Feasibility of a New Ironless-stator Axial Flux Permanent Magnet Machine for Aircraft Electric Propulsion Application

With the development of aviation electrification,higher demands for electrical machines are put forward in aircraft electric propulsion systems.The aircraft electric propulsion requirements and propulsion motor features are analyzed in this paper.Comparing with conventional PM machines,ironless stator axial flux permanent magnet(AFPM)machine topologies with Litz wire windings allow designs with higher compactness,lightness and efficiency,which are suitable for high-frequency and high-power density applications.Based on the motor requirements and constraints of aircraft electric propulsion systems,this paper investigates a high-power 1 MW multi-stack ironless stator AFPM machine,which is composed of four 250kW modular motors by stacking in axial.The design guidelines and special attentions are presented,in term of electromagnetic,thermal,and mechanical performance for the high-frequency coils and Halbach-array PM rotor.Finally,an ironless stator AFPM motor is manufactured,tested and evaluated with the consideration of cost and processing cycle.The results show that the output power is up to 53.8kW with 95%efficiency at 9000r/min at this stage.The proposed ironless stator AFPM machine with oil immersed forced cooling proves to be a favorable candidate for application in electric aircraft as propulsion motors.

Performance Analysis and Comparison for Two Topologies of Flux-Switching Permanent Magnet Machine

Flux-switching permanent magnet(FSPM)machine is a kind of stator-typed permanent magnet machine,which is suitable for driving electric vehicles and hybrid electric vehicles because of their large power/torque density and high efficiency.The axial field flux-switching permanent magnet machine(AFFSPMM)and radial field flux-switching permanent magnet machine(RFFSPMM)with H-typed iron cores are reached and compared in this paper.On the condition of the same outer diameters and total volumes,the electromagnetic performances of the two machines are analyzed and compared by the three-dimensional finite element method,including the air gap flux density,inductance,back electromotive force(EMF),electromagnetic torque and loss.The finite element results show that the copper loss of AFFSPMM is higher than that of RFFSPMM at the rated load,however,the total loss of AFFSPMM is lower than that of the RFFSPMM.Meanwhile,AFFSPMM has greater torque than RFFSPMM in the constant power range.The related experiments are done to validate the finite element results,which are basically consistent with experiment results.

Design and Optimization of a Mechanical Variable-Leakage-Flux Interior Permanent Magnet Machine with Auxiliary Rotatable Magnetic Poles

A novel mechanical variable-leakage-flux interior permanent magnet machine(MVLF-IPMM)is proposed for electric vehicles(EVs)in this paper,which employs a mechanical flux-regulating device and auxiliary rotatable magnetic poles.The magnetic poles acting as the flux adjustors can be rotated by the additional device to vary the leakage flux in magnetic circuit and realize the adjustment of the PM flux linkage.Due to the flux-regulating effect,the flux distribution in this machine is complex and changeable.Therefore,the working principle is illustrated in detail.To obtain the perfect coordination between the dominant magnetic poles and auxiliary magnetic poles,a multi-objective optimization method is presented based on the parameter sensitivity analysis combining with the Coefficient of Prognosis(CoP).Then,some design parameters with strong sensitive are selected by the sensitivity analysis and the initial model of the proposed motor is optimized by utilizing the multi-objective genetic algorithm(MOGA).According to the result of the optimization,the machine performances of the initial and the optimal design under the different flux states are compared and analyzed to verify the validity of the new variable-flux motor and the optimization method.

Novel Rotors with Low Eddy Current Loss for High Speed Permanent Magnet Machines

Due to the large rotor eddy current loss and low thermal conductivity of carbon fiber sleeve,the high temperature usually occurs in high speed permanent magnet machines(HSPMMs)at the rated operation condition,resulting in irreversible demagnetization of the permanent magnet(PM).To obtain low rotor temperature,two novel rotor structures with low rotor eddy current loss are proposed in this paper.With the output torque and air gap flux density unchanged,the performance of HSPMMs with the two proposed rotor structures are analyzed based on finite element algorithm(FEA),including eddy current loss and temperature.Finally,the appropriate parameters of the proposed rotor structures are selected,and the electromagnetic(EM)performance,rotor stress and temperature are compared with those of the conventional rotor structure.Index Terms-Eddy current loss,finite element algorithm(FEA),electromagnetic(EM)performance,high speed permanent magnet machines(HSPMMs).

