Multiobjective Electric Machine Optimization for Highest Reliability Demands

This article is about illustrating a workflow for incorporating reliability measures to typical electric machine design optimization scenarios.Such measures facilitate comparing designs not only for rated conditions,but also allow to analyze their performance in the presence of unevitable tolerances.Consequently,by additionally considering reliability or robustness as objectives compared to conventional optimization scenarios,designs featuring low parameter sensitiveness can be obtained.The analysis of the design’s reliability as part of solving optimization problems involves a significant increase in required numerical evaluations.To minimize the associated prolongation of the runtime,an approach featuring a design of experiments based reduction of required computations and a consequent surrogate modeling technique is presented here.After successful training,the metamodel can be applied for fast evaluating lots of different parameter combinations.A test problem is defined and analyzed.Based on the observed findings,the necessity of incorporating robustness evaluations to machine design optimization becomes evident.In addition,the derived models allow for studying the impact of any tolerance-affected parameter on the machine performance in detail.This facilitates further beneficial studies,as for instance the analysis of selected changes of tolerance levels rather than a general minimization of the respective ranges which usually is associated with high production cost.

Recent Developments of Modulation and Control for High-Power Current-Source-Converters Fed Electric Machine Systems

The pulse-width-modulated(PWM)current-source converters(CSCs)fed electric machine systems can be considered as a type of high reliability energy conversion systems,since they work with the long-life DC-link inductor and offer high fault-tolerant capability for short-circuit faults.Besides,they provide motor friendly waveforms and four-quadrant operation ability.Therefore,they are suitable for high-power applications of fans,pumps,compressors and wind power generation.The purpose of this paper is to comprehensively review recent developments of key technologies on modulation and control of high-power(HP)PWM-CSC fed electric machines systems,including reduction of low-order current harmonics,suppression of inductor–capacitor(LC)resonance,mitigation of common-mode voltage(CMV)and control of modular PWM-CSC fed systems.In particular,recent work on the overlapping effects during commutation,LC resonance suppression under fault-tolerant operation and collaboration of modular PMW-CSCs are described.Both theoretical analysis and some results in simulations and experiments are presented.Finally,a brief discussion regarding the future trend of the HP CSC fed electric machines systems is presented.

Numerical-Analytical Method for Magnetic Field Computation in Rotational Electric Machines

A numerical-analytical method is applied for the two-dimensional magnetic field computation in rotational electric machines in this paper. The analytical expressions for air gap magnetic field are derived. The pole pairs in the expressions are taken into account so that the solution region can be reduced within one periodic range. The numerical and analytical magnetic field equations are linked with equal vector magnetic potential boundary conditions. The magnetic field of a brushless permanent magnet machine is computed by the proposed method. The result is compared to that obtained by finite element method so as to validate the correction of the method.

Robustness Criteria for Concurrent Evaluation of the Impact of Tolerances in Multiobjective Electric Machine Design Optimization

This article is about a comparison of different measures for determining the robustness or reliability of electric machine designs in the presence of inevitable tolerances.The selected criteria shall be suitable for concurrent evaluation in the course of solving state-of-the-art large scale multi-objective opti-mization problems.In the past,besides particularly customized criteria,mainly gradient based measures,worst case information,or standard deviation based quantities were considered.In this work,the quantile measure is introduced for electric machine design optimization and compared with the existing solutions.The evaluation of a design’s robustness is typically examined based on finite element simulations.As for most measures a signif-icant number of parameter combinations and thus computations are required,a surrogate model assisted approach is presented to minimize computational effort and runtime.A test problem is defined and analyzed to illustrate the differences of selected robustness measures.Results reveal the importance of considering robustness in the optimization process.Moreover,a careful choice of appropriate measures has to be taken.Selected designs are compared and conclusions and an outlook on future activities are presented.

Real-time temperature prediction of electric machines using machine learning with physically informed features

Accurate estimation of the internal temperatures of electric machines is critical to increasing their power density and reliability since key temperatures,such as magnet temperature,are often difficult to measure.This work presents a new machine learning based modelling approach,incorporating novel physically informed feature engineering,which achieves best-in-class accuracy and reduced training time.The different features introduced are proportional to sources of machine losses and require no prior knowledge of the machine,hence the models are completely data driven.Evaluation using a standard experimental dataset shows that modelling errors can be reduced by up to 82.5%,resulting in the lowest mean squared error recorded in the literature of 2.40 K^(2).Additionally,models can be trained with less training data and have lower sensitivity to data quality.Specif-ically,it was possible to train a loss enhanced multilayer perceptron model to a mean squared error<5 K^(2) with 90 h of training data,and an enhanced ordinary least squares model with just 60 h to the same criteria.The inference time of the model can be 1–2 orders of magnitude faster than competing models and requires no time to optimise hyperparameters,compared to weeks or months for other state-of-the-art prediction methods.These results are highly important for enabling low-cost real-time temperature monitoring of electric machines to improve operational efficiency,safety,reliability,and power density.

