Sheng-Yang Lin

The Influence of Cutting Edge Deformations on Magnetic Performance Degradation of Electrical Steel

Even though it has been widely known the cutting process of the electrical steel brings deterioration effects on magnetic properties, it is still unclear how to evaluate the quality of the cutting process effectively. This research investigates the performance degradation of the punching process based on a newly developed instrument. Three needle probes are arranged in a special way to pick up the flux around the area of the cutting edge and the flux of the unaffected center area, respectively. The amount of performance degradation can be evaluated by comparing the edge and the center flux values. 50CS1300 samples with different punching clearances were produces and measurement results were obtained. The power conversion loss imposed by the punching process were evaluated in terms of several measured parameters, including magnetic flux density, iron loss, and copper loss.

Development of an Automatic On-line Gap Detection Scheme for Levitated Industrial Steel Plate Conveyance System

For stabilizing the steel plate conveyance process, efforts on providing appropriate extra electromagnetic forces at the run-out-table of a steel mill have been extensively investigated. Such objectives can be achieved by implementing fixed poles on top of the rollers at the run-out-table to provide the controllable two-dimensional (2D) lift and propulsive forces, and the movable steel plate can then be driven to the desired directions. To realize the entire process, by considering the operational environment at a steel mill, an image-based on-line gap detection scheme with real-time parameter adjustment process has been developed. Results show that the system, which being implemented with a fine-tuned interfacing/processing scheme, can supply rapid and accurate on-line 2D gap profile and thus fulfil the design and on-site operational objectives

On the Electromagnetic Steel Selections and Performance Impact Assessments of Synchronous Reluctance Motors

To achieve relatively lower costs and higher operational efficiencies, without adopting permanent magnets or rotor conductors, the synchronous reluctance motor (SynRM) has received more and more attentions as a competitive solution recently. To establish a rational guidance for the related designs and constructions, this paper is aimed to present the thorough performance impact assessments of SynRMs that are composed of different electromagnetic steels at various operational specifications. Based on the magnetization and hysteresis characteristics of the steel sheets, variations of the average torques, torque ripples, and iron losses by using different stator and rotor materials are investigated, and some valuable comparison results can be provided for designers and engineers in the related motor and metal industries.

Cutting and Punching Impacts on Laminated Electromagnetic Steels to the Designs and Operations of Synchronous Reluctance Motors

This paper is aimed to provide the detailed design and operational investigations of synchronous reluctance motors (SynRM) that are commonly assembled by laminated electromagnetic steels. The magnetic flux paths in the SynRM rotors with various barrier and segment compositions will be analyzed, along with the generated motor torque and loss assessments. As the related mechanical cutting and/or punching processes on the rotor steels are required to achieve desired direct- and quadrature-axis reluctance ratios, their impacts to the flux paths due to saturations will also be thoroughly evaluated. Assisted by 3-D finite-element analyses, the results clearly indicated that the additional annealing process on the electromagnetic steel strips must be introduced for these SynRM designs with smaller sizes and higher efficiency requirements.

Electromagnetic Stirring Systems

Electromagnetic stirring (EMS) systems have been extensively used in the continuous casting process in steel-making industries to produce high-quality steel products. Although the operational principles of such EMS facilities are well established and extensively applied, demonstrations of actual stirring effects on molten metal are always desired for comparative investigations. To fulfill the requirements for investigating EMS phenomena, a hot-mode experimental apparatus of an EMS system with liquid zinc (Zn) as the test object has been successfully established in the laboratory. The performances of the experimental apparatus are further confirmed by detailed three-dimensional (3-D) finite element analyses (FEA). With such a well-constructed appliance, the relative behaviors at various operational conditions can be thoroughly investigated, and the characteristics of such EMS facilities can be easily realized.

