Permanent Magnet Machine 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.

Diagnostics of Interior PM Machine Rotor Faults Based on EMF Harmonics

This article presents a detailed study on the diagnosis of rotor faults in an Interior Permanent Magnet Machine based on a mathematical model. The authors provided a wide literature review, mentioning the fault diagnosis methods used for Permanent Magnet Machines. The research emphasizes the necessity of precise assumptions regarding winding construction to accurately analyze the additional harmonics appearing in rotor faults caused by electromotive force (EMF), i.e., rotor eccentricity and magnet damage. The article also discusses specific features appearing in the spectrum of air gap permeance functions and the impact of rotor eccentricity and magnet damage on PM flux density distribution and as a consequence on EMF stator windings. The novelty of the presented content is the analysis of induced EMFs for cases of the simultaneous occurrence of rotor eccentricity and PM damage. The findings of this study provide valuable insights for the diagnosis and understanding of internal asymmetries in Interior PM Machines.

A versatilely high fidelity electric machines emulator for rapid testing of motor controller.

Electric machines emulators (EMEs) based on hardware-in-the-loop (HIL), which effectively act as emulators to mimic the actual motor behavior of Interior Permanent Magnet (IPM) machines. EME is frequently used to evaluate motor controller and motor control methodologies prior to development. The inverse magnetization motor model, which is used as the basis for real-time simulation in this paper's proposal for an electric machine emulator system based on HIL, uses FEA to create the motor model data. The nonlinear features of the motor may be successfully replicated with this motor model, and the accuracy of the electric machine emulator can be enhanced by using a straightforward and trustworthy motor controller. The real-time simulation tool typhoon HIL is used in the study to develop a hardware-in-the-loop simulation platform for an IPM electric machines emulator.

Torque Capacity Improvement of Flux-Switching PM Machines Based on Directional Stator Permeance Design

As one type of flux modulation machines, flux-switching permanent magnet (FSPM) machines present high sensitivity to airgap structures. Therefore, both stator/rotor teeth and slot/pole combinations have significant influences on machine performance. However, the relationships between the optimal stator structure and maximum torque capability of the FSPM machine are barely investigated. Therefore, this paper is devoted to proposing a directional stator permeance design approach to achieve the maximum torque of the FSPM machines under a given rotor, and reveal the corresponding stator structure. First, the relations between torque and air-gap permeance are presented based on a constructed torque contribution equation, where amplitudes and phase angles of the stator permeance harmonics are determined. Then, main permeance harmonics are directionally optimized to enlarge positive torque, while negative contributions are inversed to be positive. Especially, two FSPMs with 6-slot/19-pole and 6-slot/13-pole are chosen as design examples, and their optimal design processes and torque performances have been deeply analyzed, which verifies the effectiveness of the proposed design approach.

Fourier-Based Vibration Model of Electrical Machines Considering Nonideal Orthogonality Between Electromagnetic Forces and Structural Modes

This paper proposes a Fourier-based model of vibration synthesis, improving both precision and speed. For the first time, the nonideal orthogonality between electromagnetic (EM) forces and structural modes is theoretically proposed and modelled by spatial harmonics. Different from the discrete vectors used in previous literature, the proposed method achieves a one-dimension (1-D) continuous model of EM forces and modes. On the basis, the vectors of modes and forces on tooth surfaces are decomposed by fast Fourier transform (FFT), so that the vibration response is synthesized based on Fourier coefficients. Further, the proposed model is applied to a 12-slot/10-pole (12s/10p) interior permanent-magnet (IPM) machine. The spatial harmonics of mode vectors are elaborated to identify the key orders of EM forces before the vibration response is completed. Then, the proposed model is compared with the coupled-field finite element analysis (FEA). The advantages are verified in terms of computational accuracy, speed, and sensitivity to mesh quality. Finally, the feasibility of the proposed model is verified by both coupled-field finite element analysis (FEA) and experiment.

A Novel Asymmetric Interior Permanent Magnet Machine with Auxiliary Flux Barriers

AbstractA novel asymmetric interior permanent magnet (AIPM) machine is proposed in this paper. The machine's rotor consists of asymmetric poles and auxiliary flux barriers. The torque ripple of the machine is weakened by the asymmetric design of the left and right sides of the magnetic poles. The magnetic‐field‐shifting (MFS) effect improves the electromagnetic torque after adding the auxiliary flux barrier to shift the magnetic axis. The influence of critical geometrical parameters on the electromagnetic performance of the machine is investigated under the condition that the stator and permanent magnet volume remain unchanged. The relevant geometrical parameters of the machine are optimized and designed through the improved Taguchi method. The performance of the AIPM machine and the conventional machine under no‐load and load conditions are further compared by simulation analysis with finite elements, verifying the increase in electromagnetic torque and the reduction in torque ripple. © 2024 Institute of Electrical Engineers of Japan and Wiley Periodicals LLC.

