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This paper proposes the design and analysis of a flux modulated (FM) permanent magnet (PM) linear actuator for the long track gantry robot system used to detect fire hazards in an electric energy storage system (ESS). A detailed design framework for the FM-linear actuator inspired by the magnetic gearing effect is proposed which includes the selection of slot-pole pair numbers and assigning optimal geometric parameters based on working harmonic characteristics. Using the optimal model, the electromagnetic performances both under no-load and full load conditions are performed to check the feasibility of the actuator for the gantry system. A prototype is built to validate the results obtained using the 2D and 3D finite element analysis (FEA). [ABSTRACT FROM AUTHOR]

This article proposes a 65 kW rim-driven direct-drive flux concentrated permanent magnet synchronous generator (FCPMSG) used in urban water pipeline energy harvester (UWEH) system. The proposed UWEH system plans to use hydraulic bearing; thus, a balanced radial force topology should be selected with high electromagnetic performance. Considering the hydraulic bearing mechanism and the installation of the proposed PM synchronous generator (PMSG), the effect of the loading and slot harmonics on the radial magnetic forces is analyzed. Furthermore, by studying the effect of the passive and active electric loads on the PMSGs, radial force characteristics are analyzed to select the operation region. [ABSTRACT FROM AUTHOR]

• Proposed a low-cost and superior design of linear actuator for agricultural robots. • Useful for long-track and multi-actuator operation. • Uses a stator permanent magnet less actuator model to reduce the cost. • Mathematical and finite element model of the design process are proposed. • Experiments are performed to validate the results. The electromagnetic performance improvement of a double saliency (DS) flux modulated (FM)- permanent magnet linear synchronous motors (PMLSM) for agricultural robots is proposed in this work by minimizing the effect of cross-coupling. To understand the effect of the cross-coupling on the electromagnetic performance, a dq axes model of the DS FM-PMLSM is developed and analyzed under different driving conditions. Based on the result obtained, winding modification schemes are proposed to minimize the thrust ripple and improve the zero torque control. The modified models are studied using finite element analysis (FEA) and the model with the best performance is selected for prototyping. The prototype is then tested and the results are validated against the electromagnetic performance obtained using the FEA. This research targeted the development of a low-cost linear actuator for a sapling grower gantry robot that can be used by farmers around the world. [ABSTRACT FROM AUTHOR]

Axial‐flux permanent magnet synchronous machines (AF‐PMSM) using printed circuit board (PCB) windings are attracting interest because of an increased demand for machines with thinner geometries. A critical element in designing these machines is the choice of its PCB winding which should ensure high‐performance characteristics with an efficient use of the PCB surface. However, there is a gap in the knowledge regarding the performance of different PCB topologies. The research reported here is motivated by the need to compare common wave‐type PCB windings stator topologies. Accordingly, overlapping parallel wave, non‐overlapping radial wave and overlapping radial wave PCB winding topologies are assessed, using finite‐element analysis, and compared based on their key performance characteristics such as the generated back‐electromotive forces, inductances and electromagnetic torque. The PCB winding that provides the best torque production is then chosen and manufactured. Experimental tests on the prototyped PCB AF‐PMSM provide validation. [ABSTRACT FROM AUTHOR]

The problem of the computationally efficient analysis of the electromagnetic system with nonlinearity is considered in the proposed work. Unlike the previously proposed proper orthogonal decomposition (POD)-based model order reduction (MOR), the proposed method based on the dynamic mode decomposition works well even under the highly nonlinear system. Using the proposed method, a highly saturated interior permanent-magnet (IPM) motor model is analyzed. Comparisons in terms of the radial air-gap flux density and torque are made with that of the full and POD-based models. The results show that the proposed method is capable of giving a good approximation of the full model of the IPM motor. Also, a reduction in the computational time can be achieved compared with that of the traditional POD-based MOR. [ABSTRACT FROM AUTHOR]

This paper presents a novel parametric design analysis of the magnetic sensor module used to find mover positions in linear motors. The proposed framework utilizes a computationally inexpensive proper orthogonal decomposition-dynamic mode decomposition-based model order reduction (MOR), coupled with a multiparameter moment matching method. The model is then utilized by a moment-based probabilistic design optimization method that considers the manufacturing uncertainties to find the optimal sensor design. A magnetic sensor module is designed for employing the proposed framework, and the results show that: 1) the proposed MOR technique is accurate; 2) the reliability analysis performed during the probabilistic design optimization can help to reduce the excessive non-compliance costs for the manufacturers; and 3) the combined framework is able to significantly expedite the optimal design search. [ABSTRACT FROM AUTHOR]

