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A modular motor drive (MMD) is composed of multiple identical pole drive units (PDUs), which consist of a concentrated stator winding fed by a dedicated power electronic converter module. To exploit the full flexibility and reliability of these MMDs, they are equipped with multiple controllers, operating as synchronized peers, and each driving only a limited set of PDUs. An MMD can hence be considered as a multiagent system, in which all the agents cooperate to deliver a certain torque demand. The goal of this work is to distribute this torque demand among the agents of a modular drive in a completely decentralized way, in order to comply with the flexibility and reliability of the hardware, while still taking into account the present condition of each agent. A deterministic consensus algorithm is used for this purpose, in combination with decentralized proportional integral (PI) current controllers. Communication is only allowed between neighboring agents, to limit the communication load. It is shown in this article that the total torque demand is delivered, under healthy conditions as well as during agent malfunctions and with nonidentical agents. The concept is demonstrated on a modular axial-flux permanent magnet synchronous machine with 15 PDUs that are assigned to five agents. [ABSTRACT FROM AUTHOR]

In this article, a circulating-current-excited switched reluctance generator system using a standard diode rectifier is proposed and examined. It features a dc power source connected in series with the ring-connected windings, which provides the dc-bias current as the excitation current in the windings. Using a series-connected dc power source, a dc-bias current is easily realized in the ac winding. Compared with the existing machine having dc-bias in the ac winding, the proposed generator can provide dc power with a standard diode rectifier. Less active legs and no rotor position sensor are needed for the control of the circulating current of the proposed generator, which increases the reliability of the generation system. The system configuration and the operation principle are introduced in detail. Then, the electromagnetic performance of the proposed generation system is analyzed at both open-circuit and load conditions. The asymmetric current distributions are deduced and verified by the simulations. At last, the prototype is tested under varied operation conditions and the experiments agree well with the analysis. [ABSTRACT FROM AUTHOR]

In this paper, a circulating-current-excited switched reluctance generator system with the diode rectifier is comparatively studied with a field-current-separated switched reluctance generator. By using a DC power source connected in series with the winding to provide the circulating current, a controllable excitation field is established in the proposed generator. To highlight the influence of this DC voltage source, the injected field current of the field-current-separated generator is kept the same as the circulating current of the circulating-current-excited generator. Then, both advantages and disadvantages of the generators are summarized. The circulating-current-excited switched reluctance generator system inherits both the advantages of good reliability of the separated-winding generator by using the diode rectifier and low copper loss of the integrated-winding machine by combining the AC and DC current in one set of windings. Furthermore, two more practically conventional field-current-separated generators are also compared with the proposed generator in terms of the external characteristics. These two conventional generators have different winding configurations. At last, the analysis is verified by experiments. [ABSTRACT FROM AUTHOR]

In this article, a dc-link structure feasible for integration with the circumscribing polygon modular integrated drives is proposed. The proposed dc-link structure combines both the dc-link capacitors and the bus-bar together and integrates them with the machine and the converter modules without increasing the outer diameter of the integrated machine/converter structure. A generic design methodology for the proposed dc-link structure is provided and applied on a reconfigurable 15 stator coils concentrated winding axial flux machine for all its possible phase configurations. The design methodology presented in this article involves the determination of the required dc-link capacitance and the multiphysics design of the bus-bar. The parasitics of the bus-bar part of the proposed dc-link structure are evaluated using electromagnetic finite element method (FEM) models and their influence on the dc-link waveforms is evaluated. Due to the expected high ambient temperature inside an integrated drive, electromagnetic and computational fluid dynamics (CFD) models are developed for the proposed dc-link structure to evaluate the loss density and the temperature distribution of the bus-bar to ensure reliable operation. An experimental setup is built to validate the design methodology. [ABSTRACT FROM AUTHOR]

To meet the demand for increasingly high power density in electric drives, the concept of a so-called integrated modular motor drive has emerged. The machine is composed of multiple identical modules, which receive individual control signals for multiphase control, to reduce unwanted stator current harmonics. Each module is equipped with its own power electronic converter, which is integrated in the machine housing. This integration imposes strict constraints on the dc-link capacitor design. To reduce the dc-link current ripple, and hence relax the design constraints on the dc-link capacitor, without compromising the possibility to eliminate unwanted stator current harmonics by means of multiphase control, a new interleaving strategy is proposed in this article. The n modules of the machine are split into p subgroups of m modules for interleaving, while the n-phase control is preserved. An analytical model, simulations and experimental results are provided for a 4 kW test setup, confirming that multiphase control can be combined with interleaving. As a result, both the stator current harmonic distortion and the dc-link current ripple can be reduced simultaneously. [ABSTRACT FROM AUTHOR]

