Design Of Motor Research Articles

Design, FEM analysis and development of switched reluctance motor electric drive for TRI-wheeler E-vehicle application

Electric vehicles have seen substantial growth in recent years in the emerging economies of the world. The current market scenario of E-vehicles is dominated by PMSM or BLDC motors due to their higher torque-to-power density, and efficiency with added performance metrics of the motor. However, the higher capital cost of permanent magnets makes the motor designers to consider an alternative to magnetic motors, the so-called Switched Reluctance Motors (SRM). With proper FEM analysis and controller design, if SRMs can able to achieve the performance metrics of a PMSM/BLDC, it will be a breakthrough in the automotive sector with affordable prices. Based on the aforementioned facts, this research work focuses on SRM as a viable alternative to the existing PMSM/BLDC motor. The work concentrates on the design and development of an 8/6 SRM for a Tri-wheeler E-vehicle application. The designed motor is fabricated, tested and controlled by WAVECT, an FPGA-based real-time digital controller which is used to control the commutation of the 8/6 SRM. The yielded response satisfactorily proves that the designed 8/6 SRM can be effectively used for the Tri-wheeler E-vehicle application, thereby paving the way for sustainable energy conservation in the automotive sector.

Design and comparative analysis of three-phase conventional and E-core stator hybrid reluctance motor for electric three-wheeler

Design and comparative analysis of three-phase conventional and E-core stator hybrid reluctance motor for electric three-wheeler

Optimization design of a new hybrid magnetic circuit motor

The combination of permanent magnets and electrically excited windings creates an air gap magnetic field. The development of a hybrid magnetic circuit motor with an adjustable magnetic field is of great significance. This article introduces a hybrid magnetic circuit motor design that combines salient pole electromagnetic and permanent magnets. A tubular magnetic barrier has been designed to reduce inter-pole leakage and enhance the usage rate of permanent magnets in the hybrid magnetic circuit motor. The optimum eccentricity of the rotor has been accurately designed, resulting in an improved sinusoidal distribution of the air gap magnetic density waveform. An analysis of the static composite magnetic field under various excitation currents has been conducted, showcasing the capability of the hybrid magnetic circuit motor to stably adjust the air gap flux density level and output torque. A prototype has undergone comprehensive trial production and testing, conclusively confirming the machine’s superior output performance.

High Torque and Increased Wear Redefine Gearbox Longevity in Electric Motors

This study explores the accelerated wear of gearboxes driven by electric motors compared to gearboxes in combustion engines, highlighting the important role of lubrication quality. The continuous operation of sugarcane processing machines requires durable gearboxes, especially under the high torque load of electric motors. By analyzing gearbox wear through standard load tests and various lubricant qualities, the findings reveal that superior lubricants significantly reduce wear. These results not only demonstrate the need for customized gearbox designs for electric motors, but also show that improvements in lubrication practices can extend gearbox life and increase efficiency in industrial applications globally. Highlights: Continuous operation vital for production targets. Electric motorbike gearboxes need frequent maintenance. Quality lubrication crucial for gearbox longevity. Keywords: Gearbox, Grind, Sugar Factory

A design study on 20 kW class axial flux motor with HTS field winding for 100 MPa liquid hydrogen pump

This paper presents a design study of a low-speed, high torque 20 kW class motor with a high-temperature superconductor (HTS) field coil for a liquid hydrogen centrifugal pump. The motor is designed based on three key concepts: 1) employing an axial-flux motor topology that can increase torque density by reducing the axial length together with a centrifugal pump; 2) using liquid hydrogen in a pump as a coolant for HTS coil; 3) adopting no-insulation (NI) YBCO solenoid coils as field coils of the motor to improve coil protection as well as mechanical stability. In the design process, first, an electromagnetic design of the axial type motor is obtained considering the required performance of previous commercial pumps. Considering the current and temperature margin to secure the HTS coils' stable operation, two types of HTS coils (solenoid type and triangle type) are designed and their performances are compared. Second, to evaluate validity of the electromagnetic designs, mechanical stresses in the HTS coils are estimated. By comparing the solenoid type and the triangle type, it is confirmed that the solenoid type has a distinct stress-reducing effect in terms of magnetic stress as well as rotational stress. Our design study results show the potential superior performance of the axial flux motor with HTS coils for several tens of kW applications with low speed and high torque loads such as liquid hydrogen pumps.

