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High-speed solid-rotor induction machines (HSIMs) are popular within high-speed (HS) applications because of their high rotor structural integrity and their fairly well-established manufacturing process guaranteeing high quality series products. Designing a new HS electric machine requires a multidisciplinary team to accomplish the machine performance desired. In case of a HS machine design, the components and applied materials often reach their physical limits at the rated operating condition. Therefore, the design process is highly iterative and, thus, a systematic approach has a high potential to reduce the time of the design phase significantly. In this article, a systematic design process is proposed for a modular, multimegawatt (MMW) HSIM with three radial active magnetic bearings. The process includes a traditional multidisciplinary design flow with extra critical aspects of MMW HS machines: manufacturability, bearing system, housing, and operating unit. In addition, the manufactured machine is reported. The proposed systematic design process is described, including several multidisciplinary critical design aspects of HS machinery. [ABSTRACT FROM AUTHOR]

This article proposes an analytic coupled magneto-thermal analysis of an axial-flux (AF) permanent-magnet-assisted (PMA) eddy-current brake (ECB) at high-temperature working conditions. In the topology investigated, permanent magnets (PMs) are placed into stator slot openings to increase the braking torque production capability. This modification enables to control the magnet flux by altering the dc excitation current. However, the utilization of PMs will make the construction vulnerable at high operating temperatures simply because the magnet properties and the brake capability are strongly dependent on temperature. Such problems require complex coupled multiphysics finite-element analyses to obtain the actual brake performance. The proposed approach offers a simple and effective solution that consists of magnetic and thermal models, which are coupled to each other in the time domain. The nonlinear electrical, magnetic, and thermal properties are influenced by the temperature variation in time. An AF-PMA-ECB prototype is manufactured to validate the proposed coupled models and the experimental studies confirm that the proposed approach provides very practical results to determine the working conditions of the AF-PMA-ECB at high-temperature operations. [ABSTRACT FROM AUTHOR]

5-kW high-efficiency induction motor is analyzed using two-dimensional (2-D) open-source platform and the results are compared with commercial software and measurements. The importance of equivalent circuit parameters in 2-D analyses is highlighted. The noncommercial and commercial software give similar results. The motor is further analyzed in the 2.5-D domain and the results are compared with measured results. The losses obtained with 2-D, 2.5-D, and using the IEC segregation procedure of losses procedure are compared. The performance of an induction machine depends significantly on different parameters such as air gap and stator tooth tip height. Their impact on losses is studied with open-source finite-element analysis. The benefit of this open-source platform in the electrical motor analysis is the ability to use parallel-computing effectively and reduce the time required to solve the electromagnetic problem. Other benefits are the transparency of all features of the software and license-free usage. It is concluded that in 2-D analyses, the open-source software can be used on industrial-scale problems as it showed acceptable results for losses, and lower computational time when using appropriate mortar and conforming boundary conditions. [ABSTRACT FROM AUTHOR]

New global energy efficiency classification standard IEC 61800-9-2 for frequency converters and motor systems has been recently launched. It classifies the energy efficiency of the converters and motor-drive systems and introduces three different methods to determine voltage-source converter (VSC) losses for the classification. In here, experimental tests are carried out using the input–output method and the calorimetric method to determine the losses and efficiency of a 160-kW commercial VSC. The measurement results with these two independent methods are compared and the uncertainty of the methods is analyzed. The converter electric input and output power distributions are analyzed in the frequency domain and are used further to estimate the electric power measurement uncertainty. The measurement uncertainty related to losses obtained with the input–output method is compared with the loss difference between the two methods. This is the first research work to accurately evaluate the experimental methods for the determination of the power losses and examine the validity of the energy efficiency classes of the frequency converters according to new IEC61800-9-2. An urgent need to update the loss boundaries of the IE-classes has been found and the measurement uncertainty effect on the IE-classification is discussed. [ABSTRACT FROM AUTHOR]

A high demand for electrification of the transport sector has resulted in a need to provide compact and reliable electric power trains where the electric machine is a key element. The cooling system has a strong impact on the specific torque and power capability of the machine. The selection of the cooling solution should not be based on the steady-state cooling performance only but also on the transient characteristics owing to the typical operational load nature of the propulsion system, where the load is not continuous (as it usually is in industrial applications), but it frequently varies in time depending on the vehicle type and the driving style. This article investigates in detail the cooling capabilities of a direct winding liquid cooling solution and compares it with a traditional frame liquid cooling arrangement in the transient condition. As a result of the comparison, it was found that the location of heat removal close to the heat source makes the temperature transient time faster, which allows to apply overload operating points more frequently. [ABSTRACT FROM AUTHOR]

