Segmented Stator Research Articles

Sensorless Control of Segmented PMLSM for Long-Distance Auto-Transportation System Based on Parameter Calibration

The permanent magnet linear synchronous motor (PMLSM) with segmented stator is applied in the long-distance auto-transportation system. For the PMLSM with the discontinuous stators, the mismatch between the permanent magnet (PM) mover and the stator would make electromagnetic (EM) parameters deflect nominal values, and then position/speed precision of the PM mover would be affected. In this article, the sensorless control based on the parameter calibration is used to drive the PM mover above the segmented stators during the drive process. Furthermore, an improved model reference adaptive integrator based on the parameter calibration is proposed to calibrate the EM parameters during the switch process. The simulation and experimental results confirm that the speed precision and the robustness of the segmented PMLSM are enhanced distinctly.

Multiphysics Analysis of an Axial-Flux In-Wheel Motor With an Amorphous Alloy Stator

This paper presents a novel yokeless and segmented armature (YASA) axial-flux in-wheel motor with amorphous magnetic material (AMM) stator cores for a solar-powered electric vehicle. Although this new axial-flux in-wheel motor has many advantages such as high efficiency, shorter axial length, and high power density, its working condition is complicated. In-wheel motors are usually operated in electromagnetic, thermal, and other multiphysics environments. Increasing the performance requirements of in-wheel motors, such as power density, efficiency, and reliability, requires a multiphysics design approach. The focus of this paper is on the analysis of electromagnetic characteristics, losses, temperature distribution, mechanical behavior and other characteristics of the axial-flux in-wheel motor. The back electromotive force (EMF) and electromagnetic torque of the motor with harmonic current are obtained by the 3-D finite element method (FEM). The permanent magnet (PM) eddy-current losses when using different PM shapes are studied. The equivalent thermal model of the tape-wound AMM stator segments and the windings are established, and the temperature distribution of the motor is obtained. The mechanical behavior of the stator segments and the rotor disks when the motor is eccentric and axially offset is analyzed, and the structural strength of the motor is evaluated. Finally, a prototype of the motor is fabricated, and the electromagnetic performance and temperature of the motor are tested to verify the accuracy of the multiphysics design approach.

Magnet eddy-current losses reduction of an axial-flux in-wheel motor with amorphous magnet metal

The yokeless and segmented armature axial-flux in-wheel motor with amorphous magnet metal (AMM) stator segment has the advantage of low iron losses, but its open-slot structure causes high eddy-current losses of the permanent magnet (PM), which reduces the efficiency and reliability of the in-wheel motor. To avoid the demagnetization caused by the heat generated by PM losses, the mechanism of PM eddy-current losses reduction for the axial-flux in-wheel motor is revealed by the calculation model. In this paper, the time-step three-dimensional finite-element method (3-D FEM) is used to analyze the PM eddy-current loss caused by slotting effects, spatial harmonics, and time harmonics at different speeds. The effect of PM skewing, PM segmentation, and soft magnetic composite (SMC) layer inserted on the top of PM on eddy-current losses are compared. These methods cannot simultaneously meet the requirements of PM losses reduction and the electromagnetic performance of the motor. A novel combined stator segment with the SMC brim arranged on the top of the AMM stator teeth is proposed to improve the amplitude and distribution of the PM eddy-current density. The analysis results show that the combined stator segment can significantly reduce the PM eddy-current loss and improve the electromagnetic performance of the in-wheel motor.

A Novel Modular Stator Hybrid-Excited Doubly Salient Synchronous Machine With Stator Slot Permanent Magnets

This paper presents a novel modular stator hybrid-excited synchronous machine with stator slot permanent magnets (PMs). By regulating the field current, the magnetic field, and consequently the back electromotive force, as well as the average torque can be controlled. The existence of stator slot PMs alleviates the magnetic saturation and improves the flux regulation ratio. The frozen permeability method is employed to investigate the torque contributions by different magnetic sources. Possible stator and rotor pole combinations are illustrated, and the corresponding electromagnetic performances are evaluated with the finite-element method. It is revealed that 12-stator pole machines with 11- and 13-rotor poles exhibit superior average torque and lower torque ripple due to even-order harmonics elimination. Finally, a prototype with modular stator segments is manufactured to validate the analyses and simulations.