Numerical simulation of the effect of multiple factors on the ignition process of a solid rocket motor

AbstractWith the continuous development of manned space technology, higher requirements have been proposed for solid rocket motors. The ignition process of solid rocket motors affects the reliability, stability and safety of their operation. The ignition powder, cover opening pressure and grain length‐diameter ratio are the main factors affecting the ignition process. Therefore, the influence of different factors on the ignition process of solid rocket motors is studied with numerical simulations. Based on the finite volume method, the ignition process of a solid rocket motor is modelled and experimentally verified. Then, the pressure and temperature distribution characteristics during the ignition delay, flame propagation and gas filling times are analysed. Finally, the effects of different ignition powders, cover opening pressures and length‐diameter ratios on the ignition process are compared and analysed. The results show that the model has high prediction accuracy. When the ignition powder is 6 g, the maximum combustion temperature of solid rocket motor increases from 2590 K to 2620 K between 0.1 ms and 0.44 ms. Between 0.44 ms and 3.18 ms, intermittent flame propagation and pressure oscillations occur. In the gas filling time, the flow field gradually stabilizes. Increasing the ignition powder mass is beneficial to the ignition process, but the disadvantages of pressure oscillations should be considered. Increasing the cover opening pressure enhances the ignition process, while increasing the length‐diameter ratio increases the ignition pressure building time. The study results provide technical support for the structural design of solid rocket motors.

Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review.

The problem of energy consumption reduction establishes important challenges for electric motor producers in the framework of new international regulations regarding the conditions that must be accomplished by motors in the near future. One of the most important topics is related to the core loss decrease directly linked to the effect of electrical steel degradation induced by the cutting technology. Understanding exactly how this phenomenon occurs by analyzing the chemical, mechanical, crystallographic, magnetic domain, and magnetic properties is of utmost importance when manufacturing processes must be changed and adapted to a new market characterized by high-efficiency motors. Today, mechanical and laser cutting technologies are the most used because of their reduced price and high-speed process. Still, unfortunately, these methods are not the best due to the fact that they lead, in most cases, to a high value of magnetic core losses, low electromagnetic torque, and hence reduced efficiency. This review paper shows that non-conventional technologies such as water jetting and electroerosion could be applied if proper modifications are added. This paper's main idea is to present a comprehensive study regarding the impact of cutting technologies on microhardness and residual stresses, crystallographic texture, magnetic domain structure, and magnetic properties of some non-oriented electrical steels used in motor production. It provides a detailed analysis of the abovementioned aspects by including the authors' research and findings in the wider context of other research group contributions. It also offers a general idea of the mechanisms present at the macro- and microscopic levels. The readers can find some of the most used analytical models, including the cutting process's damaged effect on the magnetic properties' variation based on a simple mathematical approach and examples of finite element modeling performed on real motor designs implemented in various programs. Last but not least, some practical implementations of the cutting procedure's influence on motor working conditions are presented in the last section of the paper. It provides an up-to-date analysis regarding how the cutting method should be included in high-efficiency motor production by emphasizing the importance of the topic and identifying where supplementary research must be undertaken. From the investigated literature, by analyzing specific sample geometries associated with different characterization methods, it can be concluded that all the cutting technologies have an important contribution to the mechanical and magnetic quantities. When the magnetic core of an electric motor is produced through non-conventional methods, the overall influence of the cutting procedure has a low percentage in the motor efficiency, as presented in this paper.

Research on the Magnetic Properties of High-Saturation Magnetically Induced Alloy Motors under Magnetocaloric Coupling.

In the face of the rapid development of the motor industry, some motors with traditional soft magnetic materials can no longer meet the needs of the market. Using new high-saturation magnetic density materials has become a new breakthrough to improve the torque density of motors. Fe-Co alloys (1J22) have high-saturation magnetic induction strength, which can effectively improve the motor's magnetic field strength and increase its torque density. At the same time, the temperature rise of the motor is also an important factor to consider in the motor design process. In particular, the change in core temperature caused by loss makes the coupling of the internal temperature field and the electromagnetic field of the motor more common. Therefore, it is necessary to test the temperature and magnetic properties of 1J22 together. In this paper, a coupling measurement device for magnetic properties of soft magnetic materials is built, and a 1J22 temperature field-electromagnetic field coupling experiment is completed. It is found that the maximum loss of 1J22 decreases by 4.44% with the increase in temperature; the maximum loss is 6.41% less than that of traditional silicon steel. Finally, a finite element simulation model is built to simulate the actual working conditions of the motor, and it is verified that the magnetic properties of the material at high temperature will have a certain impact on the performance of the motor.