Concentrated windings are favourable in electric motors with a high torque density because of the achievable high winding filling factor and their short end-windings. Nevertheless, the performance of the cooling system has the biggest impact on the reachable torque density limits. This article introduces a thermally conductive insert piece that encloses the stator end-windings with extensions in the stator slots. This results in an extended contact surface between the stator windings and the machine housing, which is advantageous for the conductive heat transfer. The introduced indirect cooling concept is compatible with traditional cooling techniques such as forced air and water jacket cooling. The concept is illustrated with 3D thermal finite element simulations, including the anisotropic thermal material properties, as well as ad hoc measurements on a stator pole unit mock-up of a 6-4 switched reluctance machine. Where the stator with reference cooling system was only able to handle a continuous current density of 19.0 A/mm $^2$ , 26.5 A/mm $^2$ could be obtained in the winding of the stator with the extended end-winding cooling inserts. [ABSTRACT FROM AUTHOR]

In this article, a fault tolerant deadbeat controller is proposed, which is able to compensate for both partial and uniform demagnetization faults in axial flux permanent-magnet synchronous machines with double rotor, even with asymmetric defects in both rotors. For this purpose, the system model used by the deadbeat controller is equipped with a look-up table of the back-emf, in function of the mechanical rotor position. This look-up table is generated by means of an analytical model based on the magnetic vector potential. With this information, the deadbeat controller can eliminate both the additional bias and ripple in the stator current components caused by demagnetization faults. The proposed control strategy is validated on a 4 kW test set-up of an axial flux permanent-magnet synchronous machine with yokeless and segmented armature topology fed by a three-phase two-level voltage source inverter, both by simulations and experiments. Key performance indicators concerning bias and ripple of the current components illustrate the superior performance of the proposed control strategy in comparison to a standard deadbeat controller without an up-to-date look-up table of the back-emf. [ABSTRACT FROM AUTHOR]

This paper proposes a method to design an electrical variable transmission (EVT) of which the stator and inner rotor contain a distributed three-phase winding, and the outer rotor is equipped with permanent magnets and a dc-field winding. The main problem with the design of EVTs is that the modeling relies on time-consuming finite-element (FE) calculations. Studying the effect of design changes is, therefore, a cumbersome task. To minimize the need for FE calculations, scaling laws are applied, which reduce the computational effort to a matter of milliseconds per design. Therefore, the losses of multiple scaled designs can be analyzed for a given load cycle while taking constraints into account such as maximum torque. By presenting this data in a performance map, the optimal design regarding the losses is easily deduced. To validate the presented methodology, FE calculations, measurements, and available literature are used. [ABSTRACT FROM AUTHOR]

Squirrel‐cage induction machines (IMs) with indirect field‐oriented control are widely used in industry and are frequently chosen for their accurate and dynamic torque control. During operation, however, temperature rises leading to changes in machine parameters. The rotor resistance, in particular, alters, affecting the accuracy of the torque control. The authors investigated the effect of a rotor resistance parameter mismatch in the control algorithm on the angular rotor flux misalignment and the subsequent deviation of stator currents and motor torque from their setpoints. Hence, an online, data‐driven torque compensation to eliminate the temperature effect is proposed to enable robust torque‐controlled IMs. A model‐based analysis and experimental mapping of the temperature effect on motor torque is presented. A temperature‐torque lookup‐table is subsequently implemented within the control algorithm demonstrating the ability to reduce the detrimental effect of temperature on torque control. Experimental results on a 5.5 kW squirrel‐cage induction motor show that the proposed data‐driven online temperature compensation method is able to reduce torque mismatch when compared to having no temperature compensation. Up to 17% torque mismatch is reduced at nominal torque and even up to 23% at torque setpoints that are lower than 20% of the nominal torque. A limited torque error of <1% remains in a broad operating range. [ABSTRACT FROM AUTHOR]

