Electromagnetic Finite Element Analysis Research Articles

Ultra‐fast finite element analysis of coreless axial flux permanent magnet synchronous machines

AbstractLarge‐scale design optimisation techniques enable the design of high‐performance electric machines. Electromagnetic 3D finite element analysis (FEA) is typically employed in optimisation studies for accurate analysis of axial flux permanent magnet (AFPM) machines, which require extensive computational resources. To reduce the computational burden, a FEA‐based mathematical method relying on the geometric and magnetic symmetry of coreless AFPM machines is proposed to estimate the machine performance indicators using the least number of FEA solutions, thereby significantly lowering the running time. This method is generally applicable to AFPM machines with low saturation effects and cogging torque as exemplified for a printed circuit board (PCB) stator coreless AFPM machine. To further reduce the computation time, a systematically simplified equivalent 3D FEA model for planar PCB coils integrated with this machine is also proposed. The practical implementation of the introduced method is elaborated based on an example optimisation study, and an analytical method for fast design scaling is also discussed. The results of the proposed approach are compared with detailed transient FEA results, and a prototype 26‐pole PCB stator coreless AFPM machine was also used to validate the results experimentally.

Deep neural network-based modeling and optimization methodology of fuel cell electric vehicles considering power sources and electric motors

This study proposes a modeling and optimization methodology for fuel cell electric vehicles (FCEVs). Among FCEV components, the traction motor, lithium-ion battery, fuel cell stack, and air supply system are mainly investigated. The FCEV modeling is performed based on the vehicle specifications, electromagnetic finite element analysis, and experimental data. To conduct design optimization, deep neural networks (DNNs) are adopted and trained to predict vehicle performance considering the fluctuation of applied direct current voltage. At this stage, the adaptive layering and sampling algorithm was suggested, which enables efficient DNN construction. To confirm the feasibility of the suggested training algorithm, the number of hidden layers and sampling points of constructed DNNs are investigated. Finally, DNN-based fuel economy optimization is performed considering the driving performance. The effectiveness of the proposed optimization methodology is validated by additional optimization results.

Design and damping performance analysis of a multistage meandering hybrid valved magnetorheological damper

Abstract The current valved magnetorheological damper has a low space utilization of the piston head, which results in insufficient output damping force, and this paper proposed a multistage meandering hybrid valved magnetorheological damper. The three-dimensional structure of the damper is established and its mathematical model is derived. The electromagnetic field finite element analysis was used to simulate the damper structure, and a comparison was made between the results of traditional annular valve structures and those of multistage meandering hybrid valve. The damping performance of a multistage meandering hybrid valved damper was experimentally studied. The results indicate that the maximum output damping force of the multistage meandering hybrid valved structure is increased by 62.2% over the traditional annular valved structure at a current of 2.4 A and a coil turn count of 350 turns. The structure can effectively utilize the piston head space and improve the output damping force of the damper. The output damping force of the damper reaches 486.4N and the adjustable coefficient K reaches 8.6. The numerical simulation results are the same as the actual experimental results.

Optimized Ferromagnetic Core Magnetorquer Design and Testing for LEO Nanosatellite Attitude Control

Magnetorquers are a very suitable solution for the nanosatellite’s attitude and orbital control of low Earth orbit (LEO) given its constraints: small available volume, limited power consumption, and maximum weight limitation. In this work, an optimized ferromagnetic core magnetorquer is designed for LEO nanosatellites, considering the geometrical, electrical, and magnetic parameters in an electromagnetic finite element analysis (FEA). The final design dimensions are 10.9 mm diameter and 100 mm in length, with a ferromagnetic core made of high performance soft magnetic alloy Vacoflux50 measuring 5 mm diameter and 100 mm in length. Magnetorquer geometry has been optimized to achieve a very high compactness, reaching an optimal combination of high specific magnetic moment and magnetic moment-input power ratio at the same time. It shows a maximum magnetic moment of 1.42 Am2, a magnetic moment-input power ratio of 2.52 Am2/W, and a specific magnetic moment of 22.5 Am2/kg, with a power consumption of 0.565 W and 0.5 A. Such a combination of high-performance values has not been previously found. Furthermore, it has displayed higher magnetic moment and specific magnetic moment than previous prototypes in literature. The simulated model is validated with the experimental testing of a manufactured prototype, by measuring the magnetic and electric variables.