Design and Performance Analysis of Axial Flux Permanent Magnet Machines with Double-Stator Dislocation Using a Combined Wye-Delta Connection

Conventional fractional slot concentrated winding three-phase axial flux permanent magnet machines have an abundance of armature reaction magnetic field harmonics which deteriorate the torque performance of the machine.This paper presents a double-stator dislocated axial flux permanent magnet machine with combined wye-delta winding.A wye-delta(Y-△)winding connection method is designed to eliminate the 6 th ripple torque generated by air gap magnetic field harmonics.Then,the accurate subdomain method is adopted to acquire the no-load and armature magnetic fields of the machine,respectively,and the magnetic field harmonics and torque performance of the designed machine are analyzed.Finally,a 6 k W,4000 r/min,18-slot/16-pole axial flux permanent magnet machine is designed.The finite element simulation results show that the proposed machine can effectively eliminate the 6 th ripple torque and greatly reduce the torque ripple while the average torque is essentially identical to that of the conventional three-phase machines with wye-winding connection.

Transient characteristics analysis of linear flux-switching permanent magnet machines for precision control

A dynamical dq model is proposed for a linear flux-switching permanent magnet（LFSPM） machine which is suitable for high-precision control applications.The operation principle of the prototype machine is analyzed using the finite element method（FEM）,and the parameters,such as the back electromotive force（EMF） and the phase flux linkage,are calculated.The calculated and measured results reveal that the back EMF and the flux linkage are essentially sinusoidal,and the variation of the phase flux linkage profile of the LFSPM machine is similar to that of the linear surface permanent magnet（LSPM） machine.Based on this,a dynamical dq model and a simulation control model are proposed.The simulation results are compared with the test results obtained from a DSP-based control platform,which verifies that the model is correct and effective.Moreover,the model can be used for design optimization and control development.

Investigation of Influence of Winding Structure on Reliability of Permanent Magnet Machines

Winding is an important part of the electrical machine and plays a key role in reliability.In this paper,the reliability of multiphase winding structure in permanent magnet machines is evaluated based on the Markov model.The mean time to failure is used to compare the reliability of different windings structure.The mean time to failure of multiphase winding is derived in terms of the underlying parameters.The mean time to failure of winding is affected by the number of phases,the winding failure rate,the fault-tolerant mechanism success probability,and the state transition success probability.The influence of the phase number,winding distribution types,multi three-phase structure,and fault-tolerant mechanism success probability on the winding reliability is investigated.The results of reliability analysis lay the foundation for the reliability design of permanent magnet machines.

Novel Switched Flux Permanent Magnet Machine Topologies

This paper overviews various switched flux permanent magnet machines and their design and performance features,with particular emphasis on machine topologies with reduced magnet usage or without using magnet,as well as with variable flux capability.

Hybrid Excited Permanent Magnet Machines for Electric and Hybrid Electric Vehicles

This paper reviews various hybrid excited(HE)machines from the perspective of location of PM and DC excitation,series/parallel connection of PM and DC excited magnetic fields,and 2D/3D magnetic fields,respectively.The advantages as well as drawbacks of each category are analyzed.Since an additional control degree,i.e.DC excitation,is introduced in the HE machine,the flux weakening control strategies are more complex.The flux weakening performance as well as efficiency are compared with different control strategies.Then,the potential to mitigate the risk of uncontrolled overvoltage fault at high speed operation is highlighted by controlling the field excitation.Since additional DC coils are usually required for HE machines compared with pure PM excitation,the spatial confliction inevitably results in electromagnetic performance reduction.Finally,the technique to integrate the field and armature windings with open-winding drive circuit is introduced,and novel HE machines without a DC coil are summarized.

Investigation of an Intensifying-flux Variable Flux-leakage Interior Permanent Magnet Machine for Wide Speed Range

In this paper,a novel intensifying-flux variable flux-leakage interior permanent magnet(IFVF-IPM)machine is proposed,in which flux barriers were designed deliberately between the adjacent poles to obtain intensifying-flux effect and variable flux-leakage property.The rotor topology and design principles of the proposed machine are also introduced.Then,a multi-objective optimization method is adopted based on the sensitivity analysis,and some design variables of IFVF-IPM machine with strong sensitivity are selected to optimization progress by using the non-dominated sorting genetic algorithm-Ⅱ(NSGA-Ⅱ).Moreover,the electromagnetic characteristics of conventional IPM machine,conventional IFVF-IPM machine(CIFVF-IPM)and the novel IFVF-IPM machine are compared based on the finite element analysis(FEA)method which includes flux linkage,inductances characteristic,torque-speed envelops and power characteristic,as well as evaluation of the risk of irreversible demagnetization.Finally,the experiment results show that the IFVF-IPM machine has a better performance in flux weakening capability for wide speed range and a lower risk of irreversible demagnetization,which indicates the validity and feasibility of the proposed machine.

