Non-overlapping Windings Research Articles

Development of a Three-Phase Dual-Rotor Magnetless Flux Switching Generator for Low Power Wind Turbines

This article presents a new three-phase flux switching generator (FSG), which is mainly designed for variable-speed low power wind turbines. The magnetless structure of this generator not only reduces the machine cost but also increases the flux controllability. In order to shorten the field and armature end-windings, non-overlapped concentrated windings have been ingeniously incorporated into the dual-rotor middle-stator structure. A parametric study of both stator and rotor pole arcs is carried out, targeting maximum generated EMF, and minimum cogging torque. Using finite element method, the performance of the final design is analysed. Through the ac–dc rectification, the generated EMF is rectified to give out the dc output voltage, which can be regulated by controlling dc excitation current, and accordingly, the machine can behave as a constant-output dc generator under different conditions of rotor speeds and load currents. Finally, a prototype has been manufactured and experimented to prove its validity for dc microgrids integrated with wind generation systems.

Comparative Study of Winding Configurations of a Five-Phase Flux-Switching PM Machine

This paper introduces a general method for determination of the most suitable winding configurations for five-phase flux-switching permanent magnet (FSPM) machines, associated with feasible stator/rotor-pole combinations. Consequently, the effect of winding configurations on the performance of a five-phase outer-rotor FSPM machine is thoroughly investigated, including non-overlapping concentrated windings (single-layer, double-layer, and multi-layer) as well as distributed winding. The electromagnetic characteristics in the low-speed region, the flux-weakening capability in the high-speed region, and the fault-tolerant capability under faulty situations are evaluated and compared in detail. This work shows that compared with the conventional single-layer or double-layer concentrated windings, the FSPM machine with multi-layer type winding exhibits lower torque ripple and losses. Meanwhile, the motor with distributed windings possesses higher torque density and larger inductance. Finally, a prototype is manufactured, and the analysis results are validated by experiments.

Electromagnetic Performances and Main Parameter Sensitivity Effect on Unbalance Magnetic Flux in a New Single-Phase FEFSM with Segmental Rotor

Three-phase field excitation flux switching motor (FEFSM) with salient rotor structure has been introduced with their advantages of rotor easy temperature elimination and controllable FEC magnetic flux. Yet, the salient rotor structure is found to lead a longer magnetic flux path between stator and rotor parts, producing a weak flux linkage along with low torque performances. Hence, a new structure of single-phase FEFSM using segmental rotor with non-overlap windings is proposed with advantages of shorter magnetic flux path, light weight and robust rotor structure. Analysis on fundamental magnetic flux characteristics, armature and FEC magnetic flux linkages, cogging torque, back-Emf, various torque capabilities, refinement of unbalance magnetic flux, and torque-power versus speed characteristics are conducted using 2D FEA through JMAG Designer version 15. The results show that magnetic flux amplitude ratio has been improved by 41.2% while the highest torque and power achieved are 1.45 Nm and 343.8 W, respectively.

A Dynamic Multilayer Winding Thermal Model for Electrical Machines With Concentrated Windings

This paper presents a dynamic multilayer winding lumped-parameter thermal model dedicated to electrical machines with concentrated windings. The winding is layered into a series of circular rings by a novel layer strategy according to the winding temperature distribution obtained by a two-dimensional analytical slot winding thermal model. Accordingly, the layer number can be automatically and dynamically adjusted so as to accurately model the winding temperature distribution using the smallest layer number. Besides, the end-winding is also layered similarly to the slot-winding based on the thermal behavior of the nonoverlapping concentrated windings. The proposed winding model could accurately calculate the temperature distribution within the slot, including the winding maximum and average temperature. Experiments on a winding motorette and a water-cooled permanent magnet machines with concentrated winding intended for electric vehicles have been implemented to validate the proposed winding thermal model.