Hand-held rolling magnetic-spring energy harvester: Design, analysis, and experimental verification

Aiming at the random and low-frequency characteristics of human motion, a hand-held rolling magnetic-spring energy harvester is proposed to scavenge energy from handshaking. The harvester applies the rolling movement of a magnetically suspended magnet and possesses the merit of low damping. The dynamic model is established and the open-circuit voltages are predicted by combining Faraday's law of electromagnetic induction and finite element analysis. By calculating magnetic flux through coils, the effect of the coil’s position on energy harvesting efficiency is studied through numerical and experimental approaches. Experimental results under harmonic excitations indicate that the coil positioned directly below the stable equilibrium position of the moving magnet has the best output capability, and a maximum open-circuit voltage of 1.33 V and a half-power bandwidth of 1.61 Hz is achieved at 0.3 g. Under handshaking excitation, an instantaneous peak power of 20.15 mW is achieved, along with a maximum average power of 2.22 mW. The corresponding volume and mass power densities are respectively 26.04 μW/cm3 and 23.28 μW/g. Furthermore, handshaking excitation in 5 s to charge a capacitor of 470 μF could enable the watch, time display, timer, and hygrothermograph to operate for 1100 s, 513 s, 86 s, and 35 s respectively, demonstrating the brilliant application foreground of the proposed harvester.

The Efficiency Improvement of Track-Type Wireless Power Transmission Systems through Electromagnetic Finite Element Analysis

The original system, designed as a combination structure of a linear machine and a wireless power transmission transformer, was designed to overcome the limitations of the wired power supply method used for working robots and transportation equipment in existing smart factories, and improvements in magnetic coupling and power transfer efficiency are needed. In this work, we study the efficiency improvement of a system that can supply wireless power to track-type transportation equipment. For this purpose, electromagnetic properties such as magnetic equivalent resistance, inductance, magnetic coupling rate, and core loss are analyzed using the finite element method. In addition, the results of magnetic field finite element analysis are applied in electrical equivalent circuit modeling to analyze the voltage transfer ratio and input/output characteristics of a CLLC resonant converter designed for wireless power transmission. The efficiency improvements of the proposed model are verified through a comparison of experimental and simulation results after fabricating a prototype. From the results of this study, a more optimized wireless power transmission system design based on the analysis results from an electromagnetic perspective can be realized to improve the efficiency of wireless power transmission.

Novel Stator Slot Opening to Reduce Electrical Machine Bearing Currents

Ball bearings are largely used in electrical machines, where the high frequency common mode currents affect their lifetime. This document presents a novel Zig-Zag stator slot opening geometry to reduce the winding-to-rotor capacitance <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">C_wr</i> with the consequent reduction of Bearing Voltage Ratio and electrical discharge machining bearing currents. An improved analytical model to permit the calculation of <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">C_wr</i> for unusual slot opening geometries is implemented. Electrostatic and electromagnetic Finite Element Analysis comparisons between the Zig-Zag, oblique and original (classical slot opening configuration) machines are performed. These comparisons suggest that the Zig-Zag model presents the best performance in terms of Bearing Voltage Ratio reduction, while keeping torque performance close to the original machine. An additional comparison between the novel Zig-Zag model and the classical one with reduced slot opening to have the same <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">C_wr</i> values is proposed, showing an higher degradation in terms of torque performance for the latter. The study shows that the Zig-Zag model could be a good candidate to reduce effectively electrical machine bearing currents. A validation test is proposed on two motorette prototypes having classical and Zig-Zag slot opening configurations, respectively. Moreover, the improved analytical method can be helpful for engineers and researchers to calculate <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">C_wr</i> with a good accuracy for unusual slot opening geometries.

Power Density Increase in Permanent-Magnet Synchronous Machines Considering Active Thermal Control

The power density of electric machines for future battery electric vehicles must be further increased to improve customer benefits. To this end, this paper compares two state-of-the art electrical traction machines and evaluates the potential for increasing the power density using a third, novel high-speed machine design. The analysis is performed using an electromagnetic finite element analysis, a thermal network with lumped parameters, and a coupled electromagnetic–thermal simulation. The simulations of the three machines evaluate the potential for increasing the power density and overload margins, as well as reducing material consumption. With regard to the active thermal control, the new design aims for reduced thermal capacities and increased loss density to optimize the thermal controllablity and overall performance. The thermal active control is analyzed in thermal transient simulations and electromagnetic simulations with different magnet temperatures. The results show that higher magnet temperatures benefit efficiency and reduce losses for low torque at high speeds. However, a colder magnet is needed for maximum torque at base speed. A maximum loss reduction of 24% is achieved with a 100 °C magnet-temperature difference at maximum speed and low torque.