Optimization design of brushless DC motor based on improved JAYA algorithm

Brushless direct current motor is widely used in industrial production because of its simple structure, wide speed range and low noise. To improve the operation efficiency of brushless DC motor and reduce the production and application costs, the optimization of brushless DC motor is analyzed by introducing the JAYA algorithm. This method determines the optimal parameters of a brushless DC motor using the theory of electromagnetic structure parameter selection and efficiency calculation. The population diversity of the JAYA algorithm is improved through an empirical learning strategy, and an adaptive strategy is introduced to balance the development ability and search performance of the algorithm. This ensures population diversity and improves convergence speed. The experiment showcases that the improved JAYA algorithm has a lower rank average in unimodal function operations, demonstrating stronger local development ability and better stability. It exhibits strong search ability in many local optima of multimodal functions. Moreover, the motor's average efficiency after optimization is 94.48%. The algorithm reaches the global optimum after approximately 40 iterations and offers faster convergence speed and higher accuracy. The adaptive JAYA algorithm is stable at around 93% when the number of iterations reaches 90, with a maximum efficiency of 95.3%. It is 5–12 percentage points higher than the other three comparison algorithms. The optimal solution of the motor parameters in the adaptive JAYA algorithm is closest to the theoretical parameter optimization value, meeting both the constraints of variables and the constraints of the model. The stator diameter, tooth magnetic induction, winding current density, air gap magnetic induction, and stator yoke magnetic induction values are 201.5 mm, 1.8 T, 2.049 A/mm2, 0.63 T, and 0.91 T, respectively. The research overcomes the problem of parameter optimization in the optimization design of brushless DC motor, improving their economic value of brushless DC motor in industrial production and application.

Design and optimization of a high-performance multi-barrier IPMS motor for an electric scooter and bicycle.

Acknowledging the growing importance of electric vehicles (EVs) in the face of environmental concerns and increasing mobility needs, this study focuses on enhancing the performance of the electric motor, a critical component in EVs. The electric motor of these battery-powered vehicles is expected to have optimal characteristics and efficiency. This paper presents a comprehensive investigation into the design and optimization of a multi-barrier interior permanent magnet synchronous motor tailored for e-scooters and electric bicycles. A multi-barrier rotor structure is proposed and analysed through finite element method simulations to optimize key design parameters. The parametric analysis examines the influence of geometric variables on key motor performance criteria, including efficiency, cogging torque and weight. A correlation analysis of the variables was conducted. A very high positive correlation (0.999) was revealed, especially between the 'magnet duct dimension parameter' and efficiency. A very high negative correlation (-1) was found between 'distance from duct bottom to shaft surface' and efficiency. The optimized motor design achieves a theoretical improvement of around 7% in efficiency, reaching an overall efficiency of 89.86%. This study highlights the consideration of multiple factors such as efficiency, cogging torque and weight in the design process for the development of sustainable and high-performance EV motor designs.

Optimal design of a BLDC motor using African vulture optimization algorithm

BLDC motors are extensively favoured in robots, electric vehicles, and many industrial applications due to their superior torque, efficiency, and speed control features as compared to traditional motors. In this paper, collective intelligence-based optimization approaches are used to improve the cost-effectiveness, volume, and total loss of a BLDC motor. The geometric dimensions of the motor are considered the optimization parameters. The study employs several optimization algorithms, such as the Whale Optimization Algorithm (WOA), Grey Wolf Optimization (GWO), Cuckoo Search Algorithm (COA), Genetic Algorithm (GA), Particle Swarm Optimization (PSO), and the African Vulture Optimization algorithm (AVOA), used for the optimal BLDC motor design. The investigation can provide data on the convergence rates and optimal design parameters of a BLDC motor through optimization approaches. The standard deviation has also been calculated for each optimization technique to assess the stability and consistency of finding the optimum solution. The paper also includes a sensitivity analysis of the AVOA regulating parameter to obtain the best solutions. In comparison to GA, PSO, COA, GWO, and WOA, the AVOA technique achieves faster convergence. Additionally, the ANOVA test is employed as a statistical test to validate the efficacy of the AVOA. According to the results, AVOA outperforms all other optimization algorithms for the design of the BLDC motor.

Effectiveness of Thermal Interface Materials on Electrical Machines Thermal Performance With Heat Pipes

Thermal issue has always been a major concern in motor design. Heat pipes (HPs) have been applied in electrical machines with remarkable cooling effects reported. However, critical factors that affect HP thermal benefits have rarely been studied, such as limited contact area between HPs and heat sources, which may lead to high thermal resistance and degrade motor thermal performance. Due to limited thermal conductivities, conventional motor thermal interface materials (TIMs), such as epoxy resin, fail to maximize HP thermal benefits and minimize motor temperature rise. In this case, new TIMs with outstanding thermal properties that have not been used in electrical machines, such as thermal grease and adhesive, are potential candidates to address this issue, while their thermal impact is still unclear. This article conducts both experiments and thermal analyses to quantify the effects of TIM on motor cooling performance. Firstly, the thermal properties of ten typical TIMs in four categories are experimentally characterized. Then, the selected TIMs are applied to a stator-winding assembly with HP to evaluate their thermal impact on motor cooling performance under different cooling conditions. Finally, practical guidelines are given for TIM selection in electrical machines with HPs or other cooling media.