Comparative Study of Modular Dual 3-Phase Permanent Magnet Machines With Overlapping/Non-overlapping Windings

For modular permanent magnet (PM) machines with overlapping (OLP) windings widely employed in wind power generation, the large torque ripple and long end winding are major issues. In order to solve these problems, PM machines with non-overlapping (NOLP) windings and redundant teeth for easy modularity are proposed in this paper. The comparative study between modular machines with these two kinds of windings is necessary and is the major focus of this paper. For the sake of clarity, two modular dual 3-phase machines with 42-slots/32-poles (42S/32P) and 192S/32P combinations are chosen as examples to show the differences in terms of machine performance. The proposed 42S/32P modular machine adopts NOLP winding, while the conventional 192S/32P one uses the OLP type. Based on the results, it is found that the modular machine with NOLP winding has comparable average torque and efficiency. In the meantime, much lower torque ripple exists for the proposed modular machine regardless of the current value. The shorter and simpler end windings are beneficial to manufacturability. Moreover, the proposed modular machine with NOLP winding will be more fault tolerant due to smaller mutual inductances between phases and larger d -axis inductance. Finally, the proposed 42S/32P modular machine is prototyped and the experiments validate the correctness of the analyses in this paper. Despite two specific examples being used, the conclusion should be generic and can be employed to modular machines with other slot and pole number combinations.

Finite element analysis of a modular brushless wound rotor synchronous machine

This study presents a comparative study of different modular brushless wound rotor synchronous machines (MB-WRSM) using non-overlapping fractional slot double-layer concentrated windings. The goal of the study is to highlight the structure which offers the best fault-tolerance capability and the highest output performance. The fundamental winding factor is calculated by using the method based on voltage phasors as a significant criterion to select the preferred numbers of phases, stator slots, and poles. With the limited number of poles for a small machine (3.67 kW/7000 rpm), 15 different machines for different phase/slot/pole combinations are analysed using two- dimensional (2D) finite element method and compared according to three criteria: torque density, torque ripple, and machine efficiency. The seven-phase/seven-slot/six-pole machine is chosen with the best compromise of high torque density, small torque ripple (3.89%), and high nominal efficiency (95%). This machine is then compared with a reference design surface-mounted permanent magnet synchronous machine (SM-PMSM). The simulation results are discussed and demonstrate that the MB-WRSM presents interesting performance features, such as extended field weakening range, with overall performance closely matching that of an equivalent SM-PMSM.

Optimal design of single-phase 12S-6P FEFSM using segmental rotor and non-overlap windings

<span>Recently, a three-phase Field Excitation Flux Switching Motor (FEFSM) using salient rotor has been introduced, suitable for high torque, high power as well as high speed diverse performances due to their advantages of easy rotor temperature elimination and controllable field excitation (FE) flux. However, existing FEFSMs are found to have low torque performance as the salient rotor structure has caused longer flux path, and consequently weak flux linkage. Therefore, a new structure of a single-phase FEFSM using segmental rotor and non-overlap windings is proposed. There are two valuable findings found in this topology, first is less copper loss due to the non-overlap windings between armature and FE coils, and secondly the segmental rotor structure has produces shorter flux path to produce high torque, less rotor weight as well as robust rotor at high speed condition. Flux linkage, back-emf, average torque and output power characteristics of the initial and optimized designs have been investigated and compared using 2D Finite Element Analysis (2D-FEA) through JMAG Designer version 15. Based on the 2D-FEA analysis, the average torque has increased by 81.3% to 1.65 Nm, while the output power of 466.5 W, increased of 68.2%. In conclusions, a FEFSM using segmental rotor and non-overlap windings is considered as the best single-phase motor due to their optimal performances and less copper loss.</span>

A Comparative Study of Coreless-Type PM Linear Synchronous Machines With Non-Overlapping Windings

This paper presents the comparative study of coreless-type permanent magnet linear synchronous machines with non-overlapping windings. An analytical expression that can be applied to any combinations of pole and coil numbers is developed for evaluating the electromagnetic performances. Subsequently, a simple factor called thrust factor is introduced to find the best ${\boldsymbol{C}_{\boldsymbol{pp}}}$ family depending on the variation of coil width ratio. From the comparative study, a significant result is reported that ${\boldsymbol{C}_{\boldsymbol{pp}}} = 1/4$ , i.e., multiple 4-pole/3-coil, is the best non-overlapping winding configuration of coreless-type permanent magnet machines owing to the highest value of thrust factor. Finally, the validity of the key analyses is confirmed by optimal results, finite element results, and experimental results from prototype machines.