Weld process model for simulating metal active gas welding

Generally, optimum welding variables and conditions of manufacturing are currently mainly determined by experiments for standardized production. Virtual manufacturing and virtual testing of weldments using finite element method provide a sustainable solution for advanced applications. The aim of the current research work is to develop a weld process model, using a three-dimensional heat transfer model, to ensure general applicability for typical joints of stator segments of wind turbines as a final application. A systematic experimental research program, containing temperature measurements during welding, macrographs, and deformation measurements, is carried out on small-scale test specimens using different welding variables. In addition, a numerical study using uncoupled transient thermomechanical analysis is performed. The weld process model uses Goldak’s double ellipsoidal heat source model for a metal active gas welding power source. It describes the correspondence between heat source parameters and net heat input for two types of electrodes. The model is validated via cross-sectional areas of fusion zones and deformations based on experiments. The relationship between current and voltage is determined based on large number of experimental data; thus, selecting a wire type, travel speed, and voltage directly defines the heat source parameters of the weld process model.

Sensitivity Comparison of Open-Circuit Airgap Flux Between Surface-Mounted Permanent Magnet and Spoke-Type Permanent Magnet Machines Considering Manufacturing Tolerances

The study compares the sensitivities of open-circuit airgap flux (OCAF) between a surface-mounted permanent magnet (SPM) machine and a spoke-type PM machine based on variations in airgap length including additional airgaps between permanent magnets and rotor core and between segmented stator cores to achieve high quality electric machines. Analytical equations deduced from magnetic equivalent circuits (MECs) are used to directly compare natural-born characteristics of the OCAF of the two machines. First, the MEC of each machine is modeled by considering two additional airgaps between the PMs and rotor core and between the segmented stator cores. Second, the OCAF equation of each machine is derived from the MEC to analyze the effects of the design variables on the OCAF. Subsequently, the partial derivative equation of the OCAF equation with respect to the airgap length is obtained for sensitivity analysis. A comparison of the equations of the two machines indicates that the spoke-type PM machine exhibits inherently higher sensitivity and average value of the OCAF when compared to that of the SPM machine. Finally, the results are validated via a two-dimensional finite element method (FEM) by considering the variations in airgap lengths.

Topology Choice and Optimization of a Bearingless Flux-Switching Motor with a Combined Winding Set

The purpose of this paper is to choose a new topology for bearingless flux-switching slice motors, regarding the number of stator and rotor poles, with a combined winding set. Additionally, the selected motor topology is optimized with finite element method (FEM) simulations to improve the performance. Bearingless slice drives feature a magnetically-suspended rotor disk passively stabilized by reluctance forces due to a permanent magnet (PM) bias flux in the air gap and actively controlled by the generation of radial bearing forces and motor torque. Usage of the combined winding set, where each phase generates both motor torque and suspension forces, opens the opportunity for a new topology. The topology choice and optimization are based on FEM simulations of several motor optimization criteria, as the passive axial, tilting and radial stiffness values and the active torque and bearing forces, which are simulated regarding the motor height and specific stator and rotor parameters. Saturation, cogging torque and cogging forces are also analyzed. The 3D FEM program ANSYS Maxwell 2015 was used. The results led to an optimized bearingless flux-switching motor topology with six new stator segments and seven rotor poles. By optimizing the geometry, a considerable improvement of performance was reached. This geometry optimization is a base for a future prototype model.

Elementary Analysis of Segmental Stator Flux Switching Permanent Magnet Machine

<span lang="EN-US">Segmental structure is common especially for a rotor in electrical motor. It is to reduce the cost of production, conveniently replace, and as a module where the sum of electromagnetic torque produced comes from each segmental stator add up together. Thus, in this paper will be focusing on the elementary analysis of a segmental stator for single phase 6Slot-12Pole and 3 phase 6Slot-15Pole Switched-Flux Permanent Magnet Machine (SFPMM) as the chosen design for analysis validation from coventional permanent magnet flux switching machine to a new segmental stator structure of SFPMM. It will be focusing on the initial design and to prove that it can be operate as a flux switching machine by implement a 2D Finite Element Analysis simulations such as a No-load analysis (flux linkage, cogging torque, back emf) and Load-analysis (average electromagnetic torque. Elementary result shows that the electromagnetic torque produce for both design are 10.6 Nm and 99.95 Nm and proved that it can produce high torque although it does not surpass the conventional SFPMM. A further research and optimization will be needed to obtain a higher torque compared to conventional SFPMM.</span>

