High-efficiency Motors Research Articles

Solid-State Contactor With Si Thyristor and SiC FET Hybrid Module for High-Efficiency Motor Control

Solid-State Contactor With Si Thyristor and SiC FET Hybrid Module for High-Efficiency Motor Control

Prospects For Application of High-Efficiency and High-Power Electric Motors in New Energy Vehicles

Prospects For Application of High-Efficiency and High-Power Electric Motors in New Energy Vehicles

Utilizing MicroGenetic Algorithm for Optimal Design of Permanent-Magnet-Assisted WFSM for Traction Machines

With increasing worries about the environment, there is a rising focus on saving energy in various industries. In the e-mobility industry of electric motors, permanent magnet synchronous motors (PMSMs) are widely utilized for saving energy due to their high-efficiency motor technologies. However, challenges like environmental degradation from rare earth development and difficulties in controlling magnetic field fluctuations persist. To address these issues, active research focuses on the wound field synchronous motor (WFSM), known for its ability to regulate field current efficiently across various speeds and operating conditions. Nevertheless, compared with other synchronous motors, the WFSM tends to exhibit relatively lower efficiency and torque density. Because the WFSM involves winding both the rotor and the stator, it results in increased copper and iron losses. In this article, a model that enhances torque density by inserting permanent magnets (PMs) into the rotor of the basic WFSM is proposed. This proposed model bolsters the d axis magnetic flux, thereby enhancing the motor’s overall performance while addressing environmental concerns related to rare-earth materials and potentially reducing manufacturing costs when compared with those of the PMSM. The research methodology involves a comprehensive sensitivity analysis to identify key design variables, followed by sampling using optimal Latin hypercube design (OLHD). A surrogate model is then constructed using the kriging interpolation technique, and the optimization process employs a micro-genetic algorithm (MGA) to derive the optimal model configuration. The algorithm was performed to minimize the use of PMs when the same torque as that of the basic WFSM is present, and to reduce torque ripple. Error assessment is conducted through comparisons with finite element method (FEM) simulations. The optimized permanent-magnet-assisted WFSM (PMa-WFSM) model improved efficiency by 1.08% when it was the same size as the basic WFSM, and the torque ripple decreased by 5.43%. The proposed PMa-WFSM derived from this article is expected to be suitable for use in the e-mobility industry as a replacement for PMSM.

Vibration Analysis of the Double Row Planetary Gear System for an Electromechanical Energy Conversion System

Electromechanical energy conversion systems (EECSs) are widely used in vehicles to combine the double-row planetary gear system (DRPGS) with high transmission efficiency and high-performance motors. The integrated structure of the ring gear and motor rotor have put forward higher demands for the vibration performance of the DRPGS. This paper establishes a multibody dynamic model of the DRPGS for an EECS. Based on the kinetic relationship between the gear pairs and bearing components, the dynamic equations of the DRPGS are derived. The DRPGS model is simulated under different operating conditions. The results are compared to reveal the relationships between the system vibration and the operating speed and load torque. The typical conditions are selected to study the effectiveness of the structural parameters in reducing the DRPGS vibrations. The structural parameters, including the bearing clearance, the ball numbers, the gear tooth modification amount, and length, are comprehensively discussed. Several suggestions for the low-vibration design of the DRPGS for the EECS are provided.

Research on the energy efficiency and sustainability

Mechatronics systems, by integrating mechanical, electronic, and computer technologies, offer a comprehensive solution to optimize the generation, transmission, storage, and utilization of energy, thus reducing energy waste. This paper begins by introducing the applications of mechatronics systems in renewable energy systems, encompassing the efficient capture and management of resources such as solar and wind energy to meet energy demands. Secondly, this paper discusses the critical role of mechatronics systems in smart grids, enhancing the efficiency and reliability of power systems through advanced monitoring and control technologies. Furthermore, this study emphasizes the value of mechatronics systems in designing and implementing energy-saving devices, including high-efficiency motors, intelligent lighting, and heat recovery technologies, to reduce resource wastage and environmental impact. Finally, by reducing carbon emissions and decreasing reliance on traditional energy sources, mechatronics systems actively contribute to sustainability, promoting the development of sustainable cities and buildings, and simultaneously achieving the United Nations Sustainable Development Goals.

