Excitation Synchronous Machine Research Articles

Torque ripple reduction and increasing of torque per volume for hybrid electrical vehicle

Hybrid electrical vehicles (HEV) should be designed somehow torque is smooth. Because torque ripple not only reduces control precision but also increases elements vibration that causes acoustic noise, mechanical instability and early aging parts. Furthermore, torque per volume should be maximized and heat removal should be accomplished without torque weakening. It is proposed the volume and internal dimensions are determined due to the thermal considerations and maximize torque per volume. The mentioned application is neglected heat removal so volume is constant. Therefore, HEV is manufactured by two objective functions: either minimum fluctuations or maximum average torque. In this paper series hybrid excitation synchronous machine (SHESM) is utilized as HEV. Two-objective optimization problems are solved by MOEA/D, NSGA II, PESA II and SPEA II algorithms based on a two-dimensional (2-D) model. The performance indices of optimal structure are evaluated by 2-D and confirmed by numerical method.

A hybrid analysis method for calculating the cogging torque of consequent pole hybrid excitation synchronous machine

PurposeWhen solving the cogging torque of complex electromagnetic structures, such as consequent pole hybrid excitation synchronous (CPHES) machine, traditional methods have a huge computational complexity. The notable feature of CPHES machine is the symmetric range of field-strengthening and field-weakening, but this type of machine is destined to be equipped with a complex electromagnetic structure. The purpose of this paper is to propose a hybrid analysis method to quickly and accurately solve the cogging torque of complex 3D electromagnetic structure, which is applicable to CPHES machine with different magnetic pole shapings.Design/methodology/approachIn this paper, a hybrid method for calculating the cogging torque of CPHES machine is proposed, which considers three commonly used pole shapings. Firstly, through magnetic field analysis, the complex 3D finite element analysis (FEA) is simplified to 2D field computing. Secondly, the discretization method is used to obtain the distribution of permeance and permeance differential along the circumference of the air-gap, taking into account the effect of slots. Finally, the cogging torque of the whole motor is obtained by using the idea of modular calculation and the symmetry of the rotor structure.FindingsThis method is applicable to different pole shapings. The experimental results show that the proposed method is consistent with 3D FEA and experimental measured results, and the average calculation time is reduced from 8 h to 4 min.Originality/valueThis paper proposes a new concept for calculating cogging torque, which is a hybrid calculation of dimension reduction and discretization modules. Based on magnetic field analysis, the 3D problem is simplified into a 2D issue, reducing computational complexity. Based on the symmetry of the machine structure, a modeling method for discretized analytical models is proposed to calculate the cogging torque of the machine.

Calculating torque, back-EMF, inductance, and unbalanced magnetic force for a hybrid electrical vehicle by in-wheel drive application

To use a Hybrid Excitation Synchronous Machine (HESM) in a hybrid electrical vehicle (HEV), its performance indicators such as back-EMF, inductance and unbalanced magnetic force should be computed preferably by an analytical method. First, the back-EMF is calculated by considering alternate-teeth and all-teeth non-overlapping and overlapping windings. The effects of three types of magnetization patterns including the radial, parallel and Halbach magnetizations on the back-EMF waveform have also been investigated. Then, the self-inductance of the stator and rotor windings, the mutual inductance between the stator and rotor windings, and the mutual inductance between the stator phases are computed. Next, the components of the unbalanced magnetic force (UMF) in the direction of the x and y axes and its amplitude are computed. Moreover, the effects of the magnetization patterns on those magnetic pulls are investigated. To minimize the UMFs, symmetry must be implemented in the excitation sources; therefore, first the stator winding then the permanent magnet and rotor winding are modified in such a way that the UMFs are reduced. Increasing the temperature leads to a weakening of the magnet’s residual flux density, which strongly affects the performance characteristics of the electric machine such as Back-EMF and UMF. Finally, the ratio of the permanent magnet flux to the rotor flux is determined in such a way that the average torque is maximized. In this section, the effects of three magnetization patterns will be investigated.