Novel Modular Switched Reluctance Machines for Performance Improvement

Compared to nonmodular machines, modular topologies become increasingly attractive due to their simplified manufacture process, better fault-tolerant capability, and potentially reduced material consumption. In order to maintain or even enhance the machine performance while achieving high fault-tolerant capability, novel modular, single-layer winding switched reluctance machines (SRMs) with different pole numbers are proposed, which are supplied by rectangular wave current with different conduction angles. The influences of the pole number and flux gap width between E-core segmented stators on the electromagnetic performance have been investigated in terms of self- and mutual inductances, electromagnetic torque, copper loss, iron loss, and radial force. It has been found that the modular structures with higher rotor pole numbers than stator slot numbers (12-slot/14-pole and 12-slot/16-pole SRMs) can maintain and even improve the average torque due to the nature of self and mutual inductances. In addition, the torque ripples for modular machines are significantly reduced (below 50%), so do the iron loss and radial force, leading to higher efficiency albeit with potentially lower vibration and acoustic noise. Two prototypes with 12-slot/8-pole and 12-slot/14-pole combinations have been built with both nonmodular and modular structures to validate the predictions in terms of inductances and static torques.

Thermally Induced Mechanical Stress in the Stator Windings of Electrical Machines

The lifetime of an electrical machine mainly depends on the thermal overloading. Modern day applications of electrical machines on one hand require compact machines with high power density, while on the other hand force electrical machines to undergo frequent temperature cycling. Until recently, in the case of electrical machines, the main factor related to the degradation of the winding insulation was thought to be the thermal oxidization of the insulation materials. It has now been revealed that thermal overloading can also induce mechanical stress in the windings of electrical machines, which over time could lead to fatigue and degradation. In this paper, a comprehensive study of the thermally induced mechanical stress in the windings of an electrical machine is presented. The study is performed using combined thermo-mechanical models. The numerical results are validated by experiments on a segmented stator winding set-up.

Unbalance-induced rub between rotor and compliant-segmented stator

Today, turbomachinery designers are trying to attain zero clearances for optimizing performance and efficiency of machine by designing advanced compliant-segmented seals. This trend involves secondary issues such as rotor-to-stator contact interaction which is to be treated with more technical knowledge in rotordynamic design and condition monitoring programs. The aim of this paper is to gain insight into dynamic interaction between a flexible rotor and a set of compliant arc-shaped segments as stator system. Specifically, the unbalanced-induced forward rubbing response is investigated in tight clearance condition during resonance-passing situations. A Jeffcott rotor modeling is used for representing the flexible rotor. A set of linear elastically-mounted rigid bodies with arc-shaped inner surfaces, which are arranged circumferentially around the rotor, are assumed as the model of the stator. The effects of mass, rotary inertia, translational and tilting stiffnesses are taken into account in the segment modeling. To compute the contact dynamic response, the equations of motion are coupled via Lagrange multiplier technique. The constrained equation of motion is solved by an implicit predictor-corrector time-marching numerical algorithm. Investigations reveal that the steady-state coupled rubbing solutions exist for the rotor interacting with the segmented stator. The solutions are classified with respect to stator properties, e.g. the number of segments and the stator stiffness. The synchronous rubbing solution covers various feature including shift in resonance speed, lower amplitude of rotor's vibration, smooth rise and fall in case of soft segments, jump phenomena in case of stiff segments, chaotic orbiting motion under effects of segment mass, etc. as are discussed in detail.

Design, Optimization, and Prototyping of Segmental-Type Linear Switched-Reluctance Motor With a Toroidally Wound Mover for Vertical Propulsion Application

Linear switched-reluctance motor (LSRM) is investigated and proved to be an alternative for direct linear driving systems, especially for long-distance transportation applications, such as vertical elevator driving motor. This paper presents the design, sensitivity analysis, and optimization of a toroidally wound mover LSRM with segmental stator. The presented LSRM has much higher copper utilization ratio and flux carrying capability than the conventional LSRM for vertical linear propulsion application. The features of motor performance influenced by various geometrical parameters are described using magnetic circuit and finite element analysis to give the guidelines for selecting the reasonable range of those parameters of this kind of machine. Furthermore, an optimization procedure is performed to obtain the optimal machine dimensions considering active payload ratio and force ripples. Finally, the experimental results from the prototype validate the design procedures and analysis above.