A Novel reaching law sliding mode control method of PMSM considering iron loss

The loss of motor is ignored in the traditional speed control, while the loss minimization control (LMC) takes the high efficiency of the motor and does not consider the speed performance. Therefore, with the iron loss torque as the bond between efficiency and dynamic performance, this paper presents a sliding mode control method under the loss minimization target to achieve the high efficiency and high dynamic performance of permanent magnet synchronous motor (PMSM). Firstly, a d-axis current compensation method based on Taylor series expansion of virtual power loss (VPL) is proposed to minimize the loss of PMSM. Secondly, to eliminate the influence of iron loss on the speed performance, a PMSM speed tracking model including iron loss is established. Then, an adaptive sliding mode reaching law with disturbance estimation (ASMRLDE) is proposed to avoid energy consumption and the sliding mode chattering of the system caused by excessive sliding mode switch gain by adjusting the speed at which the system state reaches the sliding surface. Finally, the superiority of the proposed sliding mode control method under the loss minimization target in terms of loss minimization and speed control of the motor is proved through multi-condition experiments.

Study on Compressibility According to Mixing Ratio and Milling Time of Fe-6.5wt.%Si.

Recently, researchers have focused on improving motor performance and efficiency. To manufacture motors with performance and efficiency higher than those of motors manufactured through the additive process, compressibility verification through the parameter control of soft magnetic composites (SMCs) is essential. To this end, this study aims to select suitable powders for manufacturing high-performance, high-efficiency motors by exploring powder mixing ratios and milling times. Through physical property tests, the optimal mixing ratio is predicted using the Multi-Particle Finite Element Method (MPFEM) and powder compression molding analysis, and compressibility is predicted in view of the influence of a change in particle size as a function of the powder mixing ratio and milling time. In addition, based on the result of a comparative analysis of density through experiments and an analysis of internal defects through SEM, a 50:50 mixing ratio of hybrid atomizing and gas atomizing powders milled for 3 h provided the best compressibility. Therefore, the use of SMC cores fabricated using powder compression molding is expected to improve motor performance and efficiency.

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.

A study on motor characteristics based on pole-slot combinations

Electric devices called motors, which have a history of 100 years, are the devices that use the most electricity in the world. Therefore, the development of high-efficiency motors leads to efficient power use and carbon neutrality. In motor design, the combination of poles and slots is very important. It affects many characteristics including back electromotive force waveform and magnitude, torque and torque ripple, cogging torque, noise and vibration, and efficiency. The most widely used combination of poles and slots is 8 poles and 12 slots. And recently, 8-pole 9-slots are also attracting attention for their various advantages. This paper compares the characteristics of 8-pole 12 slots and 8-pole 9 slots through computer simulation. And to overcome the weaknesses of 8 poles and 9 slots, a multiple of the pole-slot combination is applied. Finally, the comparative values are verified through an experiment.

МЕТОДЫ ПОВЫШЕНИЯ ЭНЕРГОЭФФЕКТИВНОСТИ В ЭЛЕКТРИЧЕСКИХ ПРИВОДАХ ПРОМЫШЛЕННЫХ МАШИН

The paper reviews the current methods of improving energy efficiency in electric drives of industrial machinery. The main focus is on the optimization of drive parameters, the use of high-efficiency motors, the implementation of frequency-regulated drives, energy regeneration, intelligent control systems, and energy management. The results of the performance analysis of different methods are presented and recommendations are proposed for their application to reduce energy costs and improve performance.

Energy Saving by Adopting High-Efficiency Motor

Energy Saving by Adopting High-Efficiency Motor

Fractional-Order Extremum Seeking Method for Maximum Torque per Ampere Control of Permanent Magnet Synchronous Motor

Maximum torque per ampere (MTPA) control of internal permanent magnet synchronous motors (IPMSM) has become integral to high-efficiency motor drives. To minimize the influence of the traditional model-based analytical solution method on the MTPA control strategy due to the parameter variations during the motor operation, an online search MTPA method without model-based fractional-order extremum seeking control (FO-ESC) is proposed. Compared with the traditional integer-order ESC method, the Oustaloup approximation-based fractional-order calculus provides additional factors and possibilities for optimizing controller parameters to improve control performance. At the same time, the proposed approach does not require machine parameters and is thus not influenced by machine and drive nonlinearities. Simulation results show that the proposed method can ensure robust MTPA control under different loading conditions in real-time and improve the system’s dynamic response speed and steady-state accuracy.

