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.

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.

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.

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.

Multi-layer Quasi Three-dimensional Equivalent Model of Axial-Flux Permanent Magnet Synchronous Machine

Axial-flux permanent magnet synchronous machine(AFPMSM)enjoys the merits of high torque density and high efficiency,which make it one good candidate in the direct-drive application.The AFPMSM is usually analyzed based on the three-dimensional finite element method(3D FEM)due to its three-dimensional magnetic field distribution.However,the 3D FEM suffers large amount of calculation,time-consuming and is not suitable for the optimization of AFPMSM.Addressing this issue,a multi-layer quasi three-dimensional equivalent model of the AFPMSM is investigated in this paper,which could take the end leakage into consideration.Firstly,the multi-layer quasi three-dimensional equivalent model of the AFPMSM with single stator and single rotor is derived in details,including the equivalent processes and conversions of structure dimensions,motion conditions and electromagnetic parameters.Then,to consider the influence of end leakage on the performance,a correction factor is introduced in the multi-layer quasi three-dimensional equivalent model.Finally,the proposed multi-layer quasi three-dimensional equivalent model is verified by the 3D FEM based on an AFPMSM under different structure parameters.It demonstrates that the errors of flux linkage and average torque obtained by the multi-layer quasi three-dimensional equivalent model and 3D FEM are only around 2%although the structure parameters of the AFPMSM are varied.Besides,the computation time of one case based on the multi-layer quasi three-dimensional equivalent model is only 6 min,which is much less than that of the 3D FEM,1.8 h,under the same conditions.Thus,the proposed multi-layer quasi three-dimensional equivalent model could be used to optimize the AFPMSM and much time could be saved by this method compared with the 3D FEM.

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.

Reduction of Cogging Torque and Electromagnetic Vibration Based on Different Combination of Pole Arc Coefficient for Interior Permanent Magnet Synchronous Machine

Cogging torque and electromagnetic vibration are two important factors for evaluating permanent magnet synchronous machine(PMSM)and are key issues that must be considered and resolved in the design and manufacture of high-performance PMSM for electric vehicles.A fast and accurate magnetic field calculation model for interior permanent magnet synchronous machine(IPMSM)is proposed in this article.Based on the traditional magnetic potential permeance method,the stator cogging effect and complex boundary conditions of the IPMSM can be fully considered in this model,so as to realize the rapid calculation of equivalent magnetomotive force(MMF),air gap permeance,and other key electromagnetic properties.In this article,a 6-pole 36-slot IPMSM is taken as an example to establish its equivalent solution model,thereby the cogging torque is accurately calculated.And the validity of this model is verified by a variety of different magnetic pole structures,pole slot combinations machines,and prototype experiments.In addition,the improvement measure of the machine with different combination of pole arc coefficient is also studied based on this model.Cogging torque and electromagnetic vibration can be effectively weakened.Combined with the finite element model and multi-physics coupling model,the electromagnetic characteristics and vibration performance of this machine are comprehensively compared and analyzed.The analysis results have well verified its effectiveness.It can be extended to other structures or types of PMSM and has very important practical value and research significance.

Analytical Solutions for the Two-Dimensional Magnetic Fields in Disc-Type Permanent Magnet Machines

A two dimensional analytical method for predicting the magnetic field in the airgap/magnet region of a permanent magnet (PM) disc type machine is presented. The solutions of the governing field equations are given in both Cartesian and cylindrical coordinates. The expressions derived in this paper can be used conveniently for optimal design of machine. The computed results using the proposed 2D analytical method are validated by the more accurate, though a lot more complicated, 3D finite element analyses.

Coupled Electromagnetic-Thermal-Fluidic Analysis of Permanent Magnet Synchronous Machines with a Modified Model

The researches on the heat generation and dissipa-tion of the permanent magnet synchronous machines(PMSMs)are integrated problems involving multidisciplinary studies of electromagnetism,thermomechanics,and computational fluid dynamics.The governing equations of the multi-physical prob-lems are coupled and hard to be solved and illustrated.The high accuracy mathematical model in the algebraically integral con-servative forms of the coupled fields is established and computed in this paper.And the equation coupling with the fluid flow and the temperature variation is modified to improve the positive definiteness and the symmetry of the global stiffness matrix.The computational burden is thus reduced by the model modification.A 20kW 4500rpm permanent magnet synchronous machine(PMSM)is taken as the prototype,and the calculation results are validated by experimental ones.

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.

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.

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.

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.

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).

High-Speed Permanent Magnet Electrical Machines - Applications, Key Issues and Challenges

In this paper,application examples of high-speed electrical machines are presented,and the machine structures are categorized.Key issues of design and control for the high-speed permanent magnet machines are reviewed,including bearings selection,rotor dynamics analysis and design,rotor stress analysis and protection,thermal analysis and design,electromagnetic losses analysis and reduction,sensorless control strategies,as well as comparison and selection of sine-wave and square-wave drive modes.Some challenges are also discussed,so that future studies could be focused.

Electromagnetic Performance Analysis of Flux-Switching Permanent Magnet Tubular Machine with Hybrid Cores

The performance of traditional flux switching permanent magnet tubular machine(FSPMTM)are improved by using new material and structure in this paper.The existing silicon steel sheet making for all mover cores or part of stator cores are replaced by soft magnetic composite(SMC)cores,and the lamination direction of the silicon steel sheet in stator cores have be changed.The eddy current loss of the machine with hybrid cores will be reduced greatly as the magnetic flux will not pass through the silicon steel sheet vertically.In order to reduce the influence of end effect,the unequal stator width design method is proposed.With the new design,the symmetry of the permanent magnet flux linkage has been improved greatly and the cogging force caused by the end effect has been reduced.Both 2-D and 3-D finite element methods(FEM)are applied for the quantitative analysis.

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.

Analysis of temperature field for a surface-mounted and interior permanent magnet synchronous motor adopting magnetic-thermal coupling method

Aiming at obtaining high power density of surface-mounted and interior permanent magnet synchronous motor(SIPMSM),it is important to accurately calculate the temperature field distribution of SIPMSM,and a magnetic-thermal coupling method is proposed.The magnetic-thermal coupling mechanism is analyzed.The thermal network model and finite element model are built by this method,respectively.The effects of power frequency on iron losses and temperature fields are analyzed by the magnetic-thermal coupling finite element model under the condition of rated load,and the relationship between the load and temperature field is researched under the condition of the synchronous speed.In addition,the equivalent thermal network model is used to verify the magnetic-thermal coupling method.Then the temperatures of various nodes are obtained.The results show that there are advantages in both computational efficiency and accuracy for the proposed coupling method,which can be applied to other permanent magnet motors with complex structures.