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With increasing worries about the environment, there is a rising focus on saving energy in various industries. In the e-mobility industry of electric motors, permanent magnet synchronous motors (PMSMs) are widely utilized for saving energy due to their high-efficiency motor technologies. However, challenges like environmental degradation from rare earth development and difficulties in controlling magnetic field fluctuations persist. To address these issues, active research focuses on the wound field synchronous motor (WFSM), known for its ability to regulate field current efficiently across various speeds and operating conditions. Nevertheless, compared with other synchronous motors, the WFSM tends to exhibit relatively lower efficiency and torque density. Because the WFSM involves winding both the rotor and the stator, it results in increased copper and iron losses. In this article, a model that enhances torque density by inserting permanent magnets (PMs) into the rotor of the basic WFSM is proposed. This proposed model bolsters the d axis magnetic flux, thereby enhancing the motor's overall performance while addressing environmental concerns related to rare-earth materials and potentially reducing manufacturing costs when compared with those of the PMSM. The research methodology involves a comprehensive sensitivity analysis to identify key design variables, followed by sampling using optimal Latin hypercube design (OLHD). A surrogate model is then constructed using the kriging interpolation technique, and the optimization process employs a micro-genetic algorithm (MGA) to derive the optimal model configuration. The algorithm was performed to minimize the use of PMs when the same torque as that of the basic WFSM is present, and to reduce torque ripple. Error assessment is conducted through comparisons with finite element method (FEM) simulations. The optimized permanent-magnet-assisted WFSM (PMa-WFSM) model improved efficiency by 1.08% when it was the same size as the basic WFSM, and the torque ripple decreased by 5.43%. The proposed PMa-WFSM derived from this article is expected to be suitable for use in the e-mobility industry as a replacement for PMSM. [ABSTRACT FROM AUTHOR]

Electric motors play a crucial role in modern industrial and domestic applications. With the trend of more and more electric drives, such as electric vehicles (EVs), the requirements for electric motors become higher and higher, e.g., high power density with good thermal dissipation and high reliability in harsh environments. Many efforts have been made to develop high performance electric motors, such as the application of advanced novel electromagnetic materials, modern control algorithms, advanced mathematical modeling, numerical computation, and artificial intelligence based optimization design techniques. Among many advanced magnetic materials, soft magnetic composite (SMC) appears very promising for developing novel electric motors, thanks to its many unique properties, such as magnetic and thermal isotropies, very low eddy current loss, and the prospect of low-cost mass production. This paper aims to present a comprehensive review about the application of SMC for developing various electric motors for electric drives, with emphasis on those with three-dimensional (3D) magnetic flux paths. The major techniques developed for designing the 3D flux SMC motors are also summarized, such as vectorial magnetic property characterization and system-level multi-discipline robust design optimization. Major challenges and possible future work in this area are also discussed. [ABSTRACT FROM AUTHOR]

In most multiobjective optimization problems of electrical machines, the weighted function method is used to convert them into single-objective optimization problems. This paper applies a kind of new multiobjective evolutionary algorithms (MOEAs), called adaptive multiobjective black hole (AMOBH) algorithms, to achieve effective multiobjective optimization of a tubular coreless linear permanent magnet synchronous motor (LPMSM). To reduce the computation cost of the MOEAs, a one-layer analytical model (AM) is presented for the tubular coreless LPMSM in this paper. The accuracy of the simplified one-layer AM is verified by comparisons with multilayer AM and finite element analysis (FEA) under different structure parameters. It is found that the simplified AM has good accuracy and can decrease the computation cost significantly. AMOBH algorithm is subsequently introduced. The optimal Pareto front with regard to thrust, copper loss, and permanent magnet volume are analyzed, and more diversified optimization results are provided. The final Pareto solution can be selected directly by practical physical values according to the application requirements. Finally, a prototype is fabricated for the selected design; its experimental results are provided and compared with those of the FEA results. [ABSTRACT FROM AUTHOR]

