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Although it is well known that the magnetic properties of electrical steel can be deeply affected by the cutting process, it is still not clear how to accurately evaluate these effects on a prototyped machine on its final shape, especially at a high frequency or a high power rating. This research provides a more practical method for accurate measurement of magnetic losses in electrical steel with consideration of material degradation effects due to the cutting process. Unlike other similar studies, these investigations are conducted not only on a few laminations but also on a complete electrical machine core. For a fair comparison between both cases, backlack bonding is used for lamination stacking since it is the most non-damaging joining technique. Two different test setups are used to measure the steel performance at a wide range of frequency and input power. Furthermore, a full axial length stator of a switched reluctance machine (SRM) is used as a case study to identify the magnetic properties of NO20 electrical steel. Additionally, by comparing the results obtained from the individual laminations and the assembled stator, the extra losses due to the cutting process and material degradation are extracted accurately. [ABSTRACT FROM AUTHOR]

This paper compares four prototype Synchronous Reluctance Motors (SynRMs) having an identical geometry of iron lamination stacks in the stator and rotor. Two different stator winding layouts are employed: a conventional three-phase star connection and a combined star-delta winding. In addition, two rotors are considered: a conventional rotor without magnets and a rotor with ferrite magnets. The performance of the four SynRMs is evaluated using a two-dimensional (2D) Finite Element Model (FEM). For the same copper volume and current, the combined star-delta-connected stator with Permanent Magnets (PMs) in the rotor corresponds to an approximately 22% increase in the output torque at rated current and speed compared to the conventional machine. This improvement is mainly thanks to adding ferrite PMs in the rotor as well as to the improved winding factor of the combined star-delta winding. The torque gain increases up to 150% for low current. Moreover, the rated efficiency is 93.60% compared to 92.10% for the conventional machine. On the other hand, the impact on the power factor and losses of SynRM when using the star-delta windings instead of the star windings is merely negligible. The theoretical results are experimentally validated using four identical prototype machines with identical lamination stacks but different rotors and winding layouts. [ABSTRACT FROM AUTHOR]

In this paper, a set of correlations for the windage power losses in a 4 kW axial flux permanent magnet synchronous machine (AFPMSM) is presented. In order to have an efficient machine, it is necessary to optimize the total electromagnetic and mechanical losses. Therefore, fast equations are needed to estimate the windage power losses of the machine. The geometry consists of an open rotor-stator with sixteen magnets at the periphery of the rotor with an annular opening in the entire disk. Air can flow in a channel being formed between the magnets and in a small gap region between the magnets and the stator surface. To construct the correlations, computational fluid dynamics (CFD) simulations through the frozen rotor (FR) method are performed at the practical ranges of the geometrical parameters, namely the gap size distance, the rotational speed of the rotor, the magnet thickness and the magnet angle. Thereafter, two categories of formulations are defined to make the windage losses dimensionless based on whether the losses are mainly due to the viscous forces or the pressure forces. At the end, the correlations can be achieved via curve fittings from the numerical data. The results reveal that the pressure forces are responsible for the windage losses for the side surfaces in the air-channel, whereas for the surfaces facing the stator surface in the gap, the viscous forces mainly contribute to the windage losses. Additionally, the results of the parametric study demonstrate that the overall windage losses in the machine escalate with an increase in either the rotational Reynolds number or the magnet thickness ratio. By contrast, the windage losses decrease once the magnet angle ratio enlarges. Moreover, it can be concluded that the proposed correlations are very useful tools in the design and optimizations of this type of electrical machine. [ABSTRACT FROM AUTHOR]

The rotor design of Synchronous Reluctance Motors (SynRMs) has a large effect on their efficiency, torque density and torque ripple. In order to achieve a good compromise between these three goals, an optimized rotor geometry is necessary. A finite element method (FEM) is a good tool for the optimization. However, the computation time is an obstacle as there are many geometrical parameters to be optimized. The flux-barrier widths and angles are the two most crucial parameters for the SynRM output torque and torque ripple. This paper proposes an easy-to-use set of parametrized equations to select appropriate values for these two rotor parameters. With these equations, the reader can design a SynRM of distributed windings with a low torque ripple and with a better average torque. The methodology is valid for a wide range of SynRMs. To check the validity of the proposed equations, the sensitivity analysis for the variation of these two parameters on the SynRM torque and torque ripple is carried out. In addition, the analysis in this paper gives insight into the behavior of the machine as a function of these two parameters. Furthermore, the torque and torque ripple of SynRMs having a rotor with three, four and five flux-barriers are compared with three literature approaches. The comparison shows that the proposed equations are effective in choosing the flux-barrier angles and widths for low torque ripple and better average torque. Experimental results have been obtained to confirm the FEM results and to validate the methodology for choosing the rotor parameters. [ABSTRACT FROM AUTHOR]

The aim of this paper is to calculate the static eccentricity (SE) of a double rotor axial flux permanent magnet (AFPM) machine by using a general analytical model. The flux density in the air gap under healthy conditions is calculated firstly, where the axial and circumferential magnetic flux densities are obtained using a coupled solution of Maxwell's equations and Schwarz-Christoffel (SC) mapping. The magnetic flux densities under SE conditions are calculated afterwards using a novel bilinear mapping. Some important electromagnetic parameters, e.g., back electromotive force (EMF), cogging torque and electromagnetic (EM) torque, are calculated for both SE and healthy conditions, and compared with the finite element (FE) model. As for the double rotor AFPM, SE does not contribute much effect on the back EMF and EM torque, while the cogging torque is increased. At each calculated section, FE models were built to validate the analytical model. The results show that the analytical predictions agree well with the FE results. Finally, the results of analytical model are verified via experimental results. [ABSTRACT FROM AUTHOR]