Semi‐flooded cooling for high torque density modular permanent magnet machines

AbstractThe authors investigate a semi‐flooded cooling technology for modular permanent magnet machines using flux gaps (FGs) in alternate stator teeth for extra cooling channels. The investigated machine is separated into stationary and rotational components by a polyether ether ketone sleeve. Liquid is directed into the stationary component to achieve a significant temperature reduction, at the same time, avoiding the liquid leakage into the rotating component that will cause an increase in friction losses. The FGs in the modular machine increase the contact area between coolant and machine components, resulting in better cooling efficiency. Furthermore, the FGs contribute to reduced pressure loss by minimising system flow resistance. The influence of the FG width on improving machine cooling efficiency, lowering machine temperature, and reducing pressure losses is delved. Additionally, the investigation considers the impact of inlet and outlet areas to reveal the influences stemming from fluid expansions and contractions in these regions. Computational fluid dynamics (CFD) modelling is employed to simulate the cooling performances of the investigated machines. In addition, the flow network analysis has also been employed to help understand the fluid behaviour within machines. A series of tests have been carried out to validate the CFD modelling.

Nonlinear Analytical Solution in Axial Flux Permanent Magnet Machines Using Scalar Potential

Analytical model (AM) has significant value on early design stage for electric machines, in terms of both time and accuracy. AM can be developed based on vector or scalar potential, but all AMs for armature reaction are using the vector potential, and it is a difficult matter to model armature reaction by scalar potential. This is the gap that the work here proposed aims to fill. We, for the first time, report the load magnetic field prediction by using magnetic scalar potential. Also, the proposed nonlinear AM is developed for the surface mounted permanent magnet machine. The proposed model is development based on the two-dimensional harmonic subdomain approach by solving the Maxwell's equations. The magnetic sources, viz., the armature reaction is regarded as line current and solved at the connection boundaries. The comprehensive derivations and calculation algorithm are explained in detail. Moreover, the analytical model is developed for an axial flux PM machine, both finite element model and experiment are verified the correctness of proposed model, and good agreement is achieved. Moreover, a slightly modification can also be applied to the radial flux PM machines.

Open-Circuit Fault Diagnosis of Three-Phase Permanent Magnet Machine Utilizing Normalized Flux-Producing Current

In this paper, an open-circuit fault diagnostic method is proposed for three-phase permanent magnet machines. By individually applying inverse coordination transformation to <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">d</i> - and <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">q</i> -axis currents, per-phase current can be decomposed into flux- and torque-producing currents. Their post-fault behaviors are found to be highly related with the fault types and locations. Hence, the normalized flux-producing current can be used as a single fault index to detect and identify both open-switch and open-phase faults. Since the established fault index is close to zero, the proposed fault diagnostic method is naturally robust to load/speed variations. In addition, a low decision threshold can be set to reduce fault diagnostic time. The robustness and effectiveness of the proposed method are verified by the experiments on one prototype.

Multi-Objective Optimization of Yokeless and Segmented Armature Machine for In-Wheel Traction Applications Based on the Taguchi Method

For electrical machines with complex structures, the design space of parameters can be large with high dimensions during optimization. Considering the calculation cost and time consumption, it is hard to optimize all the design parameters at the same time. Therefore, in that situation, sensitivity analysis of these design parameters is usually used to sort out crucial parameters. In this paper, the sensitivity analysis-based Taguchi method is applied to optimize the axial-flux permanent magnet (AFPM) machine with yokeless and segmented armature (YASA) topology for an in-wheel traction system. According to the key parameters and their sensitivity analysis, the optimal machine scheme to meet the performance requirements can be formed. In this case study, the machine performance is improved significantly after optimization. Lastly, the experimental results verify the accuracy of the model used in this study.

