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.

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.

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.

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.

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.

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.

Statistical Description of Debris Particle Size Distribution in Electrical Discharge Machining

Gap debris as discharge product is closely related to machining process in electrical discharge machining（EDM）. A lot of recent researches have focused on the relationship among debris size, surfaces texture, remove rate, and machining stability. The study on statistical distribution of debris size contributes to the research, but it is still superficial currently. In order to obtain the distribution law of the debris particle size, laser particle size analyzer（LPSA） combined with scanning electron microscope（SEM） is used to analyze the EDM debris size. Firstly, the heating dried method is applied to obtain the debris particles. Secondly, the measuring range of LPSA is determined as 0.5–100 μm by SEM observation, and the frequency distribution histogram and the cumulative frequency distribution scattergram of debris size are obtained by using LPSA. Thirdly, according to the distribution characteristic of the frequency distribution histogram, the statistical distribution functions of lognormal, exponentially modified Gaussian（EMG）, Gamma and Weibull are chosen to achieve curve fitting of the histogram. At last, the distribute law of the debris size is obtained by fitting results. Experiments with different discharge parameters are carried out on an EDM machine designed by the authors themselves, and the machining conditions are tool electrode of red-copper material, workpiece of ANSI 1045 material and working fluid of de-ionized water. The experimental results indicate that the debris sizes of all experiment sample truly obey the Weibull distribution. The obtained distribution law is significantly important for all the models established based on the debris particle size.

Parameter optimization model in electrical discharge machining process

Electrical discharge machining (EDM) process, at present is still an experience process, wherein selected parameters are often far from the optimum, and at the same time selecting optimization parameters is costly and time consuming. In this paper, artificial neural network (ANN) and genetic algorithm (GA) are used together to establish the parameter optimization model. An ANN model which adapts Levenberg-Marquardt algorithm has been set up to represent the relationship between material removal rate (MRR) and input parameters, and GA is used to optimize parameters, so that optimization results are obtained. The model is shown to be effective, and MRR is improved using optimized machining parameters.

Micro Electrical Discharge Machining Deposition in Air for Fabrication of Micro Spiral Structures

Micro electrical discharge machining（EDM） deposition process is a new micro machining method for fabrication of metal micro structures. In this process, the high level of tool electrode wear is used to achieve the metal material deposition. Up to now, the studies of micro EDM deposition process focused mainly on the researches of deposition process, namely the effects of discharge parameters in deposition process on the deposition rate or deposition quality. The research of the formation of micro structures with different discharge energy density still lacks. With proper conditions and only by the z-axis feeding in vertical direction, a novel shape of micro spiral structure can be deposited, with 0.11 mm in wire diameter, 0.20 mm in outside diameter, and 3.78 mm in height. Then some new deposition strategies including angular deposition and against the gravity deposition were also successful. In order to find the forming mechanism of the spiral structures, the numerical simulation of the transient temperature distribution on the discharge point was conducted by using the finite-element method（FEM）. The results show that there are two major factors lead to the forming of the spiral structures. One is the different material removal form of tool electrode according with the discharge energy density, the other is the influenced degree of the movement of the removed material particles in the discharge gap. The more the energy density in single discharge is, the smaller the mass of the removed material particles is, and the easier the movements of which will be changed to form an order tendency. The fine texture characteristics of the deposited micro spiral structures were analyzed by the energy spectrum analysis and the metallographic analysis. It shows that the components of the deposited material are almost the same as those of the tool electrode. Moreover the deposited material has the brass metallic luster in the longitudinal profile and has compact bonding with the base material. This research is useful to understand the micro-process of micro EDM deposition better and helpful to increase the controllability of the new EDM method for fabrication of micro structures.

