Ilya Petrov

Performance of Low-Cost Permanent Magnet Material in PM Synchronous Machines

Permanent magnet synchronous machines (PMSM) are considered a viable option in various types of applications. However, particularly in consumer and low-power industrial applications, the price may be a factor that limits the use of PMSMs. In addition to a different technology, the main reason for the high price of PMSMs is the use of expensive neodymium or samarium-cobalt magnets. Their use is necessary only if a high motor torque T to linear current density A ratio (T/A) is required. Ferrite permanent magnets are low cost, abundant, and have negligible eddy current losses in low-frequency applications such as motor drives. They have a much lower energy product (BHmax) than the most modern magnets. Because of the high prices of rare earth magnets, many parties are seeking for opportunities to use ferrites instead. In the case of rotor surface ferrite magnets, the air gap flux density remains low. The air gap torque producing tangential Maxwell stress is proportional to the product of the air gap flux density Bδ[ Vs/m2] and the linear current density A [A/m]. If the flux density is low and A cannot be increased, the rotor has to be made larger than in machines having a high air gap flux density. In the case of multiple pole machines, the outer rotor approach, with its low rotor yoke height, offers an interesting alternative. The air gap diameter of these machines can be made larger than in conventional inner rotor type motors without increasing the machine outer dimensions. In this paper, an outer rotor PMSM with ferrite magnets is analyzed and tested. The machine characteristics in a fan drive are compared with an induction machine of the same power.

Unequal Teeth Widths for Torque Ripple Reduction in Permanent Magnet Synchronous Machines With Fractional-Slot Non-Overlapping Windings

Permanent magnet synchronous machines (PMSMs) with fractional-slot non-overlapping windings, also known as tooth-coil winding PMSMs (TCW PMSM), have been under intensive research during the latest decade. There are many optimization routines explained and implemented in the literature to improve the characteristics of this machine type. This paper introduces a new technique for torque ripple minimization in TCW PMSM. The source of torque harmonics is also described. The low-order torque harmonics can be harmful for a variety of applications, such as direct drive wind generators, direct drive light vehicle electrical motors, and for some high-precision servo applications. The reduction of the torque ripple harmonics with the lowest orders (6th and 12th) is realized by machine geometry optimization technique using finite element analysis. The presented optimization technique includes the stator geometry adjustment in TCW PMSMs with rotor surface permanent magnets and with rotor embedded permanent magnets. Influence of the permanent magnet skewing on the torque ripple reduction and cogging torque elimination was also investigated. It was implemented separately and together with the stator optimization technique. As a result, the reduction of some torque ripple harmonics was attained.

Influence of Travelling Current Linkage Harmonics on Inductance Variation, Torque Ripple and Sensorless Capability of Tooth-Coil Permanent-Magnet Synchronous Machines

This paper introduces an important source of torque ripple in permanent-magnet synchronous machines with tooth-coil windings (TC-PMSMs). It is theoretically proven that saturation and cross-saturation phenomena caused by the nonsynchronous harmonics of the stator current linkage cause a synchronous inductance variation with a particular periodicity. This, in turn, determines the magnitude of the torque ripple and can also deteriorate the performance of signal-injection-based rotor position estimation algorithms. An improved dq-inductance model is proposed. It can be used in torque ripple reduction control schemes and can enhance the self-sensing capabilities of TC-PMSMs.

Inductance Calculation of Tooth-Coil Permanent-Magnet Synchronous Machines

Analytical calculation methods for all the major components of the synchronous inductance of tooth-coil permanent-magnet synchronous machines are reevaluated in this paper. The inductance estimation is different in the tooth-coil machine compared with the one in the traditional rotating field winding machine. The accuracy of the analytical torque calculation highly depends on the estimated synchronous inductance. Despite powerful finite element method (FEM) tools, an accurate and fast analytical method is required at an early design stage to find an initial machine design structure with the desired performance. The results of the analytical inductance calculation are verified and assessed in terms of accuracy with the FEM simulation results and with the prototype measurement results.

Hybrid Cooling Method of Axial-Flux Permanent-Magnet Machines for Vehicle Applications

Thermal properties are a key issue in many applications associated with electrical machines. Because of its special configuration, an axial-flux electrical machine usually uses self-ventilation. However, this cooling method has a significant impact degrading the machine operating characteristics, and thus, an independent cooling system is desirable. The focus of this paper is on the steady-state thermal modeling and laboratory testing of an axial-flux permanent-magnet (AFPM) electrical machine intended for a traction application. The proposed hybrid cooling arrangement consists of a frame cooling circuit with a water flow inside, a set of copper bars inserted in the teeth, and a segment of potting material around the end windings. Computational fluid dynamics and finite-element analysis are applied for the preliminary design. This paper provides experimental verification of the simulation results on a 100-kW AFPM electrical machine.