This paper introduces a new nonlinear multidisciplinary design approach (NMDA) for axial-flux (AF) eddy current brakes (ECBs). The proposed NMDA is developed by nonlinear magnetic–thermal–structural coupled modeling. The nonlinear behaviors of the AF-ECB covering the BH curve, resistivity, heat capacity, thermal conductivity, and the temperature are jointly analyzed in time domain to investigate the actual brake properties and to determine brake operating range. In this paper, the nonlinear magnetic modeling based on two-dimensional (2-D) reluctance network is studied by a modified Newton–Raphson method. Furthermore, the nonlinear thermal modeling is carried out by lumped-parameters considering the change of heat capacity, thermal conductivity, and the temperature and updating the data in the evaluation process. Finally, the nonlinear structural modeling is performed to obtain the deflection and the mechanical safety factor of the brake. The nonlinear modeling methods in the proposed NMDA are validated by independent 3-D electromagnetic, thermal, and structural finite element analyses (FEAs), and the proposed NMDA is tested with two different AF-ECB prototypes. The experimental results confirm that the proposed NMDA has high accuracy, and compared to 3-D-FEA approaches, it provides a fast solution to predict the AF-ECB performance. [ABSTRACT FROM AUTHOR]

A high-speed squirrel-cage induction machine requires a totally different design compared to the traditional squirrel-cage industrial motor because of the mechanical limitations caused by the high speed. This results in a more complicated rotor construction and expensive material selection, and sets higher standards for the manufacturing precision. The objective of this paper is to demonstrate the design aspects, material selection, and manufacturing of a squirrel-cage rotor for high-speed applications. In this paper, the rotor dimensioning approach based on equations and data analysis is presented. Rotor material selection and construction topology influence on the electrical machine design are discussed. The results are illustrated with the design of a 6-kW, 120 000-r/min induction machine for a turbo circulator. The influence of rotor parameters on the electromagnetic performance of the designed machine is demonstrated. Mechanical stresses for different topologies are studied with finite-element method analysis. Several manufacturing methods for producing a high-precision rotor are described and compared. The presented rotor design approach, which enables high electromagnetic performance and robust construction, is verified by the testing of a prototype. [ABSTRACT FROM AUTHOR]

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]

High-speed (HS) electrical machines provide high system efficiency, compact design, and low material consumption. Active magnetic bearings (AMBs) bring additional benefits to the HS system, such as elimination of the friction losses, reduced wear and maintenance, and a built-in monitoring system. HS drivetrains are usually designed for specific applications and require a high level of integration. This paper describes a design method of the HS electrical machine supported by AMBs, considering their mutual influence on the system performance. The optimization procedure, which takes into account both the electrical machine and bearing designs, is developed. The optimization is based on a multiobjective genetic algorithm. The selected optimization parameters include the AMB and machine dimensions. The optimization objectives cover the electrical machine performance and the rotordynamics. The results of the proposed optimization algorithm are implemented in the constructed 350-kW, 15 000-r/min induction machine with a solid rotor supported by AMBs. The prototype tests verify the design and optimization results. [ABSTRACT FROM AUTHOR]

This paper presents an analysis of three different electrical machine topologies for a turbo circulator application. The electrical machines are designed to operate with 6 kW output power at 120 000 r/min. This paper demonstrates the design aspects of one solid rotor squirrel cage induction motor and two permanent magnet synchronous machines. The machines are compared using electromagnetic, thermal, and mechanical analyses. The benefits and disadvantages of each topology under study are discussed. For other high-speed applications presented, a comparative approach helps in selecting the suitable electrical machine topology by analyzing the performance criteria discussed. The prototype construction of one of the topologies is analyzed. [ABSTRACT FROM AUTHOR]

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]