Analytical temperature estimation process of the air supply system of the proton exchange membrane fuel cell stack in fuel cell electric vehicles

The air supply system of the proton exchange membrane fuel cell stack in fuel cell electric vehicles should be included as one of the components of the balance of plant. However, the air supply system consists of a centrifugal air compressor, driven by an ultra-high-speed motor. Therefore, there occurs a large amount of thermal energy from losses and the temperature of the air supply system should be considered. Accordingly, this study suggests the temperature estimation process for an air supply system based on a lumped parameter thermal network (LPTN). First, performance modeling is introduced using not only the empirical approach but also electromagnetic finite element analysis (FEA). Subsequently, thermal modeling based on the LPTN is presented. For this procedure, optimization techniques, screening, and surrogate model-based optimization are used. Finally, the results of LPTN construction are investigated. Furthermore, an additional experiment is conducted, and the result of this study is verified.

Analysis of Cooling Characteristics of Permanent Magnet Synchronous Motor with Different Water Jacket Design Using Electromagnetic–Thermal Fluid Coupled Analysis and Design of Experiment

Electrical losses are converted into thermal energy in motors, which heats each component. It is a significant factor in decreasing motor mechanical performance. In this paper, the motor cooling characteristics were analyzed according to the design factors of the water jacket to investigate the cooling performance of a permanent magnet synchronous motor (PMSM). First, the electrical losses generated in PMSM were calculated using electromagnetic finite element (FE) analysis. Secondly, a 3D electromagnetic–thermal fluid coupled FE analysis was performed to analyze the temperature distribution inside the motor by applying electrical loss as the heat source. Finally, the motor cooling performance according to the design factors of the water jacket was statistically analyzed using the design of experiment (DOE) method. It was found that the mass flow rate of 0.02547 kg/s and six passes of the water jacket with one inlet and two outlets could be considered the optimum conditions in terms of the maximum motor temperature.

Topology Optimization of Synchronous Reluctance Motors Considering the Optimal Current Reference in the Field-Weakening and Maximum-Torque-Per-Voltage Regions

The torque performance of the synchronous reluctance motors (SynRMs) is primarily determined by the geometric design and current control. The motor structure needs to be designed to yield the maximum output torque under the given current and voltage limitations. The current reference supplied to the stator coils also needs to be determined to maximize the output torque while suppressing the back electromotive force (EMF) to protect a power supply system. However, in the field of design optimization, it has been challenging to simultaneously consider the geometric design and current control due to their complicated relationships. To solve the aforementioned issue, this study proposes a new topology optimization that can cover the maximum-torque-per-ampere (MTPA), field weakening (FW), and maximum-torque-per-voltage (MTPV) controls under both the current and voltage limitations, thereby maximizing the output torque in an entire rotational speed range. To effectively investigate the coupling effects between the geometric design and current reference, this study proposes the design parameterization for the FW and MTPV operation by performing the electromagnetic finite element (FE) analysis and then expresses the optimal current reference in terms of design variables. At every iteration, the structural FE analysis is also performed under the design-dependent loads to obtain a structurally meaningful design. By doing so, both the optimal design and the corresponding optimal current reference can be simultaneously determined. The optimized SynRM is manufactured and experimentally validated to demonstrate the effectiveness of the proposed optimization framework.

Research on the Heating Process of CFRP Circular Tubes Based on Electromagnetic Induction Heating Method.

Based on the electromagnetic induction heating method, heating and curing of Carbon Fiber Reinforced Polymer (CFRP) have the advantages of high energy utilization and no pollution. However, in the heating process, both the material weaving structure and mold material can affect the temperature field. Therefore, in this study, an electromagnetic heating finite element analysis model for CFRP circular tubes was established based on the equivalent electromagnetic thermal characteristics of CFRP. The study investigated the temperature rise mechanism of the material weaving structure under the magnetic field, and explored in-depth the influence of molds made of 45# steel and glass fiber-reinforced plastic (FRP) on the heating process of CFRP. The CFRP circular tubes with weaving structures of 89-degree winding angle, 45-degree winding angle, and plain weave were studied. The study found that when the metal mold was heated, the CFRP structure had almost no effect on the temperature distribution. However, when the glass fiber-reinforced plastic mold was heated, the temperature field changed with the CFRP structure, and the more fiber cross points, the more uniform the temperature field. The accuracy of the finite element model was verified through experiments. The aim of this research is to provide theoretical guidance for actual industrial production.