A new axial flux permanent magnet machine (AFPM) with soft magnetic composited (SMC) cores is proposed for electric vehicle (EV) application in this paper. As its windings are wound on the stator ring core, it can be regarded as a toroidally wound internal stator (TORUS) machine. With the adopted SMC material for stator core, this machine has the benefits of 3-D magnetic flux properties. The windings and SMC cores can be designed to form a very compact structure, and thus, the torque density can be improved greatly. To obtain the a good flux concentrating ability, two TORUS machines are designed and analyzed, one is with NdFeB magnet for high-performance EV application and the other is with the cheap ferrite magnet for low-cost application. The 3-D finite-element method is used to analyze the electromagnetic parameter and performance. For performance comparison, a commercial AFPM with yokeless and segmented armature P400 is used. [ABSTRACT FROM AUTHOR]

Flux reversal linear rotary permanent magnet actuator (FR-LRPMA) is a two-degree-of-freedom actuator with two ferromagnetic (Fe) poles and two permanent magnet (PM) poles mounted on the surface of each stator pole. The flux linkage waveform of the actuator is more sinusoidal than that of the traditional topology, which are analyzed by the ideal linear model of one stator section of the proposed actuator. In order to reduce the amplitudes of the cogging torque and detent force, a key space gap parameter of the FR-LRPMA between the Fe pole and PM pole is studied in the circumferential and axial directions. The expressions of cogging torque and detent force are derived by the magnetomotive force analytical method, which are used to obtain the optimal space gap parameter value. The electromagnetic characteristics of the actuator are analyzed by the finite-element method. The amplitudes of cogging torque and detent force are reduced and the back electromotive force waveform is more sinusoidal than that of the original topology, which are verified by the experiment. [ABSTRACT FROM AUTHOR]

Compared with rotary electrical machines in linear drive applications, linear machines without rotary–linear motion conversion equipment can have higher force density and efficiency. Linear superconductivity machines (LSMs), consisting of high-performance superconducting magnets instead of permanent magnets, can offer very high force density and efficiency compared with other linear machines, such as linear induction machine, linear permanent magnet machine, and so on. In this paper, LSMs with different stators and winding configurations are investigated, specifically LSMs with concentrated or distributed windings, and unilateral or bilateral side stators. The electromagnetic parameters and performance of these LSMs are calculated and compared by using the finite element method, and then, the main difference between various design methods in LSM has been presented. [ABSTRACT FROM AUTHOR]

In this paper, a new 3-D flux transverse flux flux switching permanent magnet machine (3-DFTFFSPMM) is proposed. The cost of this machine is very low since both the soft magnetic composite (SMC) cores and ferrite magnets are very cheap, and the performance of this machine is good due to the special designed topology. For the qualitative analysis and initial design, the simplified power equation is developed to find the optimal design, and the 3-D finite-element method is applied for the quantitative analysis. Considering it is very difficult to obtain a special ferrite magnet in the current market, the 3-DFTFFSPMM for prototyping in the workshop is improved with a new design. For the prototyping, the SMC cores are made by using the manual die compacting technology. Last, the efficiency map of these two machines is obtained to judge the operational performance. [ABSTRACT FROM AUTHOR]

In this paper, a general analytical model is proposed to calculate the back electromotive forces of various manufacturing imperfections in the double-rotor axial flux permanent magnet machine. First, the axial and circumferential flux density in the air gap under healthy condition is developed by Maxwell’s equations and Schwarz–Christoffel mapping. Second, the equations of air gap length and radii are introduced to calculate the flux density with manufacturing imperfections. The back EMFs of each case are calculated. For each case, finite-element (FE) method models are developed to validate the analytical model, and the results show that the analytical model predictions match well with the FE results. Finally, the analytical model is verified by experimental results. [ABSTRACT FROM AUTHOR]