Metal additive manufacturing (AM) has been growing remarkably in the past few years. Thanks to the advantages of unmatched flexibility and zero material waste, this clean technology opens the door for new design solutions with greater material efficiency, which are not possible through conventional machining techniques. In this paper, we provide a technology overview of metal AM techniques that can be utilized in a wide range of applications, including constructing electrical machines. Different techniques of metal AM are discussed and compared. Additionally, the impact of the material forms (powder/wire) on printing speed and quality are studied. Based on the industrial and technical literature, this paper provides a comprehensive review of metal AM in the fabrication of electrical machines and their applications. This includes the current state of the art and associated benefits of AM in these applications. [ABSTRACT FROM AUTHOR]

To control the current of a surface mounted permanent magnet synchronous machine fed by a two-level voltage source inverter, a large variety of control algorithms exists. Each of these controllers performs differently concerning dynamic performance and control- and voltage quality, but also concerning sensitivity to demagnetization faults. Therefore, this paper investigates the performance degradation of three advanced predictive controllers under a partial demagnetization fault. The three predictive controllers are: finite-set model based predictive control, deadbeat control, and a combination of both previous algorithms. To achieve this goal, the three predictive controllers are first compared under healthy conditions, and afterwards under a partial demagnetization fault. A PI controller is added to the comparison in order to provide a model-independent benchmark. Key performance indicators, obtained from both simulations and experimental results on a 4 kW axial flux permanent magnet synchronous machine with yokeless and segmented armature topology, are introduced to enable a quantification of the performance degradation of the controllers under a demagnetization fault. A general conclusion is that the deadbeat controller shows superior control quality, even under partial demagnetization. [ABSTRACT FROM AUTHOR]

This paper proposes a new driving method for switched reluctance motors (SRMs) using the standard full-bridge inverter. In spite of changing the internal structure of an SRM, the proposed method uses an extra ring structure circuit to make it possible for the inverter to drive the SRM. Next to the standard converter, a controllable DC source is needed. With theoretical analysis and calculation, the reference value of the circulating current in the ring structure was determined and the new method was proven via simulation. A comparison was made with the conventional method for driving an SRM: the asymmetric H-bridges. Also, the current studies were then made to confirm that the SRM could be controlled without lowering the performance of the machine. Experimental verification was also made under different conditions, as well as comparison with the simulation results. [ABSTRACT FROM AUTHOR]

In this paper, the effect of some geometrical parameters on the steady state average temperature of the stator core, the winding and the permanent magnets of the yokeless and segmented armature (YASA) axial flux permanent magnet synchronous machine (AFPMSM) is studied. The geometrical parameters selected for the study are the air gap length, the inward heat extraction fin thickness and the permanent magnet thickness. These parametric studies make it possible to obtain a better trade-off between power density and efficiency. These investigations are very helpful in correlating the values of the geometrical parameters to some specific desired performance criteria like not going below some desired minimum efficiency, limiting the temperature of specific part to some maximum value for maximization of lifetime and also determination of the allowed speed range to limit the temperatures lower than the critical values. This is important specifically for the synchronous machines due to the fact that the speed value affects both the losses and the heat transfer convection coefficients. The air gap length has a direct effect on the overall machine losses and the air gap convection coefficient and hence on the temperature of the machine. As the fins are between the stator windings, a thicker fin reduces the space for copper windings and hence increases the losses, but at the same time improves heat evacuation. In addition, the effect on the temperature is studied of the speed variation, which influences both the losses and the convection coefficients of the machine. Every study is made based on coupled electromagnetic and thermal models. The results are obtained from analytical electromagnetic and thermal models verified by finite element simulations and validated experimentally on a 4 kW yokeless and segmented armature axial flux machine. [ABSTRACT FROM AUTHOR]

The lifetime of an electrical machine mainly depends on the thermal overloading. Modern day applications of electrical machines on one hand require compact machines with high power density, while on the other hand force electrical machines to undergo frequent temperature cycling. Until recently, in the case of electrical machines, the main factor related to the degradation of the winding insulation was thought to be the thermal oxidization of the insulation materials. It has now been revealed that thermal overloading can also induce mechanical stress in the windings of electrical machines, which over time could lead to fatigue and degradation. In this paper, a comprehensive study of the thermally induced mechanical stress in the windings of an electrical machine is presented. The study is performed using combined thermo-mechanical models. The numerical results are validated by experiments on a segmented stator winding set-up. [ABSTRACT FROM AUTHOR]

To find the temperature rise for high power density yokeless and segmented armature (YASA) axial flux permanent magnet synchronous (AFPMSM) machines quickly and accurately, a 3D lumped parameter thermal model is developed and validated experimentally and by finite element (FE) simulations on a 4 kW YASA machine. Additionally, to get insight in the thermal transient response of the machine, the model accounts for the thermal capacitance of different machine components. The model considers the stator, bearing, and windage losses, as well as eddy current losses in the magnets on the rotors. The new contribution of this work is that the thermal model takes cooling via air channels between the magnets on the rotor discs into account. The model is parametrized with respect to the permanent magnet (PM) angle ratio, the PM thickness ratio, the air gap length, and the rotor speed. The effect of the channels is incorporated via convection equations based on many computational fluid dynamics (CFD) computations. The model accuracy is validated at different values of parameters by FE simulations in both transient and steady state. The model takes less than 1 s to solve for the temperature distribution. [ABSTRACT FROM AUTHOR]