Numerical and Experimental Modelling of Gas Flow and Heat Transfer in the Air Gap of an Electric Machine. Part II: Grooved Surfaces

The study deals with the cooling of a high-speed electric machine through an air gap with numerical and experimental methods.The rotation speed of the test machine is between 5000-4000 r/rain and the machine is cooled by a forced gas flow through the air gap.In the previous part of the research the friction coefficient was measured for smooth and grooved stator cases with a smooth rotor.The heat transfer coefficient was recently calculated by a numerical method and measured for a smooth stator-rotor combination.In this report the cases with axial groove slots at the stator and/or rotor surfaces are studied.Numerical flow simulations and measurements have been done for the test machine dimensions at a large velocity range.At constant mass flow rate the heat transfer coefficients by the numerical method attain bigger values with groove slots on the stator or rotor surfaces.The results by the numerical method have been confirmed with measurements.The RdF-sensor was glued to the stator and rotor surfaces to measure the heat flux through the surface,as well as the temperature.

Overview of Advanced Control Strategies for Electric Machines

Control strategies play a key role for operation of electric machines,which would directly affect the whole system performance.In fact,different control strategies have been executed and explored for electric machines,which bring great impacts to industrial development and human society.This paper investigates and discusses the advantages control strategies for electric machines,including the field oriented control(FOC),direct torque control(DTC),finite control set model predictive control(FCS-MPC),sensorless control,and fault tolerant control(FTC).The corresponding control principles,control targets,fundamental approaches,advanced approaches,methodologies,merits and shortcomings are revealed and analyzed in detail.

Overview of the Rectangular Wire Windings AC Electrical Machine

The rectangular wire winding AC electrical machine has drawn extensive attention due to their high slot fill factor,good heat dissipation,strong rigidity and short end-windings,which can be potential candidates for some traction application so as to enhance torque density,improve efficiency,decrease vibration and weaken noise,etc.In this paper,based on the complex process craft and the electromagnetic performance,a comprehensive and systematical overview on the rectangular wire windings AC electrical machine is introduced.According to the process craft,the different type of the rectangular wire windings,the different inserting direction of the rectangular wire windings and the insulation structure have been compared and analyzed.Furthermore,the detailed rectangular wire windings connection is researched and the general design guideline has been concluded.Especially,the performance of rectangular wire windings AC machine has been presented,with emphasis on the measure of improving the bigger AC copper losses at the high speed condition due to the distinguished proximity and skin effects.Finally,the future trend of the rectangular wire windings AC electrical machine is prospected.

CUTTING REGULARITY AND DISCHARGE CHARACTERISTICS BY USING COMPOSITE COOLING LIQUID IN WIRE CUT ELECTRICAL DISCHARGE MACHINE WITH HIGH WIRE TRAVELING SPEED

The analysis of cutting regularity is provided through using and comparing two typical cooling liquids. It is proved that cutting regularity is greatly affected by cooling liquid＇s washing ability. Discharge characteristics and theoretic analysis between two electrodes are also discussed based on discharge waveform. By using composite cooling liquid which has strong washing ability, the efficiency in the first stable cutting phase has reached more than 200 mm^2/min, and the roughness of the surface has reached Ra〈0.8 μm after the fourth cutting with more than 50 mm^2/min average cutting efficiency. It is pointed out that cutting situation of the wire cut electrical discharge machine with high wire traveling speed （HSWEDM） is better than the wire cut electrical discharge machine with low wire traveling speed （LSWEDM） in the condition of improving the cooling liquid washing ability. The machining indices of HSWEDM will be increased remarkably by using the composite cooling liquid.