This paper presents a simple and efficient magnetic equivalent circuit (MEC) model for surface axial flux permanent magnet synchronous machines. The MEC model is used to solve all the electromagnetic properties of the machine including the no load, full load voltages, cogging torque, torque ripple, and stator iron core losses. Moreover, this approach can be extended for all surface permanent magnet synchronous machines. The main novelty of this approach is the development of a static system, which accounts for the rotation. The model takes into account the rotor rotation via time-dependent permanent magnet magnetization sources. The static system matrix facilitates a very fast solving. In addition, to take into account the three-dimensional (3-D) effect, a multislicing of the machine in the radial direction is done. This boosts the simulation time to only 60 s for six slices and 50 time steps including the nonlinear behavior of the stator elements with a great accuracy. Additionally, the number of elements in the MEC can be adjusted to reduce the computational time. This model is verified by means of 3-D and two-dimensional (2-D) multislice finite-element models. In addition, experimental validations are also provided at the end. [ABSTRACT FROM AUTHOR]

Control topologies in electric drive applications commonly aim at minimizing the dissipated power in the system to guarantee energy-efficient operation. Especially in vehicle electrification, loss minimization is the main objective in the supervisory control loops as this is directly related to the range of the vehicle. Advanced drive systems are characterized by an elevated complexity but require nevertheless a real-time control strategy to be implemented. Appropriate model abstraction, enabling real-time viability with a reliable system representation, is found in convex mapping procedures of the dissipated power in the drive components. These reduced-order models are generally obtained based on model information solely. This paper proposes a methodology to recursively enhance the reliability of the convex loss approximations. An instantaneous power flow estimation is assessed based on a unification of model expectations and sensor data. Using this information, a proper adaptation to the underlying convex loss coefficients is then determined. The methodology is validated in simulation for an electric drive on three different case studies. The algorithm is furthermore applied on actual experimental data of an asynchronous drive for validation purposes. Preliminary results demonstrate that the error on the loss assessment is reduced by 55.7%–89.0%. Adaptive convex loss mappings can, therefore, be consulted in practical control structures to ameliorate the reliability of loss minimization control schemes, while still maintaining a computationally efficient format. [ABSTRACT FROM AUTHOR]

Despite the use of state-of-the-art thermal modeling tools in the design stage, the measured thermal behavior of prototype electrical machines can differ significantly from the modeled ones. This paper shows how a thermal model, based on the finite-element method, of an electric machine can be improved using inverse modeling techniques. In a thorough study, a forward high fidelity finite-element thermal model of a 4-kW axial flux permanent magnet (PM) machine is introduced and improved using inverse modeling techniques via noncollocated thermal sensors. Parametric model order reduction of the high fidelity finite-element thermal model based on the moment matching method is performed to make the recovery of the actual thermal parameters characterizing the thermal behavior of the axial flux PM machine tractable. Furthermore, the same reduced order model is used to identify the different power loss components in the machine. Experimental results confirm that the presented two-stage approach is capable of identifying the thermal parameters and losses with high accuracy. [ABSTRACT FROM AUTHOR]

Increasing performance requirements for electrical machines such as energy efficiency and torque density require a multiphysics design approach. In these designs, many machine parts very often combine multiple functions, such as electromagnetic, thermal, and mechanical, to keep the design compact and reduce the overall weight, or introduce nonconventional materials in electrical machines. In this paper, epoxy potting techniques are used to keep the different stator parts of a yokeless and segmented armature axial flux PM machine together, and it focuses mainly on the multiphysics aspects of the epoxy resins as well as on their implications on the overall stator design. In this multiphysics design approach, the effect of specific epoxy resin parameters such as maximum service temperature, thermal conductivity, Brookfield viscosity, tensile strength, and coefficient of thermal expansion, on the electromagnetic, thermal and mechanical behavior of the stator are examined. Epoxy resin parameters are evaluated in detailed experiments on small test samples, and finally, measurements on a full prototype 4 kW, 2500 rpm stator are performed. [ABSTRACT FROM AUTHOR]

A time-harmonic analytical model is presented for a combined study of demagnetization and rotor eccentricity in single-stator double-rotor axial flux permanent magnet synchronous machines (AFPMSM). Demagnetization defects are modeled by scaling the magnetization “square wave” by magnetization factors for each individual magnet on both rotors. Static, dynamic, and mixed rotor eccentricities are modeled using a permeance function. The original contribution of the model is that asymmetrical defects in the two air gaps of the machine can be described with acceptable accuracy and limited additional calculation time. The model is validated with a finite element method and experiments in both healthy and defected operations. Because the model has a short computation time, it is useful for real-time condition monitoring of any AFPMSM with double air gap and either concentrated or distributed windings. [ABSTRACT FROM PUBLISHER]

