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This paper proposes an electromagnetic damping generator (EDG), which is a novel downhole generator for the rotary steerable system (RSS). The EDG is designed to solve the problem of unstable voltage output by the RSS generator. The generator is designed by integrating a traditional generator and an eddy current retarder (ECR). The system converts the excess kinetic energy of the EDG rotor into heating energy by the principle of eddy-current braking and resistance heating. The electromagnetic finite element models of the generator part and ECR part are established and solved by computer. The voltage and torque generated by the generator part and the braking torque of the ECR part are predicted. In the bench test, When the input power is 2537 W < Pinput < 3304 W, the EDG is able to output 300.8 V. When the input power is 3304 W, the output voltage of the ordinary generator is 346 V. The EDG can be adjusted by a decrement of up to 45.2 V to output the rated voltage. The problem of generator output voltage instability in the RSS is solved when mud flow is unstable. [ABSTRACT FROM AUTHOR]

To solve theproblems of an insufficient braking moment for the eddy current retarder at high speed, a small braking moment and slow response of the hydraulic retarder at low speed, and a low power density of the existing electromagnetic hydraulic retarder(EHR), a novel radially distributed electromagnetic-hydraulic retarder(R-EHR) was proposed. The R-EHR fully absorbs the advantages of the braking characteristics of hydraulic retarders and eddy current retarders. The cooling fluid is used to realize the braking of the hydraulic part. At the same time, it acts on the heating surfaces to improve the torque of the electromagnetic part. In this paper, finite element models of the flow field and electromagnetic field are established to predict braking performance. The braking performance of the R-EHR is obtained by bench test, the error between the simulation and experimental data is compared, and the experimental data are analyzed. The results show that the proportion of electromagnetic braking torque in the novel R-EHR is more reasonable. The braking torque increased by 26% and the power density increased by 37.5% at 2000 RPM compared to that of the EHR. The R-EHR can control the braking torque only by adjusting the current, thus simplifying the control system. [ABSTRACT FROM AUTHOR]

As an auxiliary brake element, the eddy current brake is widely used to ensure safe driving in heavy vehicles due to its noncontact braking characteristics. It is important to increase the power density of the eddy current brake and suppress the thermal derating of its braking performance. According to the principle of the eddy current braking and current skin effect, a decline in temperature can greatly increase the eddy current density of the low-frequency electromagnetic device. In this paper, a new heat dissipation method is proposed to cool the heating surface of the eddy current brake directly. The electromagnetic field model and the flow-heat coupling model are established to predict and analyze the steady-state temperature distribution and braking torque. A new type of internal liquid cooling eddy current brake prototype was manufactured for a bench test. The experimental data prove that the computational model is effective. The calculation results show that the new internal liquid cooling eddy current brake has improved heat dissipation advantages. [ABSTRACT FROM AUTHOR]

Heavy-duty vehicles are generally equipped with non-contact hydraulic retarders or eddy current retarders to ensure safe driving during downhill conditions. The torque of the hydraulic retarder is large when the rotor rotates at a high speed, but the torque is small when the rotor rotates at a low speed. As another commonly used retarder, the eddy current retarder has a large torque at a low speed and a low power density at a high speed. High torque at full speed is the vehicles’ requirement for the auxiliary brake system, with no retarders can achieve this goal perfectly alone. Encouragingly, the braking performances of these two kinds of retarders are complementary. Based on the above properties, the eddy current-hydraulic hybrid retarder (EHR) is designed applying the principle of eddy current and the principle of hydraulic braking. In this novel HER, both sides of the rotor are used for hydraulic braking, and the outer ring of the rotor generates eddy currents. The finite element models of the flow field and the electromagnetic field are established separately and solved by computer to predict the braking torque of the EHR. The prototype was developed and the braking performance of the EHR was obtained through the bench tests. Comparing the theoretical calculation results and experimental data, the braking characteristics of the EHR are analyzed. At low speed, the EHR mainly relies on the eddy current braking, whereas at high speed, it relies on both eddy current and hydraulic braking. Moreover, the control of the EHR can be realized only by adjusting the braking torque of the eddy current part, which simplifies the control system. [ABSTRACT FROM AUTHOR]

Braking torque is the most important performance parameter for a permanent magnet retarder used in heavy vehicles. This paper proposes a model of the permanent magnet retarder for braking torque at different speeds considering the skin effect, the magnetic leakage, and the actual path of the eddy currents. Based on the magnetic equivalent circuit and the piecewise function method, the static and the transient air-gap flux density models are established, and their accuracy is verified by comparison to the finite element method (FEM). The permeability distribution curve of the retarder stator is obtained by a simple permeability-measuring instrument, considering the skin effect on the permeability of the stator. Thus, the effective permeability function of the stator is obtained at different rotational speeds, and the transient air-gap flux density model is optimized using the effective permeability function. The simulation results showed that the optimized transient air-gap flux density of the calculation model was in good agreement with the FEM. Finally, the calculation model of the eddy current braking torque was verified by the bench test. [ABSTRACT FROM AUTHOR]