Quantitative Comparison of Electromagnetic Performance of Electrical Machines for HEVs/EVs

In this paper,various types of sinusoidal-fed electrical machines,i.e.induction machines(IMs),permanent magnet(PM)machines,synchronous reluctance machines,variable flux machines,wound field machines,are comprehensively reviewed in terms of basic features,merits and demerits,and compared for HEV/EV traction applications.Their latest developments are highlighted while their electromagnetic performance are quantitatively compared based on the same specification as the Prius 2010 interior PM(IPM)machine,including the torque/power-speed characteristics,power factor,efficiency map,and drive cycle based overall efficiency.It is found that PM-assisted synchronous reluctance machines are the most promising alternatives to IPM machines with lower cost and potentially higher overall efficiency.Although IMs are cheaper and have better overload capability,they exhibit lower efficiency and power factor.Other electrical machines,such as synchronous reluctance machines,wound field machines,as well as many other newly developed machines,are currently less attractive due to lower torque density and efficiency.

Global Control Simulation of Electric Vehicle Based on Finite State Machine Theory

Finite state machine theory (FSM) is introduced and applied to global control of electric vehicle. Theoretical adaptation for application of FSM in control of electric vehicle is analyzed. Global control logic for parts of electric vehicle is analyzed and built based on FSM. Using Matlab/Simulink, BJD6100-HEV global control algorithm is modeled and prove validity by simulation.

DK7732-1 Electric Spark CNC Wire-Cuffing Machine

The machine tool is one of the new products developed and produced by the Shanghai No.8 Machine Tool Plant. It adopts a lift adjustable wiretrame and molybdenum filament tensioning mechanism with large cutting thickness and high machining precision. It is equipped with an advanced IBM-PC 386 microcomputer-controlled system, with strong performance and CRT display. Man/

Press Conference on CAS Standard-Household Electric Double-driver Washing Machine Held in Beijing

On April 26th, 2005, the 5th World Intellectual Property Day, the China Association for Standardization (CAS) held the press conference on CAS standard--Household Electric Double-driver Washing Machine in Diao Yu Tai State Guest House in Beijing. The topic of the press conference was to Promote Technical Innovation, to Protect Intellectual Property and to Develop International Standard. Mr. Ma Lincong, General Secretary of CAS hosted the press conference.

Partial Discharge Measurement of OCP-Tapes in Rotating Electrical Machines

Nowadays, PD （partial discharge） measurements are a crucial part of the preventive maintenance of electrical equipment within high voltage engineering. Especially for electrical machines, both the supplier and the user are interested in the results of PD measurements. However, PDs hardly represent the cause of the failure, more likely they are claimed as the outcome of a failure. This paper deals with the insulation of a 6 kV electrical machine, whereas PD measurements were carried out at a single stator from wound coils. During manufacturing, these coils were equipped with different materials for the OCP （outer corona protection）. Using different PD measurement systems and different bandwidths, investigations of the PD behavior of the coils were carried out. Additionally, the surface resistivity of the corona protection was determined. As a result, conclusions for the correlations between the resistance of the OCP as well as the PD behavior are stated. Furthermore, the influence of using different measurement systems, different measuring circuits, and different bandwidths is shown.

The Principle and Architecture of a Hybrid System of a Neural Network and an Expert System in Intelligent CAD of Electrical Machines

Using expert systems in intelligent CAD of electrical machines have limitations such as knowledge acquisition bottlenecks and matching conflict, combinatorial explosion, and endless recursion in the reasoning process. This paper discusses the principle of a hybrid system of a neural network and an expert system (HNNES), i.e., knowledge representation, reasoning mechanism, and knowledge acquisition based on neural networks. An architecture of HNNES is presented in consideration of the feature of the design of electrical machines.

Optimization of micro milling electrical discharge machining of Inconel 718 by Grey-Taguchi method

The optimization of micro milling electrical discharge machining（EDM） process parameters of Inconel 718 alloy to achieve multiple performance characteristics such as low electrode wear,high material removal rate and low working gap was investigated by the Grey-Taguchi method.The influences of peak current,pulse on-time,pulse off-time and spark gap on electrode wear（EW）,material removal rate（MRR） and working gap（WG） in the micro milling electrical discharge machining of Inconel 718 were analyzed.The experimental results show that the electrode wear decreases from 5.6×10-9 to 5.2×10-9 mm3/min,the material removal rate increases from 0.47×10-8 to 1.68×10-8 mm3/min,and the working gap decreases from 1.27 to 1.19 μm under optimal micro milling electrical discharge machining process parameters.Hence,it is clearly shown that multiple performance characteristics can be improved by using the Grey-Taguchi method.