Robust Design of BLDC Motor Considering Driving Cycle

With growing environmental concerns and the limitations of fuel cell resources, replacing petrol-based engines with electric machines as the traction motor for electric vehicles (EVs) is gaining attention. Among the different electric machines topology, for lower power applications such as three-wheel motorcycle, the Brushless Direct Current (BLDC) motors are the most favorable due to their simple structure, simple control algorithm, etc. One of the key aspects of developing BLDC motors in EV applications is utilizing the fast and efficient optimization algorithm over driving cycles. Another aspect is considering manufacturing tolerances to eliminate the failure product rate in mass production. The combination of optimization algorithms with consideration of manufacturing tolerances leads to a complex and time-consuming optimization procedure. To overcome this problem, the robust design by utilizing the Design of Experiment (DOE) method can be utilized. In this study, first, a developed systematic multi-physics multi-level optimization algorithm with consideration of manufacturing tolerances and driving cycles is proposed. Then, to evaluate the accuracy of the optimization process, a prototype of the optimized motor is manufactured. The efficiency and accuracy of the optimization algorithm are compared through Finite Element Method (FEM) and experimental results, showing the effectiveness of the proposed algorithm.

Comparison and analysis of starting performance of PMSM with different rotor structures

In this paper, the electromagnetic fields of PMSM with four different rotor structures are analyzed by the finite element method, and the distribution of magnetic field lines is compared. Then the asynchronous starting process of PMSM is studied. The starting process of four kinds of permanent magnet synchronous motors with no load and load is simulated and analyzed, and the characteristics of speed, torque, and phase current are obtained. These studies can provide references for the starting design of permanent magnet synchronous motors in practical applications. Therefore, a more reliable and efficient motor starting process is realized, which provides a basis for further structural design of permanent magnet synchronous motor.

Transient Thermal Exchange Analysis of an External Rotor Hub Motor for Electrified Defense Vehicles Applications Based on FVM and TNM

This paper investigates the transient temperature distribution law of a 75kW external rotor hub motor for electrified defense vehicles (EDV) using the finite volume method (FVM) and the thermal network method (TNM). Based on thermal exchange and fluid flow theories, both a transient fluid-solid coupled thermal exchange model and a lumped parameter thermal network model (LPTNM) with transient thermal capacity parameters are established. An iterative algorithm for the heat transfer coefficient is proposed to improve the accuracy of LPTNM. Compared with existing methods, this algorithm exhibits higher accuracy and stronger practicality. In addition, an experimental platform of the hub motor temperature rise is built for measuring the end winding temperature. The calculated results are in good agreement with the experimental results, verifying the rationality of the 3D transient fluid-solid coupled thermal exchange model and the LPTNM. The axial parallel water channel structure was adopted to improve the cooling performance of the end winding, taking into account the structural characteristics and assembly mode of the hub motor. This paper provides theoretical references for the transient thermal analysis and cooling structure design of the EDV hub motor.

Multiharmonic-Layered Design and Optimization of a Flux-Concentrated PM Vernier Motor Considering Harmonic Sensitivity

Multiharmonic-Layered Design and Optimization of a Flux-Concentrated PM Vernier Motor Considering Harmonic Sensitivity

Optimization Design of Interior Permanent Magnet Synchronous Motor With U-Shaped Rotor for Low-Level Torque Ripple and Electromagnetic Vibration

Optimization Design of Interior Permanent Magnet Synchronous Motor With U-Shaped Rotor for Low-Level Torque Ripple and Electromagnetic Vibration

A Data-Driven Automatic Design of Induction Motors Based on Tree Search and Reinforcement Learning Considering Multiple Objectives

A Data-Driven Automatic Design of Induction Motors Based on Tree Search and Reinforcement Learning Considering Multiple Objectives

Design and Analysis of the High Torque Density Circumferentially Excited Permanent Magnet Motor Based on PSO

Design and Analysis of the High Torque Density Circumferentially Excited Permanent Magnet Motor Based on PSO

High Efficiency Hybrid Synchronous Motor Design With Loss and Thermal Analysis for Integrated Two-Speed e-Powertrain System in Electric Vehicles

High Efficiency Hybrid Synchronous Motor Design With Loss and Thermal Analysis for Integrated Two-Speed e-Powertrain System in Electric Vehicles