Inverse Design of Axis Fan for Permanent Magnet Drive Motor for Special Vehicles

The control of mechanical energy loss is especially key in the design of permanent magnet drive motors for special vehicles. This paper takes a 300 kW high-efficiency motor as an example, and under the operating condition of 9000 rev/min, in order to control the size of the mechanical loss Pmech, improve the efficiency of the motor, as well as enhance the ventilation and heat dissipation performance of the motor, the structural parameters of the motor’s Axis fan are identified by using the Reverse Engineering (RE), and the fan performance is simulated and analysed by using the standard k-ε turbulence model of Computational Fluid Dynamics. The mechanical loss calculation model is investigated, and the effects of different blade numbers, wrap angles, and mounting angle parameters of the fan on the mechanical loss Pmech are derived. And finally, the scheme is calculated to show that when the blade number Z is 13, the wrap angle Δφ is 60°, the front mounting angle Φ1 is 45°, and the rear mounting angle Φ2 is 30°, the mechanical loss Pmech decreases from 8.0 kW to 2.54 kW, and the motor efficiency η0 is greatly improved, increasing from 94.2% to 96.1%. Meanwhile, based on finite element simulation experiments, the effects of the motor Axis fan on the steady-state temperature field of the pre-optimised and post-optimised fans are compared, and the optimised axis fan makes the motor ventilation and heat dissipation more reasonable. The maximum temperature of the motor under the same working condition decreased by 16.7 K, the efficiency η0 of this motor was greatly improved, and the efficiency η0 increased from 94.2% to 96.1%.

Effect of Permanent Magnet Structure on Working Characteristics of LSPMSM 3000 rpm

Reducing the cost of electricity to improve production efficiency is one of the urgent tasks. Nowadays, the rapid development of Neodymium rare earth (NdFeB) permanent magnet technology has promoted the creation of high-efficiency motors to replace low-efficiency induction motors to save electricity. One of them is a line-start permanent magnet synchronous motor (LSPMSM). The permanent magnet configuration significantly affects the operating characteristics of the LSPMSM, such as working current characteristics, pulsating torque, working efficiency, and starting speed. The content of the article focuses on investigating and evaluating some permanent magnet configurations affecting the working characteristics of the LSPMSM based on the finite element method through Ansys/Maxwell software. The research results are suggested for the design and manufacture of LSPMSM used in mining to save electricity.

Design Consideration on a Low-Cost Permanent Magnetization Remanufacturing Method for Low-Efficiency Induction Motors

At present, a large number of inefficient induction motors (IMs) are still being used in various industrial fields, resulting in a huge waste of energy. Obviously, it is expensive to replace all these machines with high-efficiency motors. Therefore, this paper will investigate the method of low-cost modification of inefficient IMs and propose a low-cost permanent magnetization remanufacturing (PMR) method that can make full use of the original structure of IMs. The PMR method converts the IM’s rotor into a permanent magnet (PM) rotor by directly milling slots in the original rotor and embedding PMs, thus improving the efficiency of the original motor to meet the IE4 standard. Firstly, this paper proposes the PMR process of IM, and based on this process, a Y2-132M1-6 IM is designed for remanufacturing, and the performance of the motor before and after the PMR is compared through finite-element analysis. Then, this paper researches the factors that may affect the starting performance and rated performance of the motor in the PMR design. Finally, based on the PMR design scheme, the Y2-132M1-6 IM is remanufactured into an experimental prototype. The total cost of the PMR is calculated and the performance improvement is tested through experiments.

Electrical design for efficiency: technical and operational measures for optimizing the use of electrical power on ships

There is currently a growing concern in the shipping industry about energy consumption and environmental impacts. According to the International Maritime Organization's (IMO) energy efficiency guidelines, today's ships must have an energy efficiency management plan to reduce the CO2 emission and other pollutants. In this article, a bibliographic review of methodologies for the optimization of energy consumption on ships is carried out, starting from the identification of sources of energy losses, to the implementation of technical and operational measures that contribute to their improvement, making a qualitative evaluation of the identified methodologies. Sources of energy losses associated with equipment and auxiliary systems are analyzed, as well as opportunities for improvement in the use of electrical energy through the implementation of intelligent energy management systems, high efficiency motors, and lighting. The technical and operational energy efficiency measures described above demonstrate the importance of their implementation from the early stages of the ship's electrical design, as well as monitoring energy consumption during its life cycle, to improve energy efficiency on board.

Quantifying the energetic cost tradeoffs of photovoltaic pumping systems for Sub-Saharan African smallholder farms

As solar technology has matured, irrigation using photovoltaic pumping systems (PVPSs) has gained popularity in developing markets as an effective means to alleviate poverty and increase food security. Yet, there remains a barrier to adoption; the upfront costs of PVPSs pose a financial burden for many low-income farmers. In a PVPS, the capital cost of the solar array contributes a large portion of upfront system costs. The solar pump is the largest energy consumer in the system, thus its efficiency directly impacts the size and cost of the solar array. There is a limited quantitative understanding of how solar pump efficiency affects the capital cost of the solar array. This study presents a technoeconomic framework to directly quantify the impact of solar pump efficiency on the cost of the solar array in a PVPS, for a range of hydraulic operating conditions. New empirical efficiency scaling laws were created by characterizing the efficiencies of 4-inch multistage centrifugal borehole pumps and induction motors. The utility of the technoeconomic framework is demonstrated through a case study comparing solar pump architectures with motors of different efficiencies. Results indicate that, despite the increased motor cost, the use of high-efficiency motors in solar pumps may lead to an overall cost reduction in a PVPS. Counter to the conventional capital cost-driven process, this work demonstrates that an efficiency-driven design process could improve low-cost, solar-powered system design. Engineers and system designers can leverage the presented framework during the design process to make informed decisions to achieve more cost-effective PVPSs.