Modular Rotor Single Phase Field Excited Flux Switching Machine with Non-Overlapped Windings

This paper aims to propose and compare three new structures of single-phase field excited flux switching machine for pedestal fan application. Conventional six-slot/three-pole salient rotor design has better performance in terms of torque, whilst also having a higher back-EMF and unbalanced electromagnetic forces. Due to the alignment position of the rotor pole with stator teeth, the salient rotor design could not generate torque (called dead zone torque). A new structure having sub-part rotor design has the capability to eliminate dead zone torque. Both the conventional eight-slot/four-pole sub-part rotor design and six-slot/three-pole salient rotor design have an overlapped winding arrangement between armature coil and field excitation coil that depicts high copper losses as well as results in increased size of motor. Additionally, a field excited flux switching machine with a salient structure of the rotor has high flux strength in the stator-core that has considerable impact on high iron losses. Therefore, a novel topology in terms of modular rotor of single-phase field excited flux switching machine with eight-slot/six-pole configuration is proposed, which enable non-overlap arrangement between armature coil and FEC winding that facilitates reduction in the copper losses. The proposed modular rotor design acquires reduced iron losses as well as reduced active rotor mass comparatively to conventional rotor design. It is very persuasive to analyze the range of speed for these rotors to avoid cracks and deformation, the maximum tensile strength (can be measured with principal stress in research) of the rotor analysis is conducted using JMAG. A deterministic optimization technique is implemented to enhance the electromagnetic performance of eight-slot/six-pole modular rotor design. The electromagnetic performance of the conventional sub-part rotor design, doubly salient rotor design, and proposed novel-modular rotor design is analyzed by 3D-finite element analysis (3D-FEA), including flux linkage, flux distribution, flux strength, back-EMF, cogging torque, torque characteristics, iron losses, and efficiency.

Outer rotor wound field flux switching machine for In‐wheel direct drive application

Nowadays the flux switching machines offer pivotal role in high speed applications. The flux sources (field excitation coil and armature winding or permanent magnet) are confined to the stator leaving rotor completely passive, and thus making the flux switching machine (FSM) more suitable for industrial applications. This paper emphasizes salient rotor pole and non-overlapping windings embedded in electrical machine design possess some pertinent features such as reduced copper losses, low-cost, and usage in high speed applications. The proposed design is analyzed for coil test analysis and flux linkage and torque. On the basis of the analysis performed, it is clear that 12-slot/13-pole has low cogging torque, high flux linkage, and maximum torque, compared with other topologies of outer rotor field excitation FSM. A deterministic optimization technique is adopted to enhance the performance of 12-slot/13-pole design. Further, finite element analysis (FEA) results are verified through Global Reluctance Network (GRN) methodology, which show close resemblance with error less than 1.2%. Hence, it validates the proposed design for outer rotor field excitation FSM direct drive application. The proposed design for hybrid electric vehicle torque characteristic is compared with existing interior permanent magnet synchronous machine (IPMSM) and 6-slot/7-pole wound field flux switching machine (WFFSM).

Novel 24‐slots14‐poles fractional‐slot concentrated winding topology with low‐space harmonics for electrical machine

This paper proposes a novel winding layout for the electric machines with fractional-slot concentrated windings (FSCW) using a stator shifting concept, with which all the non-working harmonics can be completely cancelled or significantly reduced and the non-overlapping winding can be kept. First, the basic winding layout with a 24-slot 14-pole machine to reduce the significant 1st sub-harmonic will be presented for machines with single-layer (SL) windings. From this, a novel double layer (DL) winding layout using the stator-shifting concept will be introduced. By adopting two SL winding sets with a 105° mechanical angle shift with respect to each other, it is not necessary to use overlapping windings. With this configuration, the 1st sub-harmonic will be completely cancelled and the parasitic 5th harmonic will be significantly reduced. Hence, the rotor losses, specifically magnet loss will be significantly reduced. Finally, two PM machines with different DL winding layout, namely, conventional 12-slot 14-pole and 24-slot 14-pole machine, will be designed and compared to validate the advantages of this winding topology.

Double three-phase PMSM structures for fail operational control

This paper deals with permanent magnet synchronous motors (PMSM) structures. Especially their double three-phase arrangements are analysed in detail. Comparison of three different structures is treated. Non-overlapping concentrated winding is the first analysed structure. Distributed winding arrangement with interlaced sub-systems and also distributed winding arrangement with segregated sub-systems follows.The behaviour of all motor structures during normal operation is the same but the properties during faults are different. The motor behaviour during active short circuit (ASC) is discussed. ASC of whole motor and also partial ASC tests were performed. Current waveforms in different operating points are compared. Results show differences of individual structures with respect to operation during fault.