Influence of welding-induced mechanical stress on the electromagnetic properties of magnetic lamination

PurposeThis paper aims to analyze the influence of welding-induced mechanical stress of a magnetic core material on the performance behavior of a permanent magnet excited synchronous machine (PMSM). Welding, interlocking, clinching and the use of adhesives are state-of-the-art packaging technologies used in the manufacturing of electrical machines. However, the packaging processes degrade the electromagnetic properties of the electric steel sheets, thereby decreasing the performance and achievable range of the electric vehicle.Design/methodology/approachIn this paper, an approach that maps the local changes in magnetic properties due to welding induced stress with the stress values is developed. The welding process induces internal stress inside the steel sheet due to the diffusion of thermal energy into the sheets. Other effects are the changes in the micro structures of the steel sheets (grain sizes). These induced mechanical stresses lead to significant deterioration of the electromagnetic properties. They also lead to an increase in iron loss attributed to steel lamination.FindingsA low speed (city), a high-speed (highway) and WLTC-c3 driving cycle will be used to analyze the effects of the induced stresses on the machine efficiency at the different operating conditions. A high-speed PMSM with a maximum speed of 26,000 min−1 and maximum torque of 130 Nm is designed for this study.Originality/valueThe value of this study is in the development of a local varying modeling approach that analyses the influence of weld-induced stress on the performance of electrical machines. Its originality is evident in the mapping methodology. This will enable an application dependent improvement possibilities due to the understanding of the impact of weld-induced stress on the electromagnetic properties of weld-packaged core.

Electromagnetic performance analysis of a new high‐speed hybrid excitation synchronous machine

AbstractTo facilitate the regulation of the air‐gap magnetic field of permanent magnet synchronous machines, a novel topology of a high‐speed hybrid excitation synchronous machine (HESM) was presented. The electromagnetic performance of the proposed HESM was evaluated. The air‐gap magnetic field regulation principle was introduced first. Then, a mathematical model of the HESM was established. Based on the characteristics of a 3D magnetic circuit, the HESM equalled three types of 2D magnetic circuit machines in axial parallel superposition, and thus the expressions of inductance parameters were deduced. Subsequently, the voltage regulation performance of the HESM was assessed according to the mathematical model and inductance parameters. The loss and efficiency were calculated. Finally, a HESM prototype was tested and verified.

Changes in Material Behavior according to the Amount of Recycled Magnetic Materials in Polymer-Bonded Magnets Based on Thermoplastics

The applications of polymer-bonded magnets are increasing within drive technology mostly because of new concepts concerning the magnetic excitation of direct current (DC) or synchronous machines. To satisfy this rising demand for hard magnetic filler particles—mainly rare earth materials—in polymer-bonded magnets, a recycling strategy for thermoplastic-based bonded magnets has to be found that can be applied to polymer-bonded magnets. The most important factor for the recycling strategy is the filler material, especially when using rare earth materials, as those particles are associated with limited resources and high costs. However, thermoplastic-based bonded magnets reveal the opportunity to reuse the compound material system without separation of the filler from the matrix. Most known recycling strategies focus on sintered magnets, which leads to highly limited knowledge in terms of strategies for recycling bonded magnets. This paper illustrates the impact of different amounts of recycling material within the material system on material behavior and magnetic properties that can be achieved by taking different flow conditions and varying gating systems into account. The recycled material is generated by the mechanical reuse of shreds. We found that a supporting effect can be achieved with up to 50% recycled material in the material system, which leads to only minimal changes in the material’s behavior. Furthermore, changes in magnetic properties in terms of recycled material are affected by the gating system. To reduce the reduction in magnetic properties, the number of pin points should be as low as possible, and they should located in the middle. The filler orientation of the recycled material is minimally influenced by the outer magnetic field and, therefore, mainly follows the flow conditions. These flow conditions are likely to be affected by elastic flow proportions with increasing amounts of recycled material.