In this paper, various kinds of electrical machines with soft magnetic composite (SMC) cores are compared, based on the qualitative and quantitative comparison methods. In the first part, the performances of five typical electrical machines with SMC cores are qualitatively compared. Simplified power equations for transverse flux, axial flux, and radial flux electrical machines are deduced to show the main difference among them and key design points of each machine. In the second part, the outer rotor claw pole machine (CPM) and outer rotor transverse flux machine (TFM) are comprehensively compared in a quantitative way, based on the three-dimensional finite-element method. It shows that the power capability of the outer rotor CPM is much higher than that of the TFM. On the other hand, the outer rotor CPM has higher cogging torque and no-load losses than the TFM. Furthermore, the four outer rotor radial flux machines are optimized and compared with the outer rotor CPM. The calculated results of the outer rotor TFM are compared with the experiment results, showing that the analysis results match well with the experiment ones. Several useful and interesting conclusions have been obtained for the electrical machines with SMC cores. [ABSTRACT FROM AUTHOR]

This paper presents a robust approach for multidisciplinary design optimization of permanent magnet (PM) motors with soft magnetic composite (SMC) cores to improve their manufacturing quality in batch production. First, a general multidisciplinary design analysis framework is developed for PM-SMC motors, which includes electromagnetic, thermal, modal, and manufacturing analyses. Second, an improved multilevel optimization method is presented to improve the efficiency of the robust optimization. Finally, to demonstrate the effectiveness, a PM-SMC transverse flux machine is investigated. The numerical solutions, including electromagnetic and thermal analyses, are validated by the experimental results. As shown, the proposed method can significantly increase motor’s reliability and greatly reduce the computation cost, which benefits the mass production in industrial applications. [ABSTRACT FROM AUTHOR]

Due to the global winding and 3-D flux, the claw-pole machine (CPM) can exhibit higher torque ability than other types of electrical machines. Using the powder metallurgical technology, the manufacture cost of CPMs made of soft-magnetic composite (SMC) material can be much lower than that of the conventional machines, especially with the low density cores. The performance of SMC motor was improved as the material has undergone through substantial improvement in the last decades. To seek better performance, CPMs with different permanent magnet (PM) rotor structures and SMC cores, including the surface mounted PM motor, surface inset PM rotor, V-type PM rotor, and flux concentrating PM rotor, are designed and the performances compared. The magnetic parameters of these machines are obtained by the 3-D finite-element method, and the analysis method is verified by the experiment of a surface-mounted PM CPM with SMC core. [ABSTRACT FROM AUTHOR]

Soft magnetic composite (SMC) materials are especially suitable for developing electrical machines with complex structure and three-dimensional (3-D) magnetic flux path. In these SMC machines, the magnetic field is in general 3-D and rotational, so the mechanism and calculation of core loss may be quite different from that in traditional electrical machines with laminated steels in which the magnetic field is restrained. This paper investigates the calculation of core loss in a permanent magnet claw pole motor with SMC stator core. First, core loss models are developed based on the experimental data on SMC samples by using a 3-D magnetic property tester. Then, 3-D magnetic time-stepping field finite element analysis (FEA) is conducted to find the flux density locus in each element when the rotor rotates. The core loss is computed based on the magnetic field FEA results by using the developed core loss models. The calculations agree well with the experimental measurements on the SMC motor prototype. [ABSTRACT FROM PUBLISHER]

In this paper, a novel configuration for University of Technology Sydney (UTS) plug-in hybrid electric vehicle (PHEV) is introduced which has only one electric machine functioning as either a motor or generator at a time. For continuous working, more strict requests are made to the drive machine, mainly including good thermal dissipation capability, high torque density, great flux weakening ability, etc. One new laminated structure flux switching permanent magnet machine (LSFSPMM) is proposed in this paper, which stator and rotor are laminated in parallel to the axis. It can make full use of PM flux linkage and reduce the core loss particularly in the high excitation frequency. Based on the 2D model prediction by finite element algorithm (FEA), LSFSPMM has lower cogging torque, higher torque density, greater flux weakening ability, higher efficiency, etc., and hence it can be regarded as one ideal candidate for the UTS PHEV drive system. [ABSTRACT FROM AUTHOR]

A three-dimensional analytical modeling of the magnetic field of the stator-ironless axial flux permanent magnet (AFPM) machine under open-circuit condition is presented in this paper. It involves the analytical solution of the governing field equations in the region between back-irons in the cylindrical coordinate, in which the magnets are assumed to be axially magnetized and have constant relative recoil permeability. The proposed modeling method is applied to a specific AFPM machine, and the analytical results are in good agreement with those of three-dimensional finite element analysis (FEA). [ABSTRACT FROM AUTHOR]