In permanent magnet synchronous machines (PMSM), depending on the machine application, different types of permanent magnets (PM) can be used. The most common PMs are ferrite magnets, neodymium iron boron magnets (NdFeB), and samarium cobalt magnets (SmCo). The selection of a suitable magnet for a particular machine design depends on the magnet properties: remanence, conductivity, mechanical rigidity, losses, and demagnetization characteristics. Usually, the possibility of hysteresis losses in PM materials is neglected. In this paper, however, it is demonstrated that possible hysteresis losses have to be evaluated in the machine design. It is shown by measurements and simulations that in some machine designs, hysteresis losses in NdFeB, SmCo, and ferrite magnets can be a source of significant additional ac losses that may lead to too high PM operating temperatures and a reduction in the machine efficiency. [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 proper real-time system identification method is of great importance in order to acquire an analytical model that sufficiently represents the characteristics of the monitored system. While the use of different time-domain online identification techniques has been widely recognized as a powerful approach to system diagnostics, the frequency-domain identification techniques have primarily been considered for offline commissioning purposes. This paper addresses issues in the online frequency-domain identification of a mechanical system with varying dynamics; particular attention is paid to detect the changes in the system dynamics. A closed-loop online identification method is presented that is based on a sliding discrete Fourier transform at a selected set of frequencies. The method is experimentally validated by a closed-loop controlled servomechanism with a limited stroke and time-varying parameters. [ABSTRACT FROM PUBLISHER]

This paper presents an energy efficiency analysis of a 37-kW standard squirrel-cage induction motor under sinusoidal and nonsinusoidal supply. The motor losses are analyzed using the conventional IEC loss segregation method and also numerically modeled using finite-element simulations. The measured and simulated loss components are compared with three different modulation methods. The overall simulated losses are in good agreement with the measured ones, but there exist differences in the loss components. [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]

An electrical and mechanical design process for a traction motor in a hybrid bus application is studied. Usually, the design process of an electric machine calls for close cooperation between various engineering disciplines. Compromises may be required to satisfy the boundary conditions of electrical, thermal, and mechanical performances. From the mechanical point of view, the stress values and the safety factors should be at a reasonable level and the construction lifetime predicted by a fatigue analysis. In a vehicle application, the motor has to be capable of generating high torque when accelerating, and in normal operation, the losses of the machine should be low to be able to cool the machine. Minimization of the no-load iron losses becomes a very important electrical design requirement if the traction motor and the generator are mechanically connected with an internal combustion engine when it is operating as the only source of torque. The manufacturing costs of the motor are also taken into account in this paper. [ABSTRACT FROM PUBLISHER]

Synchronous reluctance motors (SynRMs) are gaining in popularity in industrial drives due to their permanent magnet-free, competitive performance, and robust features. This paper studies the power losses in a 90-kW converter-fed SynRM drive by a calorimetric method in comparison of the traditional input–output method. After the converter and the motor were measured simultaneously in separate chambers, the converter was installed inside the large-size chamber next to the motor and the total drive system losses were obtained using one chamber. The uncertainty of both measurement methods is analyzed and discussed. [ABSTRACT FROM AUTHOR]

High-speed permanent-magnet synchronous machines (HS PMSMs) are a popular topology among modern electrical machines. Suitable applications for such machines are low-power vacuum pumps, compressors, and chillers. This paper describes a systematic design methodology for an HS PMSM using two case studies. The design process for such high-speed (HS) machines is multidisciplinary and highly iterative due to the complex interaction of the many design variables involved. Consequently, no single optimum solution exists, and multiple possible solutions can meet the customer requirements. Practical solutions should be within acceptable thermal limits, should be energy-efficient, and should be rigid enough to withstand the forces exerted during operation. The proposed design flow is divided into steps that are presented in this paper in the form of a flowchart with emphasis on mechanical aspects. Each step represents a task for a thermal, mechanical, or electrical engineer. The features of each step and the prerequisites for moving to the next step are discussed. The described methodology was implemented in the design of two HS PMSMs. The output performance results of the design flow are compared with measured results of the prototypes. The design process described in this paper provides a straightforward procedure for the multidisciplinary design of HS permanent magnet electrical machines. [ABSTRACT FROM PUBLISHER]

Laminated busbar systems are commonly used in power electronic converters because of their low stray inductance. While the electromagnetic analysis of a busbar system is widely presented in the literature, there is a lack of accurate thermal modeling. In this paper, the thermal analysis of the busbar system is presented. An analytical lumped parameter thermal model (LPTM) of the busbar system is developed. The LPTM is applied to the fast estimation of the mean temperature and temperature-dependent power losses of the busbars by the proposed algorithm. Joule losses produced by nonsinusoidal currents flowing through the busbars in the converter are estimated. The skin and proximity effects, which have a strong influence on the ac resistance of the busbars, are considered in the loss estimation. Thus, a comprehensive electrothermal model of the busbar system is developed, which is of practical use in the converter design. It allows optimizing the stray inductance, material consumption, and cost of the busbar system as long as the specified temperature limits are not exceeded. The finite-element method thermal modeling validates the developed LPTM. Laboratory measurements in two operating points of the converter have been performed, and they show good correlation with the simulation results. [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]