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This paper presents a methodology for the analytical computation of the slot leakage inductance of tooth-coil winding permanent magnet synchronous machines. Generalized equations for the slot leakage inductance of the whole phase are derived, suitable for several slot-pole combinations, and meant to be used during the machine design stage. For simplicity, self- and mutual-inductance components are formulated using the classical method with detailed permeance determination for both horizontal and vertical distribution of coil sides in the slots, considering a straight-line path for the flux leakage. Several slot-pole combinations were simulated by means of the finite element (FE) method in order to validate the analytical equations in both approaches, FE and analytical, showing adequate concordance. [ABSTRACT FROM AUTHOR]

Being much more rugged than a rotor made of traditional steel sheets, a solid rotor is frequently used in high-power high-speed induction machines (IMs). Furthermore, by a solid-rotor machine, a higher rotating speed can be achieved. However, the solid rotor also has certain disadvantages, the relatively high solid-rotor eddy-current losses being the most serious one. Basically, solid-rotor eddy-current losses are mainly induced by time–spatial air-gap flux density high-order harmonics. The suppression of the high-order harmonics is the key means to mitigate the rotor eddy-current losses. In this paper, a novel computational model is proposed for evaluating the rotor harmonic eddy-current losses of a 2 MW, 12 000 r/min IM. The model was built on a special machine referred to as a virtual permanent magnet harmonic machine (VPMHM). The model was constructed by applying the finite-element method (FEM), and it is based on the time–spatial harmonics produced by a rotating magnet with sinusoidal magnetization. The VPMHM model links the air-gap flux density harmonics directly to the specific rotor eddy-current losses. Furthermore, according to the proposed model, three options, namely, the use of air-gap permeance modifying notches on the stator teeth, semimagnetic wedges, and their combination, were investigated in detail for mitigating the rotor eddy-current losses in the motor nominal operating point. The results and conclusions in this paper are based on the FEM analysis. [ABSTRACT FROM AUTHOR]

Traditional industrial electrical machines are designed avoiding strong iron saturation in the magnetic circuit. Flux-switching permanent magnet synchronous machines (FSPMSMs), however, differ significantly by their construction and magnetic circuit from the traditional PMSMs. In PMSMs, local saturation in the stator at no load can be avoided by a proper stator tooth and yoke design, but in FSPMSMs, the flux accumulates in the teeth toward the air gap, and the armature steel often becomes heavily saturated in the region close to the air gap. Therefore, it is difficult to avoid local saturation in an FSPMSM, and proper design tools are required to take this saturation into account when the machine is designed. This paper demonstrates the importance of accurate knowledge of steel properties in regions with heavy magnetic saturation. It is shown that especially the design process of an FSPMSM should be supported by an accurate $B - H$ curve of the steel up to 2.2 T and beyond (or at the point where the steel is completely saturated), because it has a significant influence on the overall performance of the machine. [ABSTRACT FROM PUBLISHER]

Efficient cooling is needed, for example, in traction motors which face regularly high torque peaks and generate high stator Joule losses. This paper studies the feasibility of the direct liquid cooling in the thermal management of a low-power low-voltage permanent-magnet machine. A tooth-coil axial-flux permanent-magnet double-stator-single-rotor test machine was first equipped with indirect liquid cooling using water cooling jackets and then with direct winding cooling. The winding material used is a hybrid conductor comprising a stainless steel coolant conduit tightly wrapped with stranded Litz wire. The performance of the motor is examined at various power levels using oil or water as the cooling fluid. The results confirm that the proposed direct cooling method is practical also in small machines, and furthermore, it offers significant improvements in the machine thermal management, especially, in cases where stator Joule losses dominate. [ABSTRACT FROM AUTHOR]