Theoretical Analysis for Rapid Design of Hybrid Excitation Synchronous Machine With Consequent Pole Rotor

Theoretical Analysis for Rapid Design of Hybrid Excitation Synchronous Machine With Consequent Pole Rotor

Analysis of Efficiency Maps of Synchronous Machines

In this contribution the efficiency maps of synchronous machines are analyzed. The tool developed to draw these efficiency maps allows considering the synchronous machines electromagnetic parameters and related losses. It will be exploited to analyze the effects of the different parameters on the efficiency maps. The developed tool is based on the synchronous machine’s electrical circuit model in the Park’s referential frame. The adopted modeling approach allows considering all types of classical synchronous machines: wound field synchronous machines (WFSM), permanent magnet synchronous machines (PMSM), hybrid excited synchronous machines (HESM) and synchronous reluctance machines (SRM). It can even indirectly consider the effect of magnetic saturation. These analyses will help identify parameters sets allowing optimizing the energy efficiency of synchronous machines for a given application like electrical traction. Particularly, the effect of saliency ratio will be considered and studied.

Research on Innovative Hybrid Excited Synchronous Machine

This paper presents research on an unconventional electric machine. It is a hybrid excited machine which includes the features of three types of machines: the Permanent Magnet Synchronous Machine, the Synchronous Machine, and the Synchronous Reluctance Machine. Therefore, a broad literature review related to the above-mentioned types of machines was constructed. The well-known Permanent Magnet assisted Synchronous Reluctance Machine joins features of Permanent Magnet Synchronous Machine and Synchronous Reluctance Machine topologies. This paper shows the results of the innovative design of the Hybrid Excited Permanent Magnet assisted Synchronous Reluctance Machine, which additionally has advantages of the Synchronous Machine. In the article the basic methods of electromagnetic flux control and the designs using them are also presented. Finally, the results of simulation studies of the effect of the stator skew on the machine performance are described.

Finite-Time Control for Dual Three-Phase Hybrid Excitation Synchronous Machine Based on Torque Sensorless Current Coordinative Strategy

In this paper, the finite time speed regulation problem is investigated for a dual three-phase hybrid excitation synchronous machine (DTP-HESM) without a torque meter. The electromagnetic torque estimation required in the current coordinative strategy is obtained through the disturbance estimation technology. This method increases fault tolerance and reduces the cost as well as complexity of the DTP-HESM system. In contrast to the existing controllers in the speed loop, the non-singular terminal sliding mode control method is adopted to ensure the finite-time convergence of speed tracking in the whole speed region. To achieve better dynamic performance in the presence of lumped disturbances, including unknown load torque and unmodeled dynamics, the disturbance estimations are introduced into the sliding mode variable to establish a composite speed regulating controller. Simulations and experiments are carried out to validate the feasibility and effectiveness of the proposed control scheme.

Overview of the technology behind hybrid excitation synchronous machines

The objective of this paper is to present a comprehensive analysis of hybrid excitation synchronous machines, including an examination of various structures found in scientific and technical literature, along with their advantages and drawbacks. Additionally, different methods of classification for these structures will be explored. The paper also delves into the contributions of the hybrid excitation principle for both motoring and generating modes and provides an overview of various models used in designing these structures.

Efficiency improvement of a high-speed permanent magnet excited synchronous machine by the use of spot-welding as lamination packaging technology

In this paper, an efficiency improvement of a high-speed permanent magnet excited synchronous machine (PMSM) by the use of spot-welding as lamination packaging technology is realized. Welding, interlocking, clinching and gluing are typical technologies to manufacture electrical steel stacks of electrical machines. However, these processes deteriorate the magnetic properties of the steel sheets, thereby decreasing the overall efficiency of the machine. Variations of line-welding (six, eight, twelve, thirty two and forty) line welds and spot-welding procedure is performed and analyzed. A semi-physical iron loss separation approach is used to extract the IEM iron loss model (Eggers et al., IEEE Transactions on Magnetics 48(11) (2012), 3021–3024). These parameters are utilized during the finite element simulation to calculate the effective iron loss (efficiency) of the machine while using each joining procedure. A low speed, high-speed and WLTC-c3 driving cycle is exemplarily used to analyze the effects of each procedure on the machine efficiency at the different operating conditions.