Prediction and Measurement of the Heat Transfer Coefficient in a Direct Oil-Cooled Electrical Machine With Segmented Stator

The heat transfer coefficient (HTC) is a critical parameter that is required for accurate thermal modeling of electrical machines. This is often achieved from empirical correlations of ideal geometries or computational fluid dynamics (CFD) simulations. This paper presents a novel technique using double-sided thin film heat flux gauges for measuring the HTC from a direct oil-cooled electrical machine with segmented stator. While thin film gauges are often used in transient measurements of the HTC on gas turbine components, their application to electrical machines has been largely unexplored. This is the topic of this paper. Due to the large viscosity of the coolant, the transient technique was found to be inadequate and a steady-state adaptation for oil-cooled machines was developed. This paper explores the challenges linked with this measurement technique when applied to oil-cooled machines, and develops new nondimensional correlations of the Nusselt number with Reynolds number. These correlations are applicable to machines with different geometries, flow, and coolant properties. The experimental results were compared to CFD simulations and existing pipe flow correlations. It is shown that these underpredict the HTC by approximately 60% at Re = 20. The discrepancy gradually decreases to around 10% at Re = 200.

A New Axial Flux Permanent Magnet Machine

This paper presents a new axial flux permanent magnet machine, named ring winding axial flux machine (AFM). The ring winding AFM (RWAFM) takes the advantage of segmented stator of yokeless and segmented armature topology with those of decoupled phases and ring winding of transverse flux topology. In this paper, the geometry of the RWAFM is introduced in detail. Furthermore, the working principle and torque production theory are discussed. To validate the concept and confirm manufacturability of the proposed topology, a prototype is fabricated. The performance of the RWAFM is studied through experimental tests, 3-D finite-element simulations, and analytical discussions.

High Torque Flux Switching Permanent Magnet Machine in Segmented Outer Rotor using Appropriate Split Ratio for Electric Scooter Propulsion

<span>Recently, permanent magnet synchronous machine (PMSM) having the diameter of 11inches was successfully developed and installed in electric scooter vehicle (ESV) for propulsion. It consists of segmented stators of 24 armature slots and 100 pieces of permanent magnet of 2 kg weight mounted on rotating rotor. Upon the huge amount of materials and permanent magnet used, PMSM produced 110Nm only. Looking at the size, this torque is low and could not sustain acceleration for long distance travels. To overcome the challenge of low torque, this paper presents a new machine type, flux switching motor (FSM) with 1 kg weight of permanent magnet flux source employing segmented outer rotor. Six ranges of split ratio of 0.80-0.85 for outer rotor 24slot-14pole FSPM motor configurations were designed and compared. The 2D-FEA by JMAG software version 14 is used to examine its performance in term of flux linkage, cogging torque, back-emf and average torque which the structure with split ratio of 0.85 took lead by securing highest torque profile of 209Nm. It also achieved low cogging torque to operate in safe region. In conclusion, appropriate split ratio significantly enhances high torque capability of permanent magnet flux switching motor for electric scooter propulsion.</span>

Electromagnetic Analysis of a Synchronous Reluctance Motor With Single-Tooth Windings

This paper explores some of the key electromagnetic design aspects of a synchronous reluctance motor that is equipped with single-tooth windings (i.e., fractional slot concentrated windings). The analyzed machine, a 6-slot 4-pole motor, utilizes a segmented stator core structure for ease of coil winding, pre-assembly, and facilitation of high slot fill factors (~60%). The impact on the motors torque producing capability and its power factor of these inter-segment air gaps between the stator segments is investigated through 2-D finite element analysis (FEA) studies where it is shown that they have a low impact. From previous studies, torque ripple is a known issue with this particular slot–pole combination of synchronous reluctance motor, and the use of two different commercially available semi-magnetic slot wedges is investigated as a method to improve torque quality. An analytical analysis of continuous rotor skewing is also investigated as an attempt to reduce the torque ripple. Finally, it is shown that through a combination of 2-D and 3-D FEA studies in conjunction with experimentally derived results on a prototype machine that axial fringing effects cannot be ignored when predicting the q-axis reactance in such machines. A comparison of measured orthogonal axis flux linkages/reactances with 3-D FEA studies is presented for the first time.