Permanent-magnet synchronous machines (PMSM) are gaining a foothold in a growing number of applications. However, the high cost of these machines compared with the prices of induction motors, whose production process is mature and material costs are low, limits the use of PMSMs with rare-earth permanent magnets in many potential cases. A viable design solution for a PMSM cost reduction is to use low-cost ferrite magnets instead of rare-earth ones. Nevertheless, it is challenging to apply ferrite magnets to a high-power rotor surface magnet PMSM because of their weaker magnetic properties compared with the rare-earth magnets and the risk of irreversible demagnetization. This paper aims to investigate the boundaries and limiting factors for achieving the maximum tangential stress and linear current density at a certain air gap diameter by using rotor surface ferrite magnets. The computed results are validated by a prototype, which was designed within the described boundaries. [ABSTRACT FROM PUBLISHER]

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. [ABSTRACT FROM PUBLISHER]

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. [ABSTRACT FROM PUBLISHER]

Fast methods to estimate iron losses of the permanent magnet traction motor during the drive cycle of the electrical vehicle are compared. The methods use the iron loss information calculated by a finite-element analysis as a function of rotational speed both at no load and with a short-circuited stator to take into account the variable frequency and field weakening of the traction motor. The effect of iron losses on the optimal current components, providing the maximum efficiency, is studied. Several methods yield a good accuracy even based on the no-load iron loss only, but the accuracy can be improved especially in deep field weakening by including the short-circuit iron loss information in the analysis. [ABSTRACT FROM PUBLISHER]

This paper proposes an extended set of variables for numerical optimizations of tooth-coil permanent magnet synchronous machines (TC-PMSMs). The design variables for the extended set are chosen based on the magnetic asymmetries introduced by the saturated core under the loading conditions. The extended set allows to reach considerably higher values of torque density and significant reduction of torque ripple in comparison with a conventional set of optimization variables. The conventional and extended sets are compared on an example of an finite element method simulation of a double-layer winding surface permanent magnet-rotor TC-PMSM. A considerably better optimal machine is obtained when the extended set of variables is utilized. The paper showcases the design and the optimization of electrical machines using only free and open-source software. [ABSTRACT FROM PUBLISHER]

To compete with other types of electrical machines as well as other manufacturers, the performance characteristics of axial-flux permanent-magnet (AFPM) machines should be improved. Reduction of the higher harmonic components from the induced back electromotive force is preferred during design process of an electrical machine. To achieve an almost sinusoidal induced phase voltage, a sinusoidal air-gap flux density distribution should be produced. Furthermore, in order to easy startup and also less noisy performance of electrical machines, the cogging torque of the machine should be reduced. In this paper, the surface-mounted AFPM machines equipped with magnets with different outlines are investigated and the machine performances are computed via 3-D finite-element analysis. According to the obtained results, magnets with sinusoidal outline offer better performance characteristics compared with cylindrical and sector-like magnets. [ABSTRACT FROM PUBLISHER]

Traction motor design significantly differs from industrial machine design. The starting point is the load cycle instead of the steady-state rated operation point. The speed of the motor varies from zero to very high speeds. At low speeds, heavy overloading is used for starting, and the field-weakening region also plays an important role. Finding a suitable field-weakening point is one of the important design targets. At the lowest speeds, a high torque output is desired, and all current reserves of the supplying converter unit are used to achieve the torque. In this paper, a 110-kW 2.5-p.u. starting torque and a maximum 2.5-p.u. speed permanent-magnet traction motor will be studied. The field-weakening point is altered by varying the number of winding turns of machine. One design is selected for prototyping. Theoretical results are verified by measurements. [ABSTRACT FROM PUBLISHER]

Most of the high-power, low-speed, direct-driven permanent magnet synchronous generators for wind energy applications apply a cooling solution where the stator core is divided into a number of substacks. Cooling air is blown through the stator through radial cooling channels formed between the adjacent stator substacks. The use of the stator substacks has an effect on the equivalent length of the generator, and thus, if neglected, leads to an incorrect no-load voltage and synchronous inductance calculation. In this paper, the design issues related to the thermal and electromagnetic design of permanent magnet synchronous machines are highlighted. The analysis starts with a preliminary electromagnetic design. Then, the allowable number and width of cooling ducts are calculated based on the maximum allowable temperatures and fluid flow speed with a thermal resistance network model. The effect of cooling ducts on the no-load voltage and synchronous inductances of the machine are discussed in detail. The calculated no-load voltage and synchronous inductances are used in the analytical performance evaluation. It is shown that the cross-saturation of the synchronous inductances must be taken into account in order to get realistic results. [ABSTRACT FROM PUBLISHER]