Nonlinear Optimal Control for Hybrid Electric Vehicles with Doubly Excited Synchronous Machine and AC/DC Converter

Nonlinear Optimal Control for Hybrid Electric Vehicles with Doubly Excited Synchronous Machine and AC/DC Converter

Possibilities in Recycling Magnetic Materials in Applications of Polymer-Bonded Magnets

Polymer-bonded magnets have increased significantly in the application of drive technology, especially in terms of new concepts for the magnetic excitation of synchronous or direct current (DC) machines. To satisfy the increasing demand of hard magnetic filler particles and especially rare earth materials in polymer-bonded magnets, different strategies are possible. In addition to the reduction in products or the substitution of filler materials, the recycling of polymer-bonded magnets is possible. Different strategies have to be distinguished in terms of the target functions such as the recovery of the matrix material, the filler or both materials. In terms of polymer-bonded magnets, the filler material—especially regarding rare earth materials—is important for the recycling strategy due to the limited resource and high costs. This paper illustrates two different recycling strategies relative to the matrix system of polymer-bonded magnets. For thermoset-based magnets, a thermal strategy is portrayed which leads to similar magnetic properties in terms of the appropriated atmosphere and process management. The mechanical reusage of shreds is analyzed for thermoplastic-based magnets. The magnetic properties are reduced by about 20% and there is a change in the flow conditions and with that, an influence on the pole accuracy.

Real-Time Digital Simulation for Coordination Analysis of V/Hz AVR Limiter With Overexcitation, Overvoltage, and Underfrequency Protections of Synchronous Generators

Synchronous generators have automatic voltage regulators with limiters that are used to prevent high or low flux in the generator by controlling the Volts/Hertz ratio. Within the operating range of this limiter, it is not necessary to activate the protection functions associated with voltage and frequency. For that, it is necessary to coordinate these limiters with such protection functions. So, this article increases the scope of (Coelho <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">et al.</i> , 2018) and (Coelho <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">et al.</i> , 2019) by including the coordination studies between Volts/Hertz limiter with overexcitation, overvoltage, and underfrequency protections of synchronous generators. A hardware-in-the-loop simulation is implemented in laboratory to test and evaluate this coordination, and the best settings for it are proposed. An actual power system was modeled in a real-time digital simulator. A great quantity of tests was applied to a synchronous machine (including all its electrical protections and controls) by separately applying frequency steps and voltage steps. The hardware-in-the-loop simulator was prepared to observe an actual digital relay's dynamic responses to these steps. A Volts/Hz limiter, associated with the generator under analysis, is added to the RTDS library. In addition, by analyzing the abovementioned protections and their interaction with the Volts/Hertz limiter of the synchronous machine's excitation system, it is demonstrated that the protections and the limiter should always be jointly investigated.

An Analytical Method for Calculating the Cogging Torque of a Consequent Pole Hybrid Excitation Synchronous Machine Based on Spatial 3D Field Simplification

Consequent pole hybrid excitation synchronous (CPHES) machines have the advantage of symmetrical bidirectional magnetomotive force increments. Compared with a traditional hybrid excitation motor (HEM), a CPHES machine improves the disadvantage of asymmetry in the adjustment range when magnetization and demagnetization occur. The calculation and analysis of the cogging torque of the CPHES machine are complex due to the complicated structure. This paper proposes an analytical method for calculating the cogging torque of a CPHES machine. This analytical method converts the complex three-dimensional magnetic field problem into a two-dimensional magnetic circuit problem and, through the accumulation method, can quickly and accurately calculate the cogging torque of the CPHES machine. In contrast with the finite element method, the calculation results basically follow each other, but the analytical method is more efficient and omits complicated meshing. This is of great significance to the preliminary electromagnetic design and performance optimization of a CPHES machine.