Comparative Analysis of Surface-Attached Cooling Structure for Efficient Thermal Management of SPMM-TW

Efficient thermal management is the essential precondition for electrical machines to achieve high power density and reliable operation. This paper presents a surface-attached cooling structure (SACS) for the thermal management of slotless permanent magnet motor (SPMM) with toroidal winding. The SACS consists of several channels attached to the surface of the toroidal winding, and the shorter heat path guarantees that the heat generated in the winding can be effectively extracted. Three-dimensional electromagnetic finite-element analysis and the computational fluid dynamics are used to evaluate the losses of the SPMM and obtain the accurate convective heat transfer coefficient (CHTC). For predicting the winding temperature accurately, the layered winding model is proposed to simulate the actual winding conditions. In addition, the influence of different channel materials on temperature rise is experimentally evaluated on the same prototype. The experimental results show that the layered winding model can well simulate and predict the actual temperature distribution of the winding, and the SACS can effectively reduce the temperature rise of the winding compared with the housing water jacket cooling, where the SPMM with the SACS can withstand a continuous current density of 17.2 A/mm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup> and a peak current density of 28 A/mm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup> .

Fast NVH Prediction for E-Motor Noise and Validation

Fast NVH analysis from the start of the motor design is important to speed up product development by avoiding major NVH issues later. In this paper, different methods for electric motor noise and vibration predictions are proposed for different stages in the design process. The results are compared to previous experimental validation [1]. The first method combines electromagnetic finite element analysis to calculate the forces, with analytical models for the stator vibration and acoustic response [2]. This requires minimal structural design data, and can be carried out rapidly, allowing the exploration of many design possibilities in the early design stage, and is implemented in Ansys Motor-CAD. This is compared with the full structural finite element analysis (FEA) [1]. It is shown that the fast analytical NVH process provides a good prediction for the motor noise level early in the design process. The structural FEA approach provides additional information about the structural response at a later stage to refine the design. The use of frequency response functions (FRF) derived from the structural FEA are demonstrated, allowing the rapid calculation of noise results from the electromagnetic forces.

Design and optimization of an external-rotor switched reluctance motor for an electric scooter

In order to reduce the global carbon foot print, the need of the hour is to provide pollution free and economically viable electric vehicles (EVs) as potential alternatives to the conventional ones. Amongst the different traction motors employed in EVs, switched reluctance motors (SRMs) being magnet-free, rugged in construction and fault-tolerant is a potential forerunner for automotive applications in the near future. Therefore, in this work, an external-rotor (ER) SRM has been designed for an electric scooter application. The proposed 4-phase SRM configuration comprises of 8 and 10 poles on the stator and rotor respectively. To achieve a well-balanced design with due consideration to the various performance indicators, a multi-objective design optimization (MOO) has been performed using particle swarm optimization (PSO). The optimization was based on the results obtained from the two-dimensional (2D) electromagnetic static finite element analysis (FEA) which aimed to maximize average torque, efficiency and minimize torque ripple respectively. In comparison to the preliminary design, the optimized ER-SRM demonstrated an increased average torque and decreased copper loss by 3% and 14% respectively. The large scale of simulations performed and the results thereby obtained confirmed that the proposed SRM design met the performance demands of the electric scooter application. The average torque at the rated and the maximum speed exceeded the desired torque requirements demanded by the electric scooter by 13.1% and 42.2% respectively.

Design and Performance Analysis of a Switched Reluctance Motor Using Finite Element Analysis and Magnetic Equivalent Circuit Model

By being magnet-free, and mechanically robust with a longer constant power range, switched reluctance motor (SRM) is gathering much attention as a potential choice to propel electric vehicles (EVs) and hybrid electric vehicles (HEVs). This paper comprehensively investigates the performance sensitivity to geometric design variables such as rotor diameter, pole arc angles, and yoke thicknesses for an SRM using static two-dimensional (2D) electromagnetic Finite-Element Analysis (FEA). The reason for the change in static characteristics due to variation in reluctance between SRM designs has not been detailed previously. This is addressed by the magnetic equivalent circuit (MEC) model that simplifies the design analysis. Results indicate that stator pole reluctance needs to be given due importance while studying the influence of rotor diameter. Also, it is imperative to set an adequate thickness of the stator and rotor yokes to minimize the effect of saturation on the performance. Rotor diameter and stator pole arc angle have a pronounced influence on the performance while the influence of rotor pole arc angle and yoke thicknesses was relatively less.