To overcome the large power consumption, the braking torque heat recession, and installation difficulties for trailers of eddy current retarder (ECR), a novel self-excited, liquid-cooled, and bridge integrated retarder (SLB-EMR) is proposed in this paper. The structure and work principle of the SLB-EMR are described particularly. Based on the magnetic equivalent circuit (MEC) method, an analytical model of the eddy current braking torque considering magnetic flux leakage and end effect is established. The power generation and braking performance of the SLB-EMR are predicted by the finite element analysis (FEA). We carried out tests for the eddy current braking torque, the heat-fade of braking torque, the no-load loss torque, and natural characteristics of the SLB-EMR respectively. The test results showed that the eddy current braking torque reached 2592 N·m at 1000 r/min. The braking torque declined by 15.5 % after the braking 12 min continuously. The analytical model of eddy current braking torque, and FEA model of the generator and eddy current brake were verified by the test. Compared with the ECR, the SLB-EMR had no-power consumption and low head-fade. [ABSTRACT FROM AUTHOR]

We propose a novel dual air-gaps and liquid-cooled eddy current retarder (ECR) based upon observing the (1) heat fade of the continuous braking and (2) large rotor weight of the traditional ECR for heavy vehicles. The new ECR maintains a low working temperature because of the liquid cooling stator structure. The eddy current distribution and braking torque characteristic curves are obtained by finite element method (FEM). Combining with 3-D FEM, Kriging approximation model is employed to optimize the structural parameters of rotor tooth. Based on the optimization method, the number of rotor teeth is determined to be 12. The braking torque increases by 14.8% after optimization and the rotor tooth weight decreases by 9.5%, which reduces the adverse influence on the vehicle transmission system. The bench test was carried out to verify the optimized calculation results and the braking torque can be stepless controlled by adjusting the excitation current. Compared with traditional ECR, the dual air-gaps and liquid-cooled ECR has better continuous braking performance and is more suitable for heavy vehicle auxiliary braking. [ABSTRACT FROM AUTHOR]

Aiming at the heat fade of the continuous braking and low power density of traditional eddy current retarder (ECR) for heavy vehicles, a new liquid-cooled and flywheel-type eddy current retarder is proposed. The new ECR can keep a low working temperature because of the cooling type. It is assembled between the engine and the clutch, which can effectively improve the braking power density. The transient electromagnetic field of the ECR is solved by the finite-element method, and the braking torque characteristic curve is obtained. The thermal-fluid coupling field is analyzed using the computational fluid dynamics method. Finally, the structure parameters optimization of the rotor tooth is carried out. The braking torque increases by 14.8% and the weight of rotor tooth decreases by 9.5% after optimization. The test results show that the heat fade ratio of the new ECR braking torque is only 8.6%, but that of the traditional ECR is 46.7%. [ABSTRACT FROM AUTHOR]

To overcome the serious thermal recession problem that has been associated with the braking torque of conventional eddy current brakes, and to conserve energy, this paper has proposed a novel self-excited eddy current retarder (S-ECR). The design includes a stator with an internally cooled channel, a rotor with double salient poles, and a built-in generator. The electromagnetic field analysis and the performance analysis of the S-ECR were carried out using the finite-element method. The S-ECR performance was tested at a test bench. The test results showed that the calculated braking torque and the generator performance were in reasonable agreement with the measured results. The braking performance did not obviously diminish during the continuous braking stage. When the speed was 1500 r/min and the exciting current was 30 A, the braking torque could reach 1600 N·m. [ABSTRACT FROM AUTHOR]

A liquid-cooled eddy current retarder (ECR) with a dual salient poles design is proposed in this paper. Finite element models were developed to perform transient magnetic analysis and steady-state conjugate heat transfer analysis. The braking torque, eddy current field and thermal field of the retarder were each predicted. The retarder was subjected to two sets of tests on a test bench, to obtain the braking torque at various rotational speeds, while utilizing two different magnetomotive forces, respectively, and the torque was also tested while maintaining a constant rotational speed, for a specific amount of time. The good agreement shown between the calculations and measured data of the braking torque served to validate the analysis method. The experiments also showed that the braking torque of the retarder decreased more slowly than the braking torque of conventional ECRs in continuous operation. [ABSTRACT FROM AUTHOR]

This paper proposes a novel permanent magnet retarder (PMR) structure that uses water cooling to improve the braking performance of conventional PMR for heavy vehicles. A finite element model for a water-cooled PMR was developed by considering the temperature dependence of magnetic characteristics and heat conductivity. The eddy current and temperature distribution were analyzed using the magneto-thermal coupled method. Retarder performance was tested at a test bench. The test results show that the calculated temperature and braking torque agreed fairly well with the measured results. PMRs can maintain a low working temperature by using water cooling. Compared with air-cooled retarder, this retarder's braking torque does not decrease much under continuous working conditions. [ABSTRACT FROM PUBLISHER]