Air-Gap Flux Oriented Vector Control Based on Reduced-Order Flux Observer for EESM

Electrically excited synchronous motor (EESM) has the characteristics of high order, nonlinear and strong coupling, so it is difficult to be controlled. However, it has the advantages of adjustable power factor, high efficiency, and high precision torque control, so it is widely used in high-power applications. The accuracy of a flux observer influences the speed control system of EESM. Based on state observer in modern control theory and electrical excitation synchronous machine state equation, a reduced-order flux observer is designed. Using the first-order difference method and forward bilinear transformation method, the reduced-order flux observer is discrete, and the stability of the motor system is analyzed. The analysis shows that the stability of the system using the bilinear transformation method is better than that using the first order forward difference method. In motor operation, motor parameters will be affected by the factors of temperature, magnetic saturation, and motor frequency. In this paper, the influence of parameter variation on the motor system is studied by using the variation of the pole distribution. Finally, the speed regulation system using the reduced-order observer is simulated, which verifies the accuracy of the reduced-order flux observer observation.

Two‐dimensional analytical model for double field excitation synchronous machines

Two‐dimensional analytical model for double field excitation synchronous machines

Mechanical Design and Analysis of a High-Torque Modular Hybrid Excitation Synchronous Machine for Electric Vehicle Propulsion Applications

Although hybrid excitation synchronous machines (HESMs) can provide an attractive flux-regulating capability, the fabrication and mechanical strength of the complex rotor are with significant challenges and need great efforts especially for high torque machines. In this article, a modular fabrication method of the dual-end magnetic-shunting rotor is proposed for high torque hybrid excitation synchronous machine. Then, by using numerical methods, the thermal stress of the rotor is calculated and compared with the 3-D FEA methods. To improve the mechanical strength of the rotor, the size of the screw, lug boss and filler is optimized, meanwhile, the rotor loss is optimized and thermal stress is evaluated. The results show that the proposed modular fabrication method demonstrates the improved mechanical strength and material utilization rate compared with the conventional fabrication process. Based on the three-dimensional finite-element analysis (3-D FEA) results, a 100 kW HESM prototype is successfully designed and manufactured using the proposed modular magnetic-shunting rotor. The experimental tests validate the effectiveness of the modular fabrication method and mechanical strength analysis.

System-Level Optimization of Hybrid Excitation Synchronous Machines for a Three-Wheel Electric Vehicle

In this article, a two-level methodology is proposed to optimize the design of a hybrid excitation synchronous machine (HESM) for a given electric vehicle (EV) over an arbitrary-selected driving cycle. We are looking at a huge analysis problem of finding an optimal hybridization ratio (HR) between the two excitation sources, namely, permanent magnet (PM) and wound excitation (WE). To find the optimal HR, the HR is scanned from 0 to 1 or from pure WE to pure PM excitation. For each HR, the motor is optimally designed at the component level, its cost is minimized, and its global efficiency over the selected driving cycle is calculated. Then, at the system level, the global efficiencies associated with each HR are compared in order to find the optimal HR. The complexity of the design optimization at the component level is addressed by nondominated sorting genetic algorithm II (NSGA-II). To make a compromise between the accuracy and speed of calculations, a nonlinear 3-D dynamic magnetic equivalent circuit (MEC) model is developed and evaluated by commercial finite element analysis (FEA) software. Following the proposed methodology and due to 300 h of computations with 48 CPU cores in parallel, the final HESM design can achieve up to 18.65% higher global efficiency than pure WE and 15.8% higher than pure PM excitation.