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Design of Powder Core Motors Design of Powder Core Motors Avo Reinap Doctoral Dissertation in Industrial Electrical Engineering Department of Industrial Electrical Engineering and Automation Department of Industrial Electrical Engineering and Automation Lund University Box 118 SE-221 00 LUND SWEDEN ISBN 91-88934-36-5 CODEN:LUTEDX/(TEIE-1044)/1-220/(2004) © Avo Reinap, 2004 Printed in Sweden by Media-Tryck, Lund University Lund 2004 ii Abstract The goal of the study presented in this thesis is to evaluate the advantages and drawbacks of using powder technology in the design of the iron core of small claw-pole electric motors. The use of soft magnetic composites (SMC) and compaction technology allows the creation of complex 3D iron cores. The additional dimension opens for new solutions of the electromechanical energy conversion. A claw-pole motor among the transversal flux machines that has particularly high specific torque is in the focus of research interest. Generally, as the iron core can be more complicated, the winding is chosen to be simpler in the powder core motors. The thesis focuses on the machine design of a single-phase and a two-phase low-power claw-pole motor. The predicted results compare well with measurements of the prototype motors. The motor design process in this thesis uses a magnetic equivalent circuit (MEC) model of the outer-rotor claw-pole motors that is accurate enough to describe the physics of the electromagnetic conversion. Additional equivalent circuits are made to evaluate the mechanic and thermal loading of the machines. The outcome of the equivalent circuit models is enough to estimate roughly the optimal size of the motor and the motor output according to the materials selected. After the rough design process, which is based on equivalent circuits, is finished, a series of FE magnetostatic analyses are made in order to evaluate the static characteristics of the motors, to specify the magnetization losses and to carry out a sensitivity study for the proposed size of the motors. Finally, the magnetic, mechanic and thermal design is analyzed dynamically and statically by the use of coupled multiphysics. The task of the coupled multiphysics is to find out the cooling capability and the thermal limit of the motor as well as the mechanic stress in the motor parts due to magneto-mechanic loading. It is discussed how the discrepancy between the calculated and measured cogging torque depends on the fineness of the 3D FE air gap mesh. iii Iron loss estimation based on the results of the FE-analysis is made taking the local rotation, and not only pulsation, of the magnetic flux into consideration. It is shown that the loss coefficients in the material model must be adapted to account for flux rotation. A part from the output of the machine as an electromechanical energy converter is their controllability in the electric drive system. Based on the static characteristics, which are calculated in the FE-analysis and verified in prototype measurements, a tailor made control method is developed for the machines designed. Results are presented of extensive simulations and experimental verifications of the proposed control strategy and power electronic circuitry. The high-speed four-pole single-phase motor shows satisfactory results. The other motor, which has 20 poles and two phases, has a main weakness in its complex assembling and a large cogging torque. iv Acknowledgement Everything that is good in this thesis is thanks for the inspiration and knowledge of the following people. Without following any order of importance they are my roommate David Martínez Muñoz, my supervisor Prof. Mats Alaküla, the prefect of the Department of Industrial Electrical Engineering and Automation Prof. Gustaf Olsson and the rest of the people at this department. My sincere gratitude goes to people who were involved in the VAMP-25 project: Tomas Johansson at Viktor Hasselblad AB, Jan-Olov Krona at Callo Sintermetall AB, Nils Pahlbäck at Sura Magnets AB, Thomas Rundqvist at ProEngCo AB, Tord Cedell, at, the Division of Production and Materials Engineering (LTH), and the other people who were involved to this project. Special thanks to Göran Nord, Lars Hultman and Lars-Olov Pennander at Höganäs AB. Invaluable FEM support was provided from Vector Fields Ltd. by John Simkin, Alex Michaelides, Klaus Hoeffer, and Chris Riley; from Comsol AB by Johan Linde, Ola Lindgren; and from The Japan Research Institute, Ltd. by Akinori Shiga and Takashi Yamada. Thanks to my family for their support. v Contents CHAPTER 1 INTRODUCTION........................................................1 1.1 BACKGROUND................................................................................................5 1.2 OBJECTIVES ....................................................................................................8 1.3 CONTRIBUTIONS............................................................................................8 1.4 OUTLINES........................................................................................................9 1.5 PUBLICATIONS..............................................................................................10 CHAPTER 2 CONSTRUCTION OF A CLAW-POLE MOTOR..... 11 2.1 MOTOR DESIGN...........................................................................................11 2.2 PHASE RING MADE OF CLAW-POLE RINGS..............................................17 2.3 SOFT MAGNETIC COMPOSITE ....................................................................23 2.4 PERMANENT MAGNET RING......................................................................26 CHAPTER 3 DESIGN MODEL .......................................................39 3.1 MAGNETIC CIRCUIT ....................................................................................40 3.2 CORE LOSS IN THE SMC CORE..................................................................48 3.3 MECHANICAL CALCULATION AND ANALYSIS.........................................53 3.4 THERMAL DESIGN .......................................................................................56 3.5 OPTIMIZATION ............................................................................................59 3.6 OPTIMAL SIZE OF A SMALL CLAW-POLE MOTOR....................................61 CHAPTER 4 NUMERIC FIELD COMPUTATION.......................67 4.1 MAGNETOSTATICS ......................................................................................68 4.2 CORE LOSS PREDICTION.............................................................................80 4.3 STRUCTURAL MECHANICS ..........................................................................84 4.4 HEAT TRANSFER ..........................................................................................87 4.5 INCORPORATING 3D FEA IN AN OPTIMIZATION ROUTINE ...............92 v ii CHAPTER 5 SENSITIVITY STUDY AND PROTOTYPING...... 105 5.1 VARIATION OF STATOR DIMENSIONS....................................................106 5.2 VARIATION OF MATERIAL PROPERTIES.................................................120 5.3 VARIATION OF MAGNETIZATION PATTERN.........................................122 5.4 THE PROTOTYPES......................................................................................132 5.5 STATIC CHARACTERISTICS........................................................................135 5.6 CORE LOSS MEASUREMENT .....................................................................141 5.7 CONCLUSIONS ............................................................................................145 CHAPTER 6 CONTROL OF A CLAW-POLE MOTOR............... 147 6.1 CONTROL STRATEGIES .............................................................................147 6.2 MODEL OF DRIVE SYSTEM .......................................................................151 6.3 SIMULATIONS .............................................................................................155 6.4 EXPERIMENTAL RESULTS.........................................................................166 6.5 CONCLUSIONS AND REMARKS ................................................................170 CHAPTER 7 CONCLUSIONS ....................................................... 173 7.1 SUMMARY OF RESULTS..............................................................................173 7.2 FUTURE WORK ...........................................................................................177 REFERENCES .................................................................................... 179 APPENDIX A MATERIAL DATA.................................................... 197 APPENDIX B MOTOR CONSTRUCTION .................................... 201 B.1 FORMULATION OF A CLAW-POLE CORE ................................................201 B.2 CORE FORMULATION IN 3D FE CONSTRUCTION ...............................204 APPENDIX C CAD INCORPORATED WITH 3D FEA................ 207 C.1 CONTROLLED CAD AND 3D FEA.........................................................207 C.2 ACCURACY OF 3D FE MODELLING........................................................210 C.3 ANALYSIS AT POST-PROCESSING LEVEL................................................214 APPENDIX D POWER ELECTRONIC CONTROL ...................... 217 D.1 DRIVER CIRCUIT.........................................................................................217 D.2 FEEDBACK ..................................................................................................218 viii Chapter 1 Introduction The potential in design and development of electromechanical
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