This paper presents a design approach for a magnetic sensor module to detect mover position using the proper orthogonal decomposition-dynamic mode decomposition (POD-DMD)-based nonlinear parametric model order reduction (PMOR). The parameterization of the sensor module is achieved by using the multipolar moment matching method. Several geometric variables of the sensor module are considered while developing the parametric study. The operation of the sensor module is based on the principle of the airgap flux density distribution detection by the Hall Effect IC. Therefore, the design objective is to achieve a peak flux density (PFD) greater than 0.1 T and total harmonic distortion (THD) less than 3%. To fulfill the constraint conditions, the specifications for the sensor module is achieved by using POD-DMD based reduced model. The POD-DMD based reduced model provides a platform to analyze the high number of design models very fast, with less computational burden. Finally, with the final specifications, the experimental prototype is designed and tested. Two different modes, 90° and 120° modes respectively are used to obtain the position information of the linear motor mover. The position information thus obtained are compared with that of the linear scale data, used as a reference signal. The position information obtained using the 120° mode has a standard deviation of 0.10 mm from the reference linear scale signal, whereas the 90° mode position signal shows a deviation of 0.23 mm from the reference. The deviation in the output arises due to the mechanical tolerances introduced into the specification during the manufacturing process. This provides a scope for coupling the reliability based design optimization in the design process as a future extension. [ABSTRACT FROM AUTHOR]

This paper presents an accurate initial pole position (IPP) estimation method for a surface mounted permanent magnet synchronous motor (PMSM) without the use of pole sensors. To estimate the IPP, the proposed method uses the concept of reference frame. In this method, three torque commands, separated by 45° electrically from each other, are applied to the PMSM. Using the reference torque commands, moving distances are measured and transformation matrix is applied to eliminate the load torque term. Finally, the IPP is determined using the secant method. The IPPs under no load and at specific loaded condition are measured. The result of the load condition is compared with the previously proposed two reference frame method. The proposed method gives better result under load condition, compared with the two reference frame method, which fails to give satisfactory result under load condition. [ABSTRACT FROM AUTHOR]

A new method to detect the mover position of a linear motor is proposed in this paper. This method employs a simple cheap Hall Effect sensor-based magnetic sensor unit to detect the mover position of the linear motor. With the movement of the linear motor, Hall Effect sensor modules electrically separated 120° along with the idea of three phase balanced condition ( va + vb + vc = 0 ) are used to produce three phase signals. The amplitude of the sensor output voltage signals are adjusted to unit amplitude to minimize the amplitude errors. With the unit amplitude signals three to two phase transformation is done to reduce the three multiples of harmonic components. The final output thus obtained is converted to position data by the use of arctangent function. The measurement accuracy of the new method is analyzed by experiments and compared with the conventional two phase method. Using the same number of sensor modules as the conventional two phase method, the proposed method gives more accurate position information compared to the conventional system where sensors are separated by 90° electrical angles. [ABSTRACT FROM AUTHOR]

• An electro-mechanical actuator system for CNC-Lathe is proposed • Electro-mechanical actuator aims to substitute the traditional hydraulic CNC lathes • A whole mechatronics system operation with different modes are proposed • Different tests are performed to validate applicability of the actuator A superior model of a novel electromechanical actuator for the computer numerical controlled (CNC) lathe has been proposed. The proposed actuator aims to achieve a high thrust of 50 kN and a spindle speed of 6000 RPM. Furthermore, a ball screw drawbar is used in the proposed model to reduce friction losses and improve mechanical efficiency. The clutch, which decides the operation mode transition in the actuator is designed by combined operation of friction plates and solenoid operated air-piston. The improved mechanical efficiency of the drawbar has helped in the reduction of the torque-speed rating of the actuator drive motor. Moreover, In terms of system power consumption, the proposed actuator consumes 90% lower power than its hydraulic counterpart. Different tests are performed on the prototype to validate its performance and machining precision. [Display omitted] [ABSTRACT FROM AUTHOR]

• Proposes an alternative method to scavenge power from transmission lines to power vibration deicing robots. • The energy harvester uses the electromagnetic field around the transmission line. • Proposes a nonlinear mathematical mode to have an initial system level design of the energy harvester. • Proper test platform has been developed to validate the performance of the energy harvester. This paper proposed the nonlinear modeling and a full-scale testing method for an electromagnetic energy harvester (EMEH) used to power-up a vibration de-icing robot used in power transmission line. The aim of the proposed work is to have an detailed analytical model of the EMEH on MATLAB environment which is capable of considering the EMEH ferromagnetic core material nonlinear characteristic in the design stage and can provide a fast and accurate analytical model with different design parameters for manufacturing. The nonlinear model is derived by considering Norton equivalent circuit of the EMEH with a nonlinear Norton equivalent inductance. With the nonlinear model design data, a prototype is manufactured and different performance tests such as the validation for the Norton equivalent circuit parameters, AC-DC conversion, and maximum power transfer from the EMEH using the discontinuously conducting DC-DC converters are conducted. [ABSTRACT FROM AUTHOR]