Surface Modification Process by Electrical Discharge Machining with Ti Powder Green Compact Electrode

This paper describes a new method of surface modification by Electrical Discharge Machining (EDM). By using ordinary EDM machine tool and kerosene fluid, a hard ceramic layer can be created on the workpiece surface with Ti or other compressed powder electrode in a certain condition. This new revolutionary method is called Electrical Discharge Coating (EDC). The process of EDC begins with electrode wear during EDM,then a kind of hard carbide is created through the thermal and chemical reaction between the worn electrode material and the carbon particle decomposed from kerosene fluid under high temperature. The carbide is piled up on a workpiece quickly and becomes a hard layer of ceramic about 20 μm in several minutes. This paper studies the principle and process of EDC systemically by using Ti powder green compact electrode. In order to obtain a layer of compact ceramic film, it is very important to select proper electric pulse parameters, such as pulse width, pulse interval, peak current. Meantime, the electrode materials and its forming mode will effect the machining surface quality greatly. This paper presents a series of experiment results to study the EDC process by adopt different technology parameters. Experiments and analyses show that a compact TiC ceramic layer can be created on the surface of metal workpiece. The hardness of ceramic layer is more 3 times higher than the base body, and the hardness changes gradiently from surface to base body. The method will have a great future because many materials can be easily added to the electrode and then be coated on the workpiece surface. Gearing the parameters ceramic can be created with different thickness. The switch between deposition and removal process is carried out easily by changing the polarity, thus the gear to the thickness and shape of the composite ceramic layer is carried out easily. This kind of composite ceramic layer will be used to deal with the surface of the cutting tools or molds possibly, in order to lengthen their life. It also can be found wide application in the fields of surface repairing and strengthening of the ship or aircraft.

Experimental Research on Effects of Process Parameters on Servo Scanning 3D Micro Electrical Discharge Machining

Servo scanning 3D micro electrical discharge machining (3D SSMEDM) is a novel and effective method in fabricating complex 3D micro structures with high aspect ratio on conducting materials. In 3D SSMEDM process, the axial wear of tool electrode can be compensated automatically by servo-keeping discharge gap, instead of the traditional methods that depend on experiential models or intermittent compensation. However, the effects of process parameters on 3D SSMEDM have not been reported up until now. In this study, the emphasis is laid on the effects of pulse duration, peak current, machining polarity, track style, track overlap, and scanning velocity on the 3D SSMEDM performances of machining efficiency, processing status, and surface accuracy. A series of experiments were carried out by machining a micro-rectangle cavity (900 μm×600 μm) on doped silicon. The experimental results were obtained as follows. Peak current plays a main role in machining efficiency and surface accuracy. Pulse duration affects obviously the stability of discharge state. The material removal rate of cathode processing is about 3/5 of that of anode processing. Compared with direction-parallel path, contour-parallel path is better in counteracting the lateral wear of tool electrode end. Scanning velocity should be selected moderately to avoid electric arc and short. Track overlap should be slightly less than the radius of tool electrode. In addition, a typical 3D micro structure of eye shape was machined based on the optimized process parameters. These results are beneficial to improve machining stability, accuracy, and efficiency in 3D SSMEDM.

Micro electrical discharge machining of small hole in TC4 alloy

Aiming at machining deeply small holes in TC4 alloy,a series of experiments were carried out on a self-developed multi-axis micro electrical discharge machining(micro-EDM)machine tool.To improve machining efficiency and decrease relative wear of electrode in machining deeply small hole in TC4 alloy,many factors in micro-EDM,such as polarity,electrical parameters and supplying ways of working fluid were studied.Experimental results show that positive polarity machining is far superior to negative polarity machining;it is more optimal when open-circuit voltage,pulse width and pulse interval are 130 V,5μs and 15μs respectively on the self developed multi-axis micro-EDM machine tool;when flushing method is applied in micro-EDM,the machining efficiency is higher and relative wear of electrode is smaller.

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.

Electrical discharge machining of 6061 aluminium alloy

The wire electrical discharge machining（EDM） of 6061 aluminium alloy in terms of material removal rate,kerf/slit width,surface finish and wear of electrode wire for different pulse on time and wire tension was studied.Eight experiments were carried out in a wire EDM machine by varying pulse on time and wire tension.It is found that the material removal rate increases with the increase of pulse on time though the wire tension does not affect the material removal rate.It seems that the higher wire tension facilitates steady machining process,which generates low wear in wire electrode and better surface finish.The surface roughness does not change notably with the variation of pulse on time.The appearance of the machined surfaces is very similar under all the machining conditions.The machined surface contains solidified molten material,splash of materials and blisters.The increase of the pulse on time increases the wear of wire electrode due to the increase of heat input.The wear of wire electrode generates tapered slot which has higher kerf width at top side than that at bottom side.The higher electrode wear introduces higher taper.

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.

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.