Dimensioning of a permanent magnet synchronous machine for electric vehicles according to performance and integration requirements

Finding the optimum design of electrical machines for a certain purpose is a time-consuming task. First results can be achieved, however, with scaling known machine designs in length and turns per coil by means of analytical equations, while scaling in diameter requires finite element analysis (FEA), since electromagnetic properties change significantly. In this paper, the influence of diameter, length and turns per coil on the torque, power and efficiency of a permanent magnet synchronous machine (PMSM) are investigated in a sensitivity analysis. Furthermore, their impact on energy consumption in different drive cycles and different vehicle types is outlined. A highway car and a city car are compared in a highway cycle, a city cycle and the Worldwide Harmonized Light Vehicle test Cycle. The results describe significant differences in energy consumption for different machine designs in one application but also between different applications. This highlights the necessity to decide whether or not the powertrain should be optimized for a single purpose or for universal use.

A Novel Sub-Harmonic Synchronous Machine Using Three-Layer Winding Topology

This paper proposes a novel brushless synchronous machine topology that utilizes stator sub-harmonic magnetomotive force (MMF) for desirable brushless operation. The sub-harmonic MMF component that is used in this novel topology is one fourth of the fundamental MMF component, whereas, in previous practices, it was half. To achieve the brushless operation, the novel machine uses a unique stator winding configuration of two sets of balanced 3-phase winding wound in 3 layers. For the rotor, additional winding is placed to induce the sub-harmonic component to achieve the brushless excitation. Unlike its predecessors, it utilizes maximum allowable space in the stator to house conductors in all of its slots. To implement the topology, 8-pole, 48-slot sub-harmonic brushless synchronous machine model has been designed. A 2-D finite element analysis (FEA) is used to simulate and validate the performance of the novel machine as a motor. The proposed topology shows better average torque than the existing sub-harmonic wound rotor brushless synchronous machine topologies.

Sliding mode control with observer for permanent magnet synchronous machine drives

<span lang="EN-US">This <span>paper aims to develop the sliding mode control (SMC) scheme in sensorless permanent magnet synchronous machine (PMSM) drives to replace conventional proportional integral (PI) speed control. The SMC is formulated based on the integral sliding surface of the speed error. And the error is corrected based on the concept of Lyapunov stability. The SMC is designed with the load torque observer so that the disturbance can be estimated as feedback to the controller. The vector control technique which is also known as field-oriented control (FOC) is also used to split the stator current into the magnetic field generating part which is the direct axis and the torque generating part which is the quadrature axis. This can be done by using Park and Clarke transformations. The performance of the proposed SMC is tested under changes in load-torque and without load for different speed commands. The results prove that the SMC produces robust performances under variations of speeds and load disturbances. The effectiveness of the proposed method is verified and simulated by using MATLAB/SIMULINK </span>software.</span>

Analytical Subdomain Model for Double-Stator Permanent Magnet Synchronous Machine with Surface-Mounted Radial Magnetization

This paper proposes an analytical subdomain model for predicting magnetic field distributions in a three-phase double-stator permanent magnet synchronous machine (DS-PMSM) during open-circuit and on-load conditions. The geometric structure of DS-PMSM is quite challenging since the stator cores are located in the outer and inner parts of the motor, while the rotor magnets are placed between these two stators. Parameters that influence the motor performance in DS-PMSM include stator outer radius, stator inner radius, magnet thickness, magnet arc, slot opening, outer and inner airgap thickness and the number of winding turns. The analytical subdomain model proposed in this paper, which can accurately predict the performances of DS-PMSM with less computational time, has an excellent advantage as a rapid design tool. The model is initially generated using the separation of variables technique in four subdomains, namely, outer airgap, outer magnet, inner magnet, and inner airgap, based on Laplace’s and Poisson’s equations in polar coordinates. The field solutions in each subdomain are derived by applying the appropriate boundary and interface conditions. Furthermore, finite element analysis (FEA) is used to validate the analytical results in fractional DS-PMSM with a different number of slots between outer and inner stators and a non-overlapping winding configuration. The electromagnetic performances that have been evaluated are the slotted airgap flux density, back-emf and output torque. The results demonstrate that the proposed analytical model is able to predict the magnetic field distributions accurately in DS-PMSM.

Research of dampher system damage physical processes of synchronous machines rotor

The physical processes in the damper system of the rotor with the appearance of a static eccentricity of the rotor for two types of salient-pole synchronous machines - a capsule hydrogenator SGK 538/160-70M with a capacity of 22 MW and a synchronous generator with a capacity of 500 kW were investigated by means of mathematical modeling. A field mathematical model has been developed that takes into account the combined action of three physical fields of different nature: electromagnetic, temperature and field of thermomechanical stresses, and makes it possible to evaluate the heating and three-dimensional distribution of thermomechanical stresses in the structural elements of the rotor damper system of a salient-pole synchronous machine. These physical processes cause gradual destruction of the structure of the rotor damper system. It is proved that the primary cause of degradation and damage of the damping system of the rotor of an open-pole synchronous machine is the uneven distribution of induced currents in the rods at the poles of the rotor, which occurs when the machine works asynchronously or with the appearance of rotor static eccentricity. The largest induced currents and heat occur in the rods located at the edges of the pole pieces, while the central rods at the pole are heated significantly less. This asymmetric heating of the damping system of the rotor leads to significant thermomechanical stresses in the elements of the damping system of the rotor, which significantly depend on the magnitude of the eccentricity and slippery of the rotor in asynchronous mode. The magnitude of the total thermomechanical stresses in the rods is influenced not only by axially directed forces but also by transverse forces in the end short-circuiting elements. At considerable slippery and eccentricities there are inadmissibly big breaking forces which break cores and face short-circuiting elements of a damping system of a rotor. According to the results of the analysis, the heating and thermomechanical stresses of the structural elements were determined and recommendations for its structural improvement were given.

Optimization, 3D-Numerical Validations and Preliminary Experimental Tests of a Wound Rotor Synchronous Machine

In this paper, a complete methodology to design a modular brushless wound rotor synchronous machine is proposed. From a schedule of conditions and a chosen structure (with 7 phases, 7 slots and 6 poles), a non-linear and non-convex optimization problem is defined and solved using NOMAD (a derivative free local optimization code): the external volume is minimized under some constraints, which are the average torque equal to 5 Nm, the torque ripple less than 5%, the efficiency greater than 94%, and the surface temperature less than 85 °C. The constraints have to be computed using 2D-finite element simulations in order to reduce the CPU-time consumption for each NOMAD iteration. Moreover, a relaxation of this optimization problem makes it possible to provide an efficient starting point for NOMAD. Thus, a good optimal design is obtained, and it is then validated by using 3D electromagnetic and thermic numerical methods. These numerical verifications show that, inside the end-winding, the leakage flux is high. This yields a lot of iron losses in this machine. Moreover, the surface and coil temperature differences between the 2D and 3D numerical approaches are discussed. Finally, the machine prototype is built following the optimal dimensions and a POKI-POKITM assembly technology. Preliminary experimental tests are carried out, and the results are devoted to the comparison of measured and predicted 3D numerical results.