An innovative natural air-cooling system technique for temperature-rise suppression on the permanent magnet synchronous machines

This paper investigates a three-dimensional finite-element (3D-FEA) thermal analysis based on an embedded cooling system with various number of ducts for the outer-rotor permanent magnet synchronous machines (PMSMs). The segmented stator core due to closed-slot topology is the reason of a high temperature-rise at this core. The application-oriented study is aimed to reduce temperature-rise of the conventional model at the stator core via radial and circumferential airflow ducts. A temperature distribution, and heat transfer comparison among all FE models such as conventional, two and four ducts in-core natural cooling systems will be comprehensively presented through freezing the electromagnetic performance. The alternative models using FEA, and computational fluid dynamic (CFD) are experimentally verified the innovative technique, in which the generator is operated by a vertical axis twisted savonius type wind turbine (VAWT).

Iron Losses Calculation of an Axial Flux Machine Based on Three-Dimensional FEA Results Corresponding to One-Sixth Electrical Period

This paper describes the iron losses calculation of an axial flux machine with yokeless and segmented armature structure based on the limited three-dimensional (3-D) finite element analysis (FEA) results corresponding to one-sixth electrical period. Considering, the 3-D magnetic flux in both stator segments and rotor yoke, soft magnetic composites are used to manufacture the soft magnetic components. Furthermore, time-consuming 3-D FEA is necessary to evaluate the performance of the machine accurately. Due to the magnetic periodicity, most of the characteristics of the machine can be easily determined through averaging the limited 3-D FEA results. However, in some models the calculation of iron losses requires always the flux density waveform in each soft magnetic composites (SMC) element of the FEA model for an entire electrical period, especially when the losses resulted by minor loops should also be taken into account. Therefore, a general method to reconstruct the complete flux density waveform in each SMC component of the FEA model based on limited 3-D FEA results is suggested in this paper. Subsequently, the iron losses can be calculated with various models in time or frequency domain. Finally, the suggested method is validated by comprising the measurement of a prototype with the calculated iron losses based on the classical Bertotti formula.

Magnetomotive force harmonic reduction techniques for fractional-slot non-overlapping winding configurations in permanent-magnet synchronous machines

Compared to conventional distributed winding configurations, the fractional-slot non-overlapping (concentrated) windings exhibit advantages such as short end-winding length, high copper packing factor (particularly with segmented stator structure), low cogging torque, good field weakening capability owing to relatively large d-axis inductance, and better fault tolerant capability due to low mutual inductance. However, one of the key problems of employing concentrated windings in Permanent-magnet Synchronous Machines(PMSMs) is the high eddy-current losses in rotor magnets and/or rotor iron due to the presence of a large number of lower and higher order space harmonics in the stator Magneto-Motive Force(MMF). These MMF harmonics also result in other undesirable effects, such as acoustic noise and vibrations, and localized core saturation which tend to reduce reluctance torque. This paper reviews the current state-of-the-art of the MMF harmonic reduction techniques for concentrated winding configurations in PMSMs, including winding split and shift, delta-star connected windings, multiple 3-phase windings, multilayer windings, uneven turn numbers, and stator flux barriers. Their concepts, advantages and disadvantages are presented and assessed.

A Novel Method of Reducing the Cogging Torque in SPM Machine with Segmented Stator

The method of stator segmentation is generally taken to enhance the electromagnetic performance of surface-mounted permanent magnet (SPM) machine and reduce its production cost. Based on the model with single slot, the expressions of cogging torque in machine with uniform or non-uniform segmentations are deduced and the optimal combination is given. Moreover, this paper discusses a structured skewing method and put forward a novel stator structure model to reduce the cogging torque in segmented permanent magnet machine. The model can reduce the cogging torque amplitude by shifting a proper angle of slot-opening. The shifting angle formula for analysis can also be suitable for other permanent machine with segmented stator. Finally the results of finite element simulation are given to prove that the method is effective and feasible.