Lightweight thermoplastic coated soft magnetic composites (SMC) and application for high-efficiency brushless DC motors

The introduction of new materials and manufacturing technologies has significantly improved soft magnetic composites (SMCs) applications, with unique 3D shapes, reduced weight, and lower energy losses, material waste, and manufacturing costs. However, coating materials and existing iron powder insulation techniques limit the applicability of SMCs. This study used an organic polyether ether ketone (PEEK) coating to insulate iron particles using a more effective technique. The prepared SMCs comprised several volume concentrations of iron and PEEK, which were evaluated based on their magnetic, electric, and physical properties. Their magnetic properties were studied at various temperature ranges, considering the operating temperature limits for different applications. A mass magnetization saturation value of 236.2 emu/g was achieved at 348.15 K for a 6.2 g/cm3 sample. Furthermore, lighter and energy-efficient brushless direct current (BLDC) motors featuring SMC cores were manufactured and compared with a laminated core-based motor. The developed SMC motors (93 %) were approximately 9.90 % more efficient than the laminated core-based motors (83.1 %), while the core losses of SMC core (<1 %) were approximately 5.50 % less than those of the laminated core (6.50 %).

Analysis of isolated phase windings and permanent magnet assists high energy efficient hybrid‐reluctance motor for electric vehicle

AbstractThis article describes the electromagnetic analysis of high efficient hybrid motor, which comprises the salient features of switched reluctance motor (SRM) and spoke‐type brushless DC motor. The main objective is to develop a motor with a high‐power density and winding faulty capability. Furthermore, this research article extends in the manner to increase the power density of the motor through the sensitivity analysis on rotor geometry by replacing the rotating part of SRM and adopting the rotor of spoke type brushless DC motor, originating the hybrid motor with the high‐power density and enhanced efficiency. To ensure the winding fault capability, a SRM‐based stator winding is adopted. Then, the modelling process for hybrid motor 48 V, 1500 RPM, 2 kW, and 12.7 Nm are detail in both analytical and finite element methods. The electromagnetic analysis is carried out to estimate the torque characteristics and flux pattern of the proposed motor. Furthermore, the proposed motor is analysed with the selection of laminating core material among M 27 24 Ga, 36F155, 46F165, 47F165, M 420 50D, and arnon 7. This infers 36F155 material assists proposed motor has high‐performance characteristics. The vibration frequencies are investigated in modal aspects to estimate the natural frequencies of vibrations. These analyses are validated among analytical and finite element results under no‐load conditions.

The development of a high-efficiency aquaculture water pump using self-adhesive electrical steel

Traditional water pump use AC motor combines with gearbox to achieve high torque and low speed to protect fish form injury by blades, which will shorten the life of waterwheel. Besides, the efficiency of the gearbox is about 40 ∼ 50%, resulting in low efficiency of whole system, and translated into poor reliability. The waterwheel in this study uses surface permanent magnet (SPM) motor instead of AC motor. However, the design of conventional waterwheel PM motor has the following drawbacks: (a) the slot fill factor cannot be too low; (b) the spacing between the rotor magnet grooves is too large, which affect the efficiency of the motor. To improve the motor efficiency without changing the shape of the stator core, this study developed an assembled stator core to improve the slot fill rate of motor winding. However, if the stack length of the stator core is too high, there will be a problem of core breakage. Therefore, this study introduced the self-adhesive steel to develop a self-adhesive assembled stator core to improve the breakage situation, and also to take advantage of the higher slot fill rate of the assembled core. Furthermore, in order to solve the problem of large spacing between the rotor magnet grooves, we optimize the magnetic circuit design by using simulation to improve the motor performance, such as magnet size, slot opening size, etc, to make the back electromotive force waveform as a sine wave. In addition, this design also reduces the thickness of magnets to reduce the cogging torque of the motor, and effectively reduces magnet usage to reduce the cost. As a result, this study developed a high-efficiency waterwheel SPM motor about 86.32% at 123 rpm, by using self-adhesive assembled stator core to increase the slot fill factor. The overall efficiency of system reaches about 78.72%.