A Novel Fault Tolerant Machine With Integral Slot Non-Overlapping Concentrated Winding

A novel fault tolerant machine with integral slot non-overlapping concentrated winding (ISNCW) is proposed in this paper. With the distribution of phase windings in axial, the proposed machine realized excellent isolation capability between different phases. The performance comparisons between the proposed machine and the traditional integer slot overlapping winding (ISOW) machine are made by the analytical method and finite element analysis (FEA). Compared to the ISOW machine, the proposed machine has better performance in low speed high torque applications, and much better fault tolerant capability and flux weakening capability. Especially, the proposed machine appears excellent performance in limiting the short circuit current and preventing the irreversible demagnetization of permanent magnet under short-circuit fault. The phase independent structure makes the maintenance and replacement of the fault module convenient and saves the maintenance cost further.

Performance Comparison between Salient and Segmental Rotors Single-Phase FEFSM Using Non-Overlap Windings for Home Appliances

Field excitation flux switching machines (FEFSMs) in which their torque performance produced by interaction between armature and field excitation (FE) coils have been widely designed for various applications. In this regard, three-phase salient rotor FEFSM with overlap windings is considered the most suitable candidate for high speed applications because of their advantages of flux controllability, and robust due to single piece of rotor structure. However, the overlap windings cause a high copper loss, hence efficiency of the motor becomes low and higher stack length. Besides, the salient rotor structure is found to produce low torque performance due to the longer flux path in stator and rotor yielding weak flux linkage. In this paper, a new single-phase FEFSM using non-overlap windings between armature coils and FE coils is proposed. Both non-overlap windings FEFSMs with salient and segmental rotors have been designed using JMAG Designer version 15 and the investigation process is conducted via 2D finite element analysis. The proposed motor performances verification has been done by comparing the results of flux linkage, flux line and distribution, flux strengthening, various torque capability, and torque-power versus speed characteristics. As a conclusion, single-phase non-overlap windings FEFSM using segmental rotor with power, torque and speed capabilities of 277.5 W, 0.91 Nm and 2,899 rpm, respectively considered as the best candidate for low torque high speed applications.

An Analytical Subdomain Model of Torque Dense Halbach Array Motors

A two-dimensional mathematical model estimating the torque of a Halbach Array surface permanent magnet (SPM) motor with a non-overlapping winding layout is developed. The magnetic field domain for the two-dimensional (2-D) motor model is divided into five regions: slots, slot openings, air gap, rotor magnets and rotor back iron. Applying the separation of variable method, an expression of magnetic vector potential distribution can be represented as Fourier series. By considering the interface and boundary conditions connecting the proposed regions, the Fourier series constants are determined. The proposed model offers a computationally efficient approach to analyze SPM motor designs including those having a Halbach Array. Since the tooth-tip and slots parameters are included in the model, the electromagnetic performance of an SPM motor, described using the cogging torque, back-EMF and electromagnetic torque, can be calculated as function of the slots and tooth-tips effects. The proposed analytical predictions are compared with results obtained from finite-element analysis. Finally, a performance comparison between a conventional and Halbach Array SPM motor is performed.

Design and analysis of a three‐phase brushless flux switching generator for aircraft ground power units

This study proposes a new three-phase dual-rotor middle-stator brushless flux switching generator for 400Hz diesel-driven aircraft ground power units. For the proposed machine, both field and armature windings are hosted in the stator in such a way that not only fulfils brushless structure, but also realises the flux switching function. Moreover, both windings have non-overlapping concentrated windings to shorten the end-windings and reduce the copper losses. In the meantime, the rotor has only slots without any active parts. First, the machine detailed design is provided, and its performance is analysed using finite element method. Also, a selection topology of both stator and rotor pole arcs is carried out, targeting maximum generated electromotive force, minimum harmonic content, and minimum cogging torque. Then, a prototype is implemented and experimented to confirm the feasibility of the proposed machine.

