Abstract
This paper describes the design process of a 10 kW 19 000 r/min high power density surface mounted permanent magnet synchronous machine for a directly coupled pump application. In order to meet the required specifications, a compact machine with cooling channels inside the slots and flooded airgap has been designed through finite element (FE) optimization. For high power density, high-speed machines, an accurate evaluation of the power losses, and the electromechanical performance is always extremely challenging. In this case, the completely flooded application adds to the general complexity. Therefore, this paper deals with a detailed losses analysis (copper, core, eddy current, and mechanical losses) considering several operating conditions. The experimental measurements of ac copper losses, as well as the material properties (BH curve and specific core losses) including the manufacturing process effect on the stator core, are presented. Accurate 3-D FE models and computational fluid dynamics analysis have been used to determine the eddy current losses in the rotor and windage losses, respectively. Based on these detailed analysis, the no-load and full-load performance are evaluated. The experimental results on the manufactured prototype are finally presented to validate the machine design.
Highlights
Integrated pump driven motors are widely used in aerospace electrical hydraulic actuators where reliability and size are critical
The design of a high performance interior permanent magnet machine rated at 46.6 kW, 1500 rpm for a hydraulic motor-pump application is discussed in [8]
In [10], the power losses analysis of a 100 kW, 20000 rpm, 6 poles, four phases, permanent magnet synchronous motor (PMSM) fault tolerant drive for pump applications is investigated and very important suggestions for improving the efficiency are provided
Summary
Integrated pump driven motors are widely used in aerospace electrical hydraulic actuators where reliability and size are critical. Removing shaft seals results in a reduction in the risk of oil leakages, while the thermal improvement comes from the fact that the coolant (oil in the case at hand) in the pumping system can be be used to cool the electrical machine itself Various examples of this concept in terms of electro hydraulic actuators (EHA) can be found in literature [1,2,3]. Ahmed Al-Timimy*, Paolo Giangrande*, Michele Degano*+,, Zeyuan Xu*,Giovanni Lo Calzo, Michael Galea*, Chris Gerada*+ are with the Power Electronics, Machines and Control Group, the University of Nottingham, Nottingham, UK. He Zhang is with the PEMC Group, the University of Nottingham Ningbo China, Ningbo, China. This means that no mechanical advantage is present in the system indicating the need for a high power density, high speed and very robust electrical machine
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