Topology Optimization Framework for Simultaneously Determining the Optimal Structural Design and Current Phase Angle of the IPMSMs for the MTPA Control

Although it is crucial to design the magnetic flux path and the maximum torque per ampere (MTPA) current reference under the current limitation, it is challenging to simultaneously consider these features in developing an interior permanent magnet synchronous motors (IPMSM) due to complicated coupling effects. In this article, to overcome the above issue, the motor-design parameters are estimated by conducting electromagnetic finite element (FE) analysis two times at every iteration of topology optimization. Then, the MTPA current phase angle can be analytically expressed in terms of an elementwise relative density (i.e., design variable in topology optimization). In addition, the structural safety is assessed by conducting the structural FE analysis under design-dependent loads to reflect a high-speed rotation. The proposed two-stage topology optimization enables us to simultaneously optimize both a structural design and current phase angle to achieve the maximum electromagnetic performance. Structural safety and manufacturability are also considered to obtain a practically meaningful design. With two different types of permanent magnets, the optimized IPMSMs are obtained and manufactured to validate the proposed method. Simulation and experimental results demonstrate the validity and potential of this work.

Design of a temperature-feedback controlled automated magnetic hyperthermia therapy device.

Magnetic hyperthermia therapy (MHT) is a minimally invasive adjuvant therapy capable of damaging tumors using magnetic nanoparticles exposed radiofrequency alternating magnetic fields. One of the challenges of MHT is thermal dose control and excessive heating in superficial tissues from off target eddy current heating. We report the development of a control system to maintain target temperature during MHT with an automatic safety shutoff feature in adherence to FDA Design Control Guidance. A proportional-integral-derivative (PID) control algorithm was designed and implemented in NI LabVIEW®. A standard reference material copper wire was used as the heat source to verify the controller performance in gel phantom experiments. Coupled electromagnetic thermal finite element analysis simulations were used to identify the initial controller gains. Results showed that the PID controller successfully achieved the target temperature control despite significant perturbations. Feasibility of PID control algorithm to improve efficacy and safety of MHT was demonstrated.

AI‐ML-Enabled Electromagnetic Homing Guidance System for Scientific Autonomous Underwater Vehicles

Abstract Subsea homing and docking systems are used for increasing the spatiotemporal capabilities of autonomous underwater vehicles (AUVs) involved in long endurance scientific, survey, and surveillance missions. They offer necessary guidance for the AUV, and maneuver into the dock, considering the vehicle attitude and the dynamic response capabilities. Short-range homing is critical for successful docking as carrying outgross course and heading corrections is difficult when the AUV is closer to the dock. The article describes the development of an artificial intelligence (AI)-enabled short-range AUV electro-magnetic homing guidance system (EMHGS) based on differential magnetometry principle. System engineering is carried out with the aid of electromagnetic Finite Element Analysis software; supervised and unsupervised machine learning algorithms are implemented for determining the range and heading correction in real time. The proposed algorithms aid the reliable and accurate homing operation in an unknown dynamic environment, and the algorithm is very easily implementable and independent of AUV configuration and payloads. The EMHGS with an AI-enabled MagHomer AUV is demonstrated for autonomous intelligent homing over a range of 7 m.

Electrical, thermal and electro-magnetic analyses of a 100 kHz interleaved power electronic transformer

In this paper, the finite element electrical, thermal and electro-magnetic analysis of an interleaved power electronic transformer structure operable at 100 kHz is presented. The analysed power electronic transformer structure is modelled with an EE-shaped core and interleaved primary and secondary windings. Electromagnetic analysis was done on the structure to study its properties like magnetic flux density, magnetic field, current density and relative permeability. Electrical and thermal analysis was done on the transformer to study its operating efficiencies and losses in isolation, buck and boost working modes. The analyses were done for different frequencies to ascertain that 100 kHz is the better choice of frequency for the designed power electronic transformer. The results are compared to a non-interleaved power electronic transformer structure to study the improvement obtained in the interleaved model. It was seen that transformer efficiencies of about 99 % could be obtained on using interleaved winding technique rather than non-interleaved method. Finite element modelling software-Altair FLUX was used to simulate the transformer and analytic equations were used to verify the obtained results.