Toward More Electric Powertrains in Aircraft:Technical Challenges and Advancements

The main purpose of this article is to provide an instructive review of the technological challenges hindering the road toward more electric powertrains in aircraft.Hybrid,all-electric,and turboelectric powertrain architectures are discussed as possible fuel consumption and weight reduction solutions.Among these architectures,the short-term implementation of hybrid and all-electric architectures is limited,particularly for large-capacity aircraft due to the low energy/power density levels achievable by state-of-the-art electrical energy storage systems.Conversely,turboelectric architectures with advanced distributed propulsion and boundary layer ingestion are set to lead the efforts toward more electric powertrains.At the center of this transition,power converters and high-power density electric machines,i.e.,electric motors and generators,and their corresponding thermal management systems are analyzed as the key devices enabling the more electric powertrain.Moreover,to further increase the fuel efficiency and power density of the aircraft,the benefits and challenges of implementing higher voltage powertrains are described.Lastly,based on the findings collected in this article,the projected roadmap toward more electric aircraft powertrains is presented.Herein,the individual targets for each technology,i.e.,batteries,electric machines,and power converters,and how they translate to future aircraft prototypes are illustrated.

Cogging Torque Sensitivity considering Imperfect Magnet Positioning for Permanent Magnet Machines of Different Slot and Pole Count

This work is about analyzing surface mounted permanent magnet machines regarding their sensitiveness related to erroneous magnet positioning.A finite element analysis based approach is presented and different topologies in terms of slot and pole count are compared.The study further includes the analysis of multiple magnet widths and stator teeth widths.By contrast to most of previous studies,the work is based on evaluating the cumulative distribution function of the cogging torque in case of non-idealities.A Monte Carlo importance sampling based strategy is focused.This approach facilitates studying arbitrary tolerance distributions.Results reveal that topologies with particularly promising rated cogging torque behaviour exhibit the most significant performance degradation in presence of tolerances.A linear relationship is identified for cogging torque performance as function of the accuracy in magnet positioning.Results emphasize the necessity of tolerance analyses for electric machine design to not overrate their performance in the presence of manufacturing uncertainties.

Electric Generators and Motors: an overview

Starting with Faraday’s law of electromagnetic induction in 1831,electric(electromagnetic)machines have been developed ever since as“assembles”of electric and magnetic coupled circuits that convert mechanical to electrical energy(in generators)and vice versa(in motors),via magnetic energy storage.Generators and motors are reversible.The Maxwell four equations(laws)later in 19th Century have prompted the rapid development of all basic(DC.brush and travelling field AC machines by 1900.Then by 1930 AC(alternating current)power(energy)systems evolved by connecting in parallel electric synchronous generators(with voltage boost and buck electric transformers for efficient AC power transmission lines)of rather constant frequency and voltage,driven by turbines(prime movers)that harness fossil(coal,gas or nuclear fuels),thermal or hydro energy.The last 50 years have witnessed a dramatic extension of generators power/unit,renewable energy generators and of variable speed AC motor drives in applications with variable output such as ventilators,pumps compressors,conveyors,orr-mills,electric transport(mobility),industrial automation,robotics,home appliances and info-gadgets.This formidable development,required by the need of more but cleaner energy,was mainly driven by power electronics,better materials,better modeling,design methodologies and digital control.This humble inaugural overview attempts to combine a brief history of electrical generators and motors with recent progress and trends in their design and control,for representative applications.

Difference in Unbalanced Magnetic Force of Fractional-Slot PM Machines between Internal and External Rotor Topologie

This paper presents a comparative investigation into unbalanced magnetic force(UMF)of asymmetric permanent magnet machines without rotor eccentricities,particularly focusing on the difference between internal-and external-rotor topologies.The asymmetric field distribution results in radial and tangential asymmetric force waves.Although the radial and tangential stresses are in different direction,the UMF components they produce are nearly aligned.The UMF from asymmetric radial force wave can be additive or subtractive to that from asymmetric tangential force wave.Investigation shows that for the same pole slot number combination,if the UMFs due to radial and tangential force waves are additive in internal rotor machine,they are subtractive in the external rotor counterpart,and vice versa.Investigation reveals a general rule determining whether additive or cancelling:for a UMF produced by any two field harmonics,they are additive if the higher order is produced by the outer part outside the airgap,but cancelling if the higher order is produced by the inner part.Therefore,for a machine with pole number 2p=3k+1,they are additive if it is an external-rotor machine,but otherwise subtractive.On the other hand,for a machine with pole number 2p=3k-1,they are subtractive if it is an external-rotor machine,but otherwise additive.For the UMF due to armature reaction only,they are subtractive for external-rotor machines,but otherwise additive.The investigation is carried out by an analytical model and validated by finite element analysis.