• Model-Based design of a 60 kW nonsalient-pole PMSG is proposed. • The model-based design considers different subsystems. • Mechanical constraints, power electronics, control logics, and speed profiles are used to generate κ. • κ is combined with machine geometric coefficients to realize the PMSG model. This paper proposes the model-based design methodology of a 60-kW direct drive variable speed permanent magnet synchronous generator (PMSG) used in an urban water pipeline energy harvesting system. The whole study aims to design the PMSG considering different system parameters of the energy harvesting system such as the mechanical parameters, electric circuit, power electronics and the variable speed drive operation. The electric and geometric parameters of the PMSG is then designed based on different design constraints imposed by the system. To incorporate the effect of the variable speed drive into the PMSG electric parameters, this work introduces a parameter called κ , which can map the electric parameter variations with the variation of the PMSG input speed profile. This proposed work achieved a successful coupling among the system mechanical and variable speed drive parameters with the PMSG electric and geometric parameters. The coupling is performed in a python-based environment which couples MATLAB and Altair FLUX. The results are tested and validated against the desired values of the PMSG which shows a good agreement among different results. This whole design process can be useful in achieving a model-based design that can provide a detail analysis option before prototyping and testing different components of the harvester system. [ABSTRACT FROM AUTHOR]

• Proposed operation needs to ensure a high torque (>1 KNm) magnetic coupling. • A radial flux-CPMC (RF-CPMC) with magnet retaining rings and a flux concentrating-CPMC (FC-CPMC) are compared. • The electromagnetic and electromechanical characteristics are used for comparison. • Based on the installation environment and the magnet use, RF-CPMC is prototyped and tested. This paper presents design and comparative study of high torque coaxial permanent magnet couplings (CPMC) for the use in a tidal current generation (TCG) system. Two different models such as a radial flux-CPMC (RF-CPMC) with magnet retaining rings and a flux concentrating-CPMC (FC-CPMC) with inner and outer rotor yoke changed by retaining rings are analyzed to find the best model under certain design constraint conditions to achieve a minimum pull-out torque of 1.0 kNm. Moreover, the effect of the electromechanical characteristics such as the radial force, stress and deformation are analyzed for both models. Based on the analysis it is found that both RF-CPMC and FC-CPMC are capable of producing the pull-out torque higher than 1.0 kNm, however considering the installation environment and the magnet use, RF-CPMC is selected for prototyping, which is tested using a 3 MW induction motor based dynamometer system to compare its torque production capability with respect to the simulated model. The comparison shows that the prototype is capable of producing the required amount of pull-out torque. [ABSTRACT FROM AUTHOR]

• Transmission line robots use batteries or diesel generators as a power source. • There is a need to find a sustainable and greener alternative as a power source. • Purpose is served by using a dual-core electromagnetic energy harvester. • The electromagnetic design, analytical model, airgap shape design are considered. • 3D-finite element coupled with MATLAB in python is used to analyze the harvester. The present work proposes the design process of a novel dual-core electromagnetic energy harvester (EMEH) for the use in a deicing robot, used on power transmission lines. The EMEH is designed with a dual-core where Silicon (Si) and Nickel (Ni) steels have been used in order to take advantage of both materials characteristics. An analytical model for the EMEH has been proposed in this paper which is compared with the 3D finite element method (FEM) based model of the EMEH under the same design specification. Moreover, considering the magnetic equivalent circuit model of the EMEH, equivalent circuit parameters are determined. Furthermore, to obtain the impedance matching and to extract the maximum real power from the EMEH, power optimization circuit consisting of a capacitor and a buck-boost converter is proposed and the parameters for the power optimization circuit are evaluated. To validate the effectiveness of the EMEH and its power optimization circuit, a co-simulation design platform is developed using the 3D-FEM and MATLAB coupled in a python-based environment. On the co-simulation platform, the charging of a rechargeable battery of 15 V is verified. [ABSTRACT FROM AUTHOR]

This article proposes the design and driving mechanism of a single drive motor integrated electromechanical actuator system for the application in computer numerical control (CNC) lathe machines. The electromechanical actuator is designed in such a way that it can replace the conventionally used hydraulically powered headstocks of the lathe machine. To achieve a drawbar thrust of 50 kN and a spindle speed of 4000 r/m, a detailed design with an explanation of different internal parts of the electromechanical actuator is presented. The production ready model was simulated to select the safety factor of the whole system and to enquire the amount of deformation when 50 kN thurst is generated. A prototype is manufactured based on the analysis model and is tested for different modes of operation. The experimental results validate the capability of the electromechanical actuator to produce the require drawbar thrust of 50 kN and spindle speed of 4000 r/m. [ABSTRACT FROM AUTHOR]