Cutting and punching impacts on laminated electromagnetic steels to the designs and operations of synchronous reluctance motors

This paper is aimed to provide the detailed design and operational investigations of synchronous reluctance motors (SynRM) that are commonly assembled by laminated electromagnetic steels. The magnetic flux paths in the SynRM rotors with various barrier and segment compositions will be analyzed, along with the generated motor torque and loss assessments. As the related mechanical cutting and/or punching processes on the rotor steels are required to achieve desired direct- and quadrature-axis reluctance ratios, their impacts to the flux paths due to saturations will also be thoroughly evaluated. Assisted by 3-D finite-element analyses, the results clearly indicated that the additional annealing process on the electromagnetic steel strips must be introduced for these SynRM designs with smaller sizes and higher efficiency requirements.

Online Realizations of Dynamic Gap Detection and Control for Levitated Industrial Steel-Plate Conveyance System

To design a stable and fully controllable process for conveying steel plates with less noise, we have extensively investigated the feasibility of incorporating the structure that can provide appropriate extra electromagnetic attraction forces. By implementing appropriate fixed electromagnetic poles on top of the rollers at the run-out table of a steel mill, controllable lift and propulsive forces can thus be provided to drive the movable steel plate to the desired 2-D directions. Based on the stringent operational environment at a steel mill, an online recursive gap detection scheme combined with a real-time fuzzy-based controller has been developed. Realization results showed that the system, being implemented with the proposed fine-tuned processing/control scheme, can supply rapid and accurate online 2-D controls onto the steel plates and thus fulfill the design and operational objectives.

On the electromagnetic steel selections and performance impact assessments of synchronous reluctance motors

To achieve relatively lower costs and higher operational efficiencies, without adopting permanent magnets or rotor conductors, the synchronous reluctance motor (SynRM) has received more and more attentions as a competitive solution recently. To establish a rational guidance for the related designs and constructions, this paper is aimed to present the thorough performance impact assessments of SynRMs that are composed of different electromagnetic steels at various operational specifications. Based on the magnetization and hysteresis characteristics of the steel sheets, variations of the average torques, torque ripples, and iron losses by using different stator and rotor materials are investigated, and some valuable comparison results can be provided for designers and engineers in the related motor and metal industries.

Applications of Optical Image Processing Technique for Steel Mill Non-contacting Conveyance System Operations

This paper provides a feasibility evaluation of applying the optical inspection system to provide accurate and rapid on-line gap measurements for a specially designed non-contacting steel plate conveyance structure in a steel mill. Framework of the conveyance system has been designed based on a linear induction motor configuration with sets of stator primary windings being energized to supply desired fluxes, while the steel plate is operated as the movable secondary that can be both lifted and conveyed to the designated directions. The optical inspection system at a steel mill is commonly employed to determine the dimension accuracy of produced steel plate. Based on such scheme, preliminary investigation of using the optical inspection system to the on-line dynamic gap measurements of a laboratory non-contacting conveyance system operations have been successfully performed. More complicated software and hardware data filtering and adjustments based on digital image processing techniques have been adapted to the entire system formulation and estimation. Results show that the system, which being implemented with a fine-tuned interfacing/processing scheme, can supply accurate and rapid gap measurements and thus fulfil the design and field operational objectives.

Electromagnetic Steel Products: A Systematic Iron Loss Evaluating Scheme

To sell electromagnetic steel in competitive markets, test results that can properly indicate the iron losses of those products at different specifications are desired. However, with limited measurements, the available data sheets can only cover typical data that were determined from common Epstein frame tests, and further information regarding possible iron losses beyond the measurement setups can only be estimated by approximations. Accuracies in applying these data for related machine performance evaluations at those operational conditions are always uncertain, and more credible data sheets that can adequately characterize the electromagnetic steel properties are certainly expected. Based on the Preisach model and available measurements, a systematic scheme to establish a generalized guidance for evaluating the hysteresis characteristics of electromagnetic steel is proposed. Supported by experimental measurements and detailed three-dimensional (3-D) field analyses, iron losses of those mechanisms constructed by laminated electromagnetic steel can then be estimated with enough confidence.