Rotor surface ferrite magnet synchronous machine for generator use in a hybrid application — Electro-magnetic and thermal analysis

To reach a particular tangential stress in a PMSM the magnetic loading and the electric loading should have corresponding values. This means that if the magnetic loading is restricted by the characteristics of cheap and relatively weak ferrite permanent magnets, the electric loading should be increased to keep the tangential stress at desirable value. However, the latter is also limited because of the demagnetization risk of the permanent magnets by a high armature reaction. Therefore, surface ferrite PMSMs should have a low tangential stress in order to avoid the demagnetization risk, which consequently leads to a low torque density. This is one of the main drawbacks of ferrite magnets used in electric motor drives. This paper describes some possibilities for improving the torque density with surface ferrite PMSMs, describes the restrictions which one can meet while designing this type of the electric machines and observe the influence of temperature variation in the magnets on the electric machine performance. An example is done with the analytical and the FEM analyses of a 50 kW, 3000 rpm, permanent magnet generator for a series hybrid electric vehicle application.

Rotor Eddy-Current Losses Reduction in an Axial Flux Permanent-Magnet Machine

A novel rotor structure for a tooth-coil-winding (concentrated winding) open-slot axial-flux permanent-magnet (PM) machine that reduces the eddy currents and increases the main flux linkage is proposed in this paper. A composite-body-based rotor assembly and a steel-laminated layer inserted on top of the magnets are used to reduce eddy-current losses in the PMs. A prototype of an axial flux generator for a heavy-duty vehicle following this structure is optimized, analyzed and measured. The tooth coil windings produce high-amplitude harmonics in the air gap and the large slot openings reduce the rotor flux. Consequently, a rotor structure that decreases the amount of harmonics travelling through the magnets is required. Steel laminations covering the magnets have positive effects on both phenomena. Two-dimensional and three-dimensional finite-element analysis is used to verify and optimize the geometry of the laminations. Computations are verified by experimental measurements of a 100 kW test machine prototype.

Hysteresis Losses in Different Types of Permanent Magnets Used in PMSMs

In permanent magnet synchronous machines (PMSM), depending on the machine application, different types of permanent magnets (PM) can be used. The most common PMs are ferrite magnets, neodymium iron boron magnets (NdFeB), and samarium cobalt magnets (SmCo). The selection of a suitable magnet for a particular machine design depends on the magnet properties: remanence, conductivity, mechanical rigidity, losses, and demagnetization characteristics. Usually, the possibility of hysteresis losses in PM materials is neglected. In this paper, however, it is demonstrated that possible hysteresis losses have to be evaluated in the machine design. It is shown by measurements and simulations that in some machine designs, hysteresis losses in NdFeB, SmCo, and ferrite magnets can be a source of significant additional ac losses that may lead to too high PM operating temperatures and a reduction in the machine efficiency.

Torque ripple reduction in double-layer 18/16 TC-PMSMs by adjusting teeth widths to minimize local saturation

The saturation in the stator teeth of an 18-slots 16-poles TC-PMSM with sinusoidal current supply caused by the interaction of armature reaction fluxes and rotor-PM-produced fluxes is studied. It is found that under load some teeth are saturated deeper than others. An increase in the width of these teeth reduces the oversaturation, which locally prevents the decrease in the inductance and back-EMF, and, consequently, reduces the torque ripple in the machine. The proposed technique can also be applied to other types of TC-PMSMs.

Direct Liquid Cooling in Low-Power Electrical Machines: Proof-of-Concept

This paper evaluates the feasibility of a direct liquid cooling approach in the thermal management of an axial flux permanent-magnet machine. To demonstrate the cooling method, a test motor was fitted with helical tooth coil windings formed from a hybrid conductor comprising a stainless steel coolant conduit tightly wrapped with a stranded Litz wire. The motor is a 100-kW permanent-magnet, axial-flux, double-stator, single-rotor machine. The proof of concept integrated the motor with a closed liquid coolant loop, appropriate instrumentation, and a data acquisition system. The general performance of the motor was examined at various power levels using polyalphaolefin oil as the cooling fluid. The results show the proposed cooling method to be feasible, and furthermore, to provide significant improvements to the machine thermal management.