Analytical model of an ironless axial flux permanent magnet machine for electromagnetic force calculation and vibration analysis

Analytical model of an ironless axial flux permanent magnet machine for electromagnetic force calculation and vibration analysis

Enhancing Heat Transfer Efficiency in Permanent Magnet Machines through Innovative Thermal Design of Stator Windings

This paper investigates innovative methods for enhancing heat transfer efficiency in high-power permanent magnet electrical machines. The objectives are to quantify the effects of increasing the air speed, increasing the turbulence intensity, and introducing the spacing between windings on cooling performance. The cooling of stator windings is studied through experimental wind tunnel testing and Computational Fluid Dynamics (CFD) modelling. The CFD model is validated against wind tunnel measurements to within 4 Kelvin (K). The results demonstrate that each enhancement method significantly improves the cooling capability. Increasing the air speed from 10 m/s to 40 m/s reduces the winding hotspot temperature by 34%. Introducing a high turbulence intensity of 40% leads to a 21% lower hotspot temperature compared to 0.5% turbulence intensity. Creating a 1.5 mm spacing between coils also substantially improves convection and conduction heat transfer. Overall, combining these optimised design parameters yields over a 40% reduction in hotspot temperature compared to the original design. This research provides practical guidance for maximising heat transfer efficiency in high-power permanent magnet machines, without increasing complexity. The findings will lead to higher machine efficiency, reliability, and longevity for aerospace and other applications.

A Stiffness Approach for Coupling Structural and Magnetic Models for the Sustainable Design, Optimisation and Real-Time Structural Integrity Assessment of Radial Flux Permanent Magnet Generators for Direct-Drive Wind Turbines

The mass of a direct-drive generator is often defined by the requirements for structural stiffness to meet the magnetic stiffness between the rotor and stator surfaces. This paper analyses this magnetic stiffness and estimates the structural stiffness of direct-drive generators for different modes of deflection. The magnetic stiffness modelling is based on an analytical model of the airgap closing forces. The final models are verified using finite element analysis and developed for both permanent magnet and wound rotor generators. It shows that wound rotor machines have higher stiffness requirements than permanent magnet machines. The structural stiffness of the generator rotor and stator is evaluated for different modes by applying spatially varying forces and finding the associated deflections. Structural stiffnesses for the rotor, stator and bearing are then combined. Finally, the magnetic and structural stiffnesses are combined and a stiffness margin can be found. This method is applied to a relatively stiff and a relatively compliant set of generator structures in a case study. The analytical model presented in this paper is useful for structural optimisation purposes or as part of an online structural health monitoring system as it could assess the integrity of the machines in real time.

Analysis and reduction of electromagnetic vibration in integral-slot PM machine by functional magnet structure

It is significant to balances torque and vibration performance for the surface-mounted permanent magnet (PM) machines. This paper proposes a functional magnet structure to suppress the vibration response of integral-slot surface-mounted PM machines. At the same time, the torque ripple is also greatly reduced without sacrificing the average torque. Firstly, taking the 48-slot/8-pole PM machine as an example, the main sources of the air-gap radial force are analyzed based on the Maxwell stress equation. Thereby, the main PM flux density harmonic components that contribute to the radial force are pointed out. Secondly, the design method of different functional magnet structure is investigated. Then, the effects of different magnet shapes on the torque and vibration performances are compared. The result shows that the proposed sinusoidal+3rd-order harmonic injection functional magnet structure can effectively improve the vibration performance without sacrificing the average torque. Finally, the prototype of the 48-slot/8-pole PM with functional magnet structure is manufactured, and the experiments are carried out for validation.

Full harmonic spectrum calculation of magnetic pressures in synchronous permanent magnet machines based on a new realistic partial analytical model: application to SVPWM and DPWM2

PurposeThe purpose of this paper is to propose a new method that allows to compare the magnetic pressures of different pulse width modulation (PWM) strategies in a fast and efficient way.Design/methodology/approachThe voltage harmonics are determined using the double Fourier integral. As for current harmonics and waveforms, a new generic model based on the Park transformation and a dq model of the machine was established taking saturation into consideration. The obtained analytical waveforms are then injected into a finite element software to compute magnetic pressures using nodal forces.FindingsThe overall proposed method allows to accelerate the calculations and the comparison of different PWM strategies and operating points as an analytical model is used to generate current waveforms.Originality/valueWhile the analytical expressions of voltage harmonics are already provided in the literature for the space vector pulse width modulation, they had to be calculated for the discontinuous pulse width modulation. In this paper, the obtained expressions are provided. For current harmonics, different models based on a linear and a nonlinear model of the machine are presented in the referenced papers; however, these models are not generic and are limited to the second range of harmonics (two times the switching frequency). A new generic model is then established and used in this paper after being validated experimentally. And finally, the direct injection of analytical current waveforms in a finite element software to perform any magnetic computation is very efficient.