Modularity Techniques in High Performance Permanent Magnet Machines and Applications

This paper reviews the modularity techniques in the stator manufacture of permanent magnet machines for different applications.Some basic concepts of modular machines are firstly introduced.Modular machines for several typical applications are then described in details,including domestic appliances,automobiles and electric vehicles,more electric aircrafts and civic applications,wind power generators,etc.Besides,the influence of manufacture tolerance gaps and flux barriers on the electromagnetic performance is discussed.

Analytical Solution of a Fractional-slot Double-layer-winding Open-slot Vernier Permanent Magnet Machine with Tooth Tips

An analytical solution(ANA)for a fractional-slot double-layer-winding open-slot vernier permanent magnet(VPM)machine with tooth tips is presented.Magnetic vector potential equations are analytically solved using the technique of variable separation in four subdomains in a two-dimensional polar coordinate system.Based on the solved magnetic vector potential,the flux density distribution,torque,flux linkage,inductance,electromotive force(EMF)and power factor are analytically developed.An 18-slot/32-rotor-pole prototype is analyzed,and the results match well with the finite element analysis(FEA),which validates that the ANA consumes less time than FEA.Therefore,the tooth tips are optimized using the ANA to improve the average torque.Moreover,the ANA can be used to evaluate the demagnetization withstand capabilities of permanent magnets.The material utilization,slot-filling factor,EMF,and torque are compared between the models with three and four subdomains.Finally,an experimental prototype is constructed and tested,and the results validate the ANA.

High-order sliding mode control of a doubly salient permanent magnet machine driving marine current turbine

Due to the harsh and changeable marine environment,one low speed stator-permanent magnet machine named doubly salient permanent magnet machine with toothed pole is applied for marine current energy conversion system.Indeed,this machine has simple structure,intriguing fault tolerance,and higher power density,which could adequately satisfy the different complicated operation conditions.However,its permanent magnet flux-linkage has the same variation period as the inductance which leads to a strong nonlinear coupling system.Moreover,the torque ripple caused by this special characteristics,uncertainty of system parameters and disturbance of load greatly increases the difficulty of control in this strongly coupling system.Consequently,the classical linear PI controller is difficult to meet the system requirement.In this paper,the high-order sliding mode control strategy based on the super-twisting algorithm for this system is creatively utilized for the first time.The stability of the system within a limited time is also proved with a quadratic Lyapunov function.The relative simulation results demonstrate convincingly that,the high-order sliding mode control has little chattering,high control accuracy and strong robustness.

Electromagnetic Performance Analysis of Variable Flux Memory Machines with Series-magnetic-circuit and Different Rotor Topologies

In this paper,the electromagnetic performance of variable flux memory(VFM)machines with series-magnetic-circuit is investigated and compared for different rotor topologies.Based on a V-type VFM machine,five topologies with different interior permanent magnet(IPM)arrangements are evolved and optimized under same constrains.Based on two-dimensional(2-D)finite element(FE)method,their electromagnetic performance at magnetization and demagnetization states is evaluated.It reveals that the iron bridge and rotor lamination region between constant PM(CPM)and variable PM(VPM)play an important role in torque density and flux regulation(FR)capabilities.Besides,the global efficiency can be improved in VFM machines by adjusting magnetization state(MS)under different operating conditions.

Design and Performance Analysis of Permanent Magnet Claw Pole Machine with Hybrid Cores

Permanent magnet claw pole machine(PMCPM) is a special kind of transverse flux permanent magnet machine. Compared with other electrical machines, it has the advantages of high torque density and high efficiency for high speed operation. However, because of its complex irregular structure, the manufacturing process using silicon sheets is complicated. Soft magnetic composite material(SMC) is manufactured by powder metallurgy technology, which can produce various shapes of stator core structures, so it is easier to produce various irregular shapes of the stator core. However, the raw SMC material is relatively expensive, and the mechanical strength of SMC is weak. In this paper, a PMCPM with hybrid cores is proposed. With the adoption of hybrid silicon sheet-SMC cores and amorphous alloy-SMC cores, the torque ability of PMCPM can be improved greatly and it can have higher efficiency for more wide operation frequency. Meanwhile, its mechanical strength has been improved and it can be designed for high torque direct drive applications as it is a modular machine. Furthermore, three methods are proposed to reduce the additional eddy current loss which resulted from the employment of hybrid cores in PMCPM.