Core-loss prediction is an important issue in design and analysis of permanent-magnet (PM) motors. Because of the diverse structure, flux distribution, and rotational variation of flux, it is difficult to predict the core loss in a machine exactly. In this paper, a core-loss model for the PM motor is introduced in which flux variation loci in different parts of the motor are predicted by carrying out a finite-element transient analysis. Since the flux variation pattern is complicated, an improved equation based on the conventional three-term expression is used for core-loss calculation. The core-loss model is developed totally in ANSYS parametric design language as a parametric model and it can be used easily for different types of PM motors. Calculation and experiments on a high-speed PM motor have shown that the model can produce results that agree with the experimental ones. [ABSTRACT FROM PUBLISHER]

Accurate measurements of magnetic properties of soft magnetic composite (SMC) material are performed on an improved 3-D tester by means of novel precision B-H sensing coils attached to the surface of a cubic SMC specimen. By controlling the adjustable excitation topologies, magnetic properties over wide excitation frequency range from 2 Hz to 1000 Hz are acquired and analyzed. In this paper, the relationship between the magnetic flux density vector B and magnetic field strength vector H has been systematically measured under alternating and 3-D conditions, and the core loss features have been analyzed. Compared with the conventional magnetic properties only at 50 Hz, wide-range-frequency magnetic properties contribute to extending application area of the new SMC electrical machines. [ABSTRACT FROM AUTHOR]

In this paper, one new axially laminated-structure flux-switching permanent magnet machine (ALSFSPMM) with 6/7 (stator/rotor) poles is proposed. Different from the conventional flux-switching permanent magnet machine (FSPMM), the stator and rotor of ALSFSPMM are laminated parallel to the axial direction, which can make full use of PM flux linkage, decrease part magnetic saturation, and reduce the iron loss particularly in the range of high speed. By the 2-D model prediction of finite element algorithm (FEA), ALSFSPMM has lower cogging torque, stronger flux weakening ability, greater torque density, higher efficiency, etc., and hence it is an ideal candidate for the drive system of plug-in hybrid electrical vehicle (PHEV). [ABSTRACT FROM AUTHOR]

In this paper, magnetic properties of soft magnetic composite (SMC) materials under alternating and various rotational magnetizations have been properly measured, modeled, and analyzed at typical frequencies of 5, 50, and 500 Hz. The relationship between the magnetic flux density vector B and magnetic field strength vector H has been systemically studied when the B loci are well controlled to be circles and ellipses in three orthogonal planes of the three-dimensional (3-D) tester. The core loss features against magnetic flux densities with alternating and rotational magnetizations are also compared and analyzed. It is found that the rotational core losses are nearly twice of the alternating core losses at the same magnitude of flux density. Experimental results show that SMC materials have good 3-D features, and great potential for application in rotational magnetic flux machines. [ABSTRACT FROM AUTHOR]

Abstract: Soft magnetic composite (SMC) materials are especially suitable for construction of electrical machines with complex structures and three-dimensional (3D) magnetic fluxes. In the design and optimization of such 3D flux machines, the 3D vector magnetic properties of magnetic materials should be properly determined, modeled, and applied for accurate calculation of the magnetic field distribution, parameters, and performance. This paper presents the measurement of 3D vector magnetic properties and determination of 3D reluctivity tensor of SMC. The reluctivity tensor is a key factor for accurate numerical analysis of magnetic field in a 3D flux SMC motor. [Copyright &y& Elsevier]

An electromagnetic design of a double-sided high temperature superconducting (HTS) linear synchronous motor (HTSLSM) with an HTS bulk magnet secondary is introduced in this paper. A HTS magnetic suspension system is applied to replace the sliding rail to levitate the secondary mover resulting in the HTSLSM moving without sliding friction. The thrust model of the HTSLSM is built using a magnetic circuit method and the thrust characteristics obtained from the model are compared with finite element analysis and practical testing results. The theoretical analysis on the prototype has also been verified by measurements. [ABSTRACT FROM AUTHOR]