The paper studies demagnetization detection in axial flux permanent magnet synchronous machines of the yokeless and segmented armature (YASA) type. In YASA machines, asymmetrical defects can occur: the demagnetization defects in the permanent magnets of both rotors differ from each other. Many techniques can indicate that there is a defect, even if it is an asymmetrical defect, but cannot detect which rotor has the defect, i.e., exactly locate the asymmetrical defect. In this paper, a method is proposed to detect and locate asymmetrical demagnetization defects in AFPMSMs. The method is useful for real-time condition monitoring of demagnetization defects, or as virtual temperature sensor for the magnets. A sensing coil is placed in each air gap. An analytical model is constructed, which uses the demagnetization defect and the three-phase current as input and calculates the sensing coil back-EMF. Sensing coils back-EMF data are combined with the data from the analytical model to solve an electromagnetic inverse problem. The results are the demagnetization amount and location of the demagnetization defect. The method is validated with the experimental data. [ABSTRACT FROM AUTHOR]

An electrical variable transmission (EVT) is an electrical machine consisting of a stator and two concentric rotors. It is a competitive alternative for power split devices used in current series–parallel hybrid electric vehicles (HEVs). Although tending to have high power densities, permanent magnet (PM) machines suffer from no-load iron losses. Since the torque interaction between stator and outer rotor is low during large time intervals, the EVT in this paper possesses a flux bridge with dc-field winding to modulate the stator field, while maintaining the inner rotor flux linkage. In this paper, a torque controller is proposed that optimally combines the stator, dc-field, and inner rotor currents in order to minimize the copper and iron losses in every operating point of torque and speed on both rotors. Also the electromagnetic coupling between both rotors is considered. It turns out that there are two optimal load angles for the stator currents, of which one of the two is dominant depending on speed and torque. The control is tested on a 120 kW prototype EVT, and measurement results are given to illustrate the optimal performance obtained with the proposed torque control. In addition, efficiencies are measured in order to support the statements made concerning the proposed method. [ABSTRACT FROM PUBLISHER]

The rotor discs in axial flux permanent magnet (PM) machines have similar properties as a radial fan, and therefore, the convective cooling may have a significant influence on the thermal design of these machines. To research the impact of convective cooling on the thermal properties of axial flux PM machines, a coupled electromagnetic and thermal model is introduced in this paper. This technique models a segment of the stator and the rotor only and links them together by analytical equations of the convective heat transfer at different boundaries of the machine model. This results in an accurate and time efficient multiphysics model. The coupled electromagnetic and thermal modeling technique is validated with measurements on a 4 kW axial flux PM machine having the yokeless and segmented armature topology. [ABSTRACT FROM AUTHOR]

In this paper, a simple lamination stacking method for the teeth of an axial flux permanent-magnet synchronous machine with concentrated stator windings is proposed. In this simple lamination stacking method, only two lamination profiles are used and are stacked alternately. To evaluate the performance of this stacking method, a comparison is made between the proposed method with two profiles and a conventional stacking method that uses different profiles for each lamination layer, using a multilayer 2-D finite element model. [ABSTRACT FROM PUBLISHER]

Accurate temperature estimation inside an electrical motor is key for condition monitoring, fault detection, and enhanced end-of-life duration. Additionally, thermal information can benefit motor control to improve operational performance. Lumped-parameter thermal networks (LPTNs) for electrical machines are both flexible and cost-effective in computation time, which makes them attractive for use in real-time condition monitoring and integration in motor control. However, the accuracy of these thermal networks heavily depends on the accuracy of its system parameters, some of which are difficult to calculate analytically or even empirically and need to be determined experimentally. In this paper, a methodology for the thermal condition monitoring of long-duration transient and steady-state temperatures in an induction motor is presented. To achieve this goal, a computationally efficient second-order LPTN for a 5.5 kW squirrel-cage induction motor is proposed to apprehend the dominant heat paths. A fully thermally instrumented induction motor has been prepared to collect spatial and temporal temperature information. Using the experimental stator and rotor temperature data collected at different motor operating speeds and torques, the key thermal parameter values in the LPTN are identified by means of an inverse methodology that aligns the simulated temperatures of the stator windings and rotor with the corresponding measured temperatures. Validation results show that the absolute average thermal modelling error does not exceed 1.45 °C with maximum absolute error of 2.10 °C when the motor operates at fixed speed and torque. During intermittent motor-loading operation, a mean (maximum) stator temperature error of 0.38 °C (0.92 °C) was achieved and mean (maximum) rotor errors of 2.11 °C (3.40 °C). These results show the validity of the proposed thermal model but also its ability to predict in real time the temperature variations in stator and rotor for condition monitoring and motor control. [ABSTRACT FROM AUTHOR]