Two-Dimensional Exact Subdomain Technique of Switched Reluctance Machines with Sinusoidal Current Excitation

This paper presents a two-dimensional (2D) exact subdomain technique in polar coordinates considering the iron relative permeability in 6/4 switched reluctance machines (SRM) supplied by sinusoidal waveform of current (aka, variable flux reluctance machines). In non-periodic regions (e.g., rotor and/or stator slots/teeth), magnetostatic Maxwell’s equations are solved considering non-homogeneous Neumann boundary conditions (BCs). The general solutions of magnetic vector potential in all subdomains are obtained by applying the interface conditions (ICs) in both directions (i.e., r- and θ-edges ICs). The global saturation effect is taken into account, with a constant magnetic permeability corresponding to the linear zone of the nonlinear B(H) curve. In this investigation, the magnetic flux density distribution inside the electrical machine, the static/dynamic electromagnetic torques, the magnetic flux linkage, the self-/mutual inductances, the magnetic pressures, and the unbalanced magnetic forces (UMFs) have been calculated for 6/4 SRM with two various non-overlapping (or concentrated) windings. One of the case studies is a M1 with a non-overlapping all teeth wound winding (double-layer winding with left and right layer) and the other is a M2 with a non-overlapping alternate teeth wound winding (single-layer winding). It is important to note that the developed semi-analytical model based on the 2D exact subdomain technique is also valid for any number of slot/pole combinations and for non-overlapping teeth wound windings with a single/double layer. Finally, the semi-analytical results have been performed for different values of iron core relative permeability (viz., 100 and 800), and compared with those obtained by the 2D finite-element method (FEM). The comparisons with FEM show good results for the proposed approach.

On-Load Analysis of Saturated Surface Permanent Magnet Machines Using Conformal Mapping and Magnetic Equivalent Circuits

This paper presents an iterative method based on conformal mapping and magnetic equivalent circuits for on-load analysis of saturated surface permanent magnet machines with integer slot and fractional slot windings. Magnetic saturation is taken into account by defining additional point wires in the stator slots and interpolar region between the magnets. The added point wires create magnetomotive force equal to the magnetic voltage drops across iron core flux tubes that are calculated using magnetic equivalent circuit. An improved stator tooth model has been introduced that enables more accurate field calculations for tooth geometries with highly saturated tooth tips. The model also takes into account variation of permanent magnet magnetization due to external magnetic field. The proposed method has been implemented on a saturated 12 slot, 10 pole surface permanent magnet machine with nonoverlapping concentrated winding and shows a very good agreement with finite element calculations in terms of flux density, back electromotive force, and torque waveforms as well as $d$ - and $q$ -axis inductances, cross-saturation inductance, and permanent magnet flux linkage in both axes.

Analysis and Implementation of New Ironless Stator Axial-Flux Permanent Magnet Machine With Concentrated Nonoverlapping Windings

This paper presents the integrated design and analysis of a new axial-flux permanent magnet (AFPM) machine, which consists of an ironless stator with double-layer concentrated nonoverlapping windings and twin external rotors with Halbach-array PMs. A general sizing equation based on fundamental theory, easily adjustable for ironless stator AFPM machine with concentrated windings, is derived to obtain preliminary parameters. Then, by using three-dimensional (3-D) finite element analysis (FEA), the optimization of a primary machine is implemented. A precise and fast calculation method based on a 3-D FEA model is proposed to confirm the eddy-current loss for ironless stator winding. By making a tradeoff between dc current loss and eddy-current loss of Litz wire for winding, the efficiency is further improved for a high frequency operation. Despite using Halbach-array PMs, a certain thickness of a rotor yoke is recommended to increase air-gap flux density. Finally, a prototype machine is developed, experimented, and evaluated. The test results reveal the strong overload and heat dispersal capacity of the proposed stator ironless AFPM machine with the maximum efficiency of 98.5%. Measured performances of the manufactured prototype verify the validity of the proposed analysis method and FEA results.

Active Zone of Permanent Magnet Synchronous Machine with a Non-Overlapping Concentrated Winding

Abstract The research is devoted to the investigation of NdFeB permanent magnet (PM) based synchronous generators with non-overlapping concentrated windings. The rotor of such a generator has 10 pole pairs (PMs), which is dictated by the nominal voltage frequency (f=50 Hz) and the rotational speed (n=300 RPM). Comparison is made for four generators with three-phase winding coils and stator tooth numbers 18, 21, 24 and 27.