Design Optimization of a Novel Axial-radial Flux Permanent Magnet Claw Pole Machine with SMC Cores and Ferrite Magnets

Soft magnetic composite(SMC)material is an ideal soft magnetic material employed for developing 3D magnetic flux electromagnetic equipment,due to its advantages of 3D magnetic isotropy characteristic,low eddy current loss,and simple manufacturing process.The permanent magnet claw pole machine(PMCPM)with SMC cores is a good case that the SMC to be adopted for developing 3D flux electrical machines.In this paper,a novel axial-radial flux permanent magnet claw pole machine(ARPMCPM)with SMC cores and ferrite magnets is proposed.Compared with the traditional PMCPM,the proposed ARPMCPM is designed with only one spoke PM rotor and its whole structure is quite compact.For the performance prediction,the 3D finite element method(FEM)is used.Meanwhile,for the performance evaluation,a previously developed axial flux claw pole permanent magnet machine(AFCPM)is employed as the benchmark machine and all these machines are optimized by using the combined multilevel robust Taguchi method.It can be seen that the proposed ARPMCPM is with higher torque/weight density and operation efficiency.

New Topologies of High Torque Density Machine Based on Magnetic Field Modulation Principle

With the increasing demand for high torque density in motors,more and more new topologies emerge.Furthermore,the magnetic field modulation principle is widely concerned and has evolved into an effective analysis method for studying the new motor topology.This paper introduces the principle of magnetic field modulation.And the research on high torque density in recent years is reviewed from the perspective of magnetic field modulation,including permanent magnet vernier machine(PMVM),flux reverse machine(FRM),flux switching machine(FSM),dual permanent magnet(DPM)machine,and DC biased machine.The principle of magnetic field modulation makes it possible to propose higher torque density topologies in the future.

THREE-PHASE BRIDGE INVERTER FOR 9kW DOUBLY SALIENT PERMANENT MAGNET MOTOR

The three-phase bridge inverter is used as the converter topology in the power controller for a 9 kW doubly salient permanent magnet （DSPM） motor. Compared with common three-phase bridge inverters, the proposed inverter works under more complicated conditions with different principles for special winding back EMFs, position signals of hall sensors, and the given mode of switches. The ideal steady driving principles of the inverter for the motor are given. The working state with asymmetric winding back EMFs, inaccurate position signals of hall sensors, and the changing input voltage is analyzed. Finally, experimental results vertify that the given anal ysis is correct.

Calculation for Stator Loss of High-Speed Permanent Magnet Synchronous Machine in Torque-speed Envelope and Restraint Approach for Circulating Current in Windings

Iron loss and copper loss are the significant parts of electrical loss of machines,which are the major parts particularly under high frequency condition.High-speed permanent magnet synchronous machines(HS-PMSM)have the benefits of high power density,high efficiency and wide speed range.Which causes the calculation for iron loss and copper loss in whole operating range complex.By analyzing the components and influencing factors of iron loss and copper loss in stator,we have deduced the calculation formula of iron loss and copper loss in whole operating range based on the analytical solution and finite element approach(EFA)solution.According to the calculation solution,taking the influence of operating temperature on the iron loss and copper loss into account,we propose a temperature correction factor and establish the calculation method for the iron loss and copper loss with temperature influences.Finally,by the conductor transposition,we restrain the circulating current under high-frequency operating condition.

Multiphysics Design of a High-Speed Permanent Magnet Machine for a Micro Gas Turbine Application

This paper presents a detailed and comprehensive multiphysics design process of an 80 kW, 60 000 r/min high-speed permanent magnet machine (HSPMM) for a micro gas turbine application. First, the preliminary design of the HSPMM is carried out according to the mechanical and electromagnetic theory. Afterwards, the influence of carbon fiber sleeve (CFS) thickness, rotor diameter and core length on rotor stress and rotor dynamics is carefully analyzed to obtain the optimal range of rotor diameter and core length. On this basis, the electromagnetic and power loss characteristics are analyzed in detail to obtain the final design scheme. Fluid-solid coupling model is used to calculate the temperature field of the HSPMM to verify the rationality of the scheme. The rotor thermal stress analysis considering the multi-layer and multi-angle winding of CFS is carried out to obtain the rotor models suitable for prototype and mass production, respectively. Finally, the prototypes are manufactured and tested to verify the reliability of the multiphysics design process.