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 (BH\max) 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 B\delta[ \Vs/m^2] 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. [ABSTRACT FROM PUBLISHER]

This paper deals with the design of permanent magnet synchronous motors (PMSMs) with ferrite magnets and their comparison with synchronous machines with NdFeB magnets. In recent years, ferrite magnets have become popular due to their rather low cost and, what is more important, due to increasing of the NdFeB magnets cost last time. The progress in ferrite magnet material properties during the latest decade gave rise to their use in high power applications. Their remanent flux density today reaches values beyond 0.4 T, which allows design electrical machines with acceptable performance. In this paper, three designs of ferrite machines are presented and compared with a real PMSM with NdFeB magnets. Furthermore, the influence of the stator winding type and the shape of the slot opening on the PMSM properties will be demonstrated. All machines are designed for the same output power as the original PMSM with NdFeB magnets. This paper demonstrates that ferrite magnets can, to some extent, be used as replacements for the NdFeB magnets in high-efficiency power applications. [ABSTRACT FROM AUTHOR]

A lumped-parameter thermal model is presented for axial flux permanent magnet (AFPM) machines. The model provides the steady-state thermal solution to derive the temperatures at different parts of the machine, including the temperatures in the stator windings and the temperature of the magnets. Temperature-dependent thermal properties of the materials used in the machine construction as well as the stator winding resistance and consequently copper losses require temperature update in accurate design of the machine. Therefore, an iterative coupled electromagnetic and thermal design program is proposed in this study. A 5-kW AFPM generator is designed using the proposed program with regarding the thermal behavior of the machine. Tests performed on the designed machine verify that the defined thermal resistance network has a high ability to predict the nodal temperatures accurately. [ABSTRACT FROM AUTHOR]

Optimal design for an axial-flux permanent magnet synchronous generator (AFPMSG) using genetic algorithm (GA) is presented, and the condition for minimum active material cost is deduced. A computer-aided design procedure based on the results of the GA is proposed. In the design procedure the practical and performance characteristics are taken into account as some restrictions for the object function used in the optimization algorithm. A 30-kW AFPMSG with two parallel connected stators and rotor-surface PMs is designed using the developed program, and then 3-D finite-element analyses are carried out to validate the design procedure. [ABSTRACT FROM AUTHOR]

The energy efficiency of an electro-hydraulic forklift is significantly improved by using a permanent-magnet-synchronous-motor-servo-drive-based direct pump control to control the position of the fork without control valves. This paper provides a short evaluation of the hydraulic system and a more detailed analysis of the losses of the electric machine drive system. A theoretical approach is taken and the results are verified by practical measurements. Finally, possible improvements of the energy efficiency in the suggested system are discussed. [ABSTRACT FROM PUBLISHER]

Mechanical interactions between a wind turbine and a direct-driven permanent-magnet synchronous generator (PMSG) are studied, and a model to analyze the system behavior is suggested. The proposed model can be applied to analyze the mechanical vibrations of direct-driven wind turbine installations both in steady state and in dynamic cases. The cogging torque and torque ripple of the PMSG are used as excitation sources in the mechanical model. Four different permanent-magnet rotor constructions are analyzed. It is shown that the maximum allowable value of the cogging torque of the direct-driven permanent-magnet wind generator in this case is 1.5%–2% of the rated torque even when the corresponding resonance frequency does not occur in the operational speed range of the wind turbine. Furthermore, it was noticed that the resonance caused by the excitation torque should occur at the lowest possible speed. [ABSTRACT FROM AUTHOR]