the appropriate pneumatic hammer to ensure the interference requirements. Energy per blow of the pneumatic hammer is a proclaimed parameter from the riveting hammer manufacturer. It is difficult for the designer to choose the riveting hammer in practical riveting scheme based on energy per blow. Tolerance analysis is an efficient way to model the manufacturing variation and implement process control. This paper presents the tolerance allocation of the pneumatic percussive riveting based on the process capability of the pneumatic hammer. In order to obtain the designed interferences of the rivet/hole, a tolerance chain is built with the process capability of the pneumatic hammer, the diameter of the pre-hole and the diameter of the rivet shank. The process capability of the pneumatic hammer is represented with the interferences of the rivet/hole after riveting. It is an intuitive parameter for the designer to choose the riveting hammer in practical riveting scheme. The process capability of the pneumatic hammer is obtained from the designed riveting experiments with the pneumatic percussive riveting platform. The diameter of the pre-hole affects the interference of the rivet/hole also. The tolerance for manual hole-drilling should be determined to assure the interference requirements and high drilling operation efficiency simultaneously. The variation of the pre-hole is obtained from the manual drilling experiments and diameter measurements. Different hole-drilling results in different mating conditions between the pre-hole and the rivet. The fit conditions of different pre-holes are modeled and the final interferences after riveting are analyzed. Worst case method and statistical analysis method are two common methods for tolerance analysis. For the manual hole-drilling and the pneumatic percussive riveting, worst case method is employed to analyze the constructed tolerance chain in order to accomplish the interferences of the rivet/hole. The different analyzed dimensions, rivet-hole clearances and pre-hole drilling variation, are investigated respectively. The reported work enhances the understanding of the tolerance allocation for the pneumatic percussive riveting. The interference based process capability of the pneumatic hammer provides good reference for pneumatic hammer choosing in riveting scheme. The reported tolerance chain of the interference could be used for the tolerance determination of manual hole-drilling with good quality and high efficiency.

Effect of air gap variation on the performance of single stator single rotor axial flux permanent magnet generator

2017 ◽  
Author(s):  
Muhammad Kasim ◽  
Pudji Irasari ◽  
M. Fathul Hikmawan ◽  
Puji Widiyanto ◽  
Ketut Wirtayasa
Keyword(s):  
Permanent Magnet ◽  
Air Gap ◽  
Axial Flux ◽  
Permanent Magnet Generator

Automating Linear Tolerance Analysis Across Assemblies

1992 ◽  
Vol 114 (1) ◽  
pp. 174-179 ◽  
Author(s):  
N. P. Juster ◽  
P. M. Dew ◽  
A. de Pennington
Keyword(s):  
Mathematical Model ◽  
Manufacturing Process ◽  
Tolerance Analysis ◽  
Mathematical Framework ◽  
Worst Case ◽  
Experimental Software

One of the tests carried out by designers in an attempt to check whether an assembly of components will function correctly is tolerance analysis. Tolerance analysis, although relatively straightforward, is liable to be time consuming and error prone. It cannot be automated unless a suitable mathematical framework is developed to model the variations introduced by the manufacturing process. The designer allows for the variations by means of tolerances attached to the dimensions. This paper describes a suitable mathematical model and shows how it may be used to automate linear worst case tolerance analysis across assemblies. Experimental software has been written, based on the theory.

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