Comparative analysis of dual stator machines

Electromagnetic performance of three different types of double stator permanent magnet machine is analyzed and compared in this study. The analyzed machines in this study are Machine 1, Machine 2 and Machine 3. These machines are designated as: M 1, M 2 and M 3, respectively. The studies are implemented using two-dimensional and three-dimensional finite element analysis (2D-FEA and 3D-FEA) methods. The predicted performance indices are: total harmonic distortion of the voltage, torque ripple, cogging torque, winding inductances, output torque and unbalanced magnetic force (UMF). The studies show that the investigated machine types have negligible reluctance torque and thus, similar axes inductance values. Therefore, the machines’ bulk torque components are contributed mainly by the magnets while the armature excitation sources yield lesser torque components. Amongst the compared machines, M 3 type has an outstanding performance in almost all the performance metrics, compared to M 2 and M 1 types. Nevertheless, M 1 machine type has some good attributes, particularly, with respect to its high output torque per applied magnet volume, in addition to its widest operating speed range ability. Low-speed high-torque applications are most suitable for the investigated machines in practice.

Prototype development of a fully coreless multi-stage axial-flux permanent-magnet machine (AFPM) through the performance comparison between single-stator double-rotor (SSDR) and double-stator single-rotor (DSSR) configurations

Cascading rotor and stator in axial flux permanent magnet (AFPM) machine is a beneficial concept to increase the power density without increasing the diameter of the machine. Multi-stage AFPM can provide higher torque capability in applications requiring high power density. In this regard single-stator double- rotor (SSDR) and double-stator single-rotor (DSSR) are efficient machines compared to single -stage AFPM. Since SSDR and DSSR are also considered modular units to make multi-stage AFPM, like single-stage AFPM, this paper makes a comparison with analysis between SSDR and DSSR AFPM machines. Based on 3-D finite element analysis (FEA), the air-gap magnetic flux, voltage, current, torque, torque ripple, power and power density, efficiency are comparatively investigated to evaluate their performance. Results show that fully coreless topology only be achieved in SSDR AFPM machine with a higher power density. Finally, a prototype multi-stage coreless generator has been developed using a single stator double rotor (SSDR) configuration to justify the fully coreless concept. This prototype coreless generator eliminates eddy current losses and reduces weight, making it a suitable option for certain portable applications.

Equivalent Analytical Model of Magnetic Field in Parallel Magnetic Circuit Axial Flux Permanent Magnet Machines

The axial flux permanent magnet (AFPM) machines with the parallel magnetic circuit (PMC) rotor can effectively improve its torque density. The PMC rotor consists of two sub‐rotors, radial Halbach array permanent magnet (PM) and tangential PM. The magnetic fields generated by two sub‐rotors are not in the same 2‐D analytical planes. In this paper, an equivalent analytical model of PMC‐AFPM machines is proposed to solve this problem. The radial Halbach array PM rotor is equated to the axial Halbach array PM rotor based on the equivalent transformation principle. The exact subdomain models of equivalent axial Halbach array PM rotor and tangential PM rotor are built respectively and then superimposed to obtain the magnetic field distribution. The electromagnetic characteristics of the PMC‐AFPM machine under no‐load and load conditions are calculated by the proposed analytical model and compared with calculations of the finite element model (FEM). The results verify the accuracy of the equivalent analytical model. The comparative analysis of the AFPM machines with PMC rotor and tangential PM rotor verifies the advantage of PMC rotor configuration to improve the torque density. © 2024 Institute of Electrical Engineer of Japan and Wiley Periodicals LLC.

A triple 3-phase fault-tolerant fractional slot concentric winding interior permanent-magnet machine with low space harmonics

A triple 3-phase fault-tolerant fractional slot concentric winding interior permanent-magnet machine with low space harmonics

Cogging Torque Reduction of Axial-Modular Flux Switching Permanent Magnet Machine by Module Combination Technique

Flux switching permanent magnet machine exhibits high cogging torque due to the doubly salient topology and high air gap flux density. This paper proposes a new axial-modular flux switching permanent magnet (AM-FSPM) machine, which has an improved torque capability and the potential of cogging torque suppression by module combination technique. The cogging torque analytical expression of the machine with axial-modular topology is derived based on a magnetomotive force-permeance model. Then, the AM-FSPM machines are divided into two types by the combinations of stator-slot and rotor-pole, named fundamental harmonic offset naturally and fundamental harmonic offset manually. In addition, four approaches are investigated to reduce cogging torque by changing modular magnetomotive force and changing modular permeance. It can be concluded that the modular rotor tooth combination method has the most attractive torque performances among the four methods. Finally, the effectiveness of the proposed approaches is verified by the 3D finite element analysis and experimental results.