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Integrated Design of a High Speed Magnetic Levitated Brushless Direct Current Motor System

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energies Article Integrated Design of a High Speed Magnetic Levitated Brushless Direct Current Motor System Gang Liu 1,2 and Xu Liu 1,2,* ID 1 School of Instrumentation Science and Optoelectronics Engineering, Beijing University of Aeronautics and Astronautics, Beijing 100191, China; [email protected] 2 Beijing Engineering Research Center of High-Speed Magnetically Suspended Motor Technology and Application, Beijing University of Aeronautics and Astronautics, Beijing 100191, China * Correspondence: [email protected] or [email protected]; Tel.: +86-010-8233-9106 Received: 4 April 2018; Accepted: 10 May 2018; Published: 12 May 2018 Abstract: High speed magnetic levitated brushless direct current motor system mainly consists of a motor, a rotor and two magnetic bearings. New ideas demonstrate advances in the design of integration interface and selection of the dynamic design parameters. In this paper, integrated design procedure is interpreted, considering the structural, electromagnetic and thermal aspects with their contradiction and integration. The motor design is set as the initial design entrance to determine its stator diameters with other key parameters as dynamic design parameters. Then, magnetic bearing design is set as the interface for rotor, with magnetic bearings’ diameters and lengths determined. So, all the dynamic parameters will be specified considering rotor dynamics and the corresponding strength/thermal analysis. Finally, several validations including finite element method and experiment, have been carried out. Prototype of this maglev motor system has been designed and manufactured, with sufficient experiment processes validated. It rotates over 55,332 rpm under load with drag system, corresponding to above design results. Keywords: design methodology; integrated design; brushless machines; FEM; magnetic bearing 1. Introduction With advances in active magnetic bearing (AMB) [1,2], electronic converters, new material, and control strategy, limitation of speed for rotating machines got a greatly improvment [3,4]. High speed maglev electric motors are widely and increasingly applied in various industrial applications [5–9]. The advantages gained by such high-speed motors with AMBs are that of being able to increase efficiency and reliability by removing bearing lubrication and suppressing rotor vibration, resulting in decrease of sizes [7]. No mechanical wearing parts or lubricants are utilized in magnetic levitated motor (MLM) thus further lessening life cycle costs [8]. Such MLMs have been applied in several different types such as turbo-machinery, centrifugal compressors, turbo-molecular pumps, turbo refrigerant compressors, turbo-expanders, and engine waste-heat recovery [9]. The performance of high speed MLM is much more improved by advanced design guidelines, better reliability of materials, and precisely manufacturing [2]. Further, volume constrains [2], need for heat dissipating [10], and stability control constrains of AMB-rotor [11] are main issues for design of MLMs. High-speed induction machine (IM) have some challenges in design procedure [2,10]. Brushless direct current motor (BLDCM) offer many advantages such as high-power density, high efficiency and low temperature rise etc. [12]. Therefore, design approaches for high-speed BLDCM are proposed [11], including multidisciplinary impact on its performance. There are more technical problems for MLMs than some other high speed machines [13], because the motor part and MBs of MLM all needed analyze Energies 2018, 11, 1236; doi:10.3390/en11051236 www.mdpi.com/journal/energies EnergiesEnergies 20182018,, 1111,, 1236x FOR PEER REVIEW 22 ofof 2524 MLM all needed analyze and design [14]. Above all, design methods mentioned in above literatures andcan determine design [14]. initial Above design all, design parameters methods for mentioned high speed in motors above literatures[14–17]. can determine initial design parametersHigh-speed for high rotor speed of MLM motors is [suspended14–17]. by AMBs in five degree-of-freedom (DOF) directions, whichHigh-speed is driven by rotor a high of MLM-speed is IM suspended or BLDCM. by AMBs A high in-speed five degree-of-freedom MLM for ultra-centrifuge (DOF) directions, has been whichstudied is [18]. driven Various by a high-speedtopologies IMof high or BLDCM.-speed motors A high-speed are applied MLM for for some ultra-centrifuge industrial or has science been studiedapplications [18]. [19] Various with different topologies control of high-speed technologies motors and design are applied methods. for someIn addition, industrial MLM or for science turbo applicationsmolecular vacuum [19] with pump different with fault control-tolerant technologies magnetic andbearings design has methods. been manufactured In addition, and MLM applied for turbo[20]. C molecularonfiguration vacuum of MLM pump for withturbo fault-tolerant refrigerant compressor magnetic bearings has been has researched been manufactured [21]. An active and appliedRMB is [20developed]. Configuration for high of-speed MLM forturbo turbo-machinery refrigerant motors compressor [22]. However, has been researchedfew literatures [21]. Ansystematically active RMB and is developed sequentially for high-speedintroduce the turbo-machinery integration design motors guidelines [22]. However, for maglev few literatures BLDCM, systematicallyespecially for comprehensive and sequentially consideration introduce theof BLDCM integration and magnetic design guidelines bearings. for maglev BLDCM, especiallyAccounting for comprehensive for above consideratio considerationns, ofthis BLDCM paper andproposes magnetic integrated bearings. design procedures and tests Accountingof the maglev for BLDCM above considerations,system, which consists this paper of a proposeshigh-speed integrated rotor and design three stators procedures for radial and testsmagnetic of the bearing maglev (RMB) BLDCM [23 system,,24], combined which consists radial of-axial a high-speed magnetic rotorbearing and (CRAMB) three stators [25] for, radialand a magneticbrushless bearing DC motor (RMB) respectively [23,24], combined (Figure radial-axial 1).Here, magneticideas about bearing integration (CRAMB) design [25], and interface a brushless and DCdynamic motor design respectively parameters (Figure are1).Here, put forward. ideas about Mechanical, integration electromagnetic design interface and and thermal dynamic aspects design are parametersall synthesized are putfor forward.their contradiction Mechanical, and electromagnetic integration. The and motor thermal design aspects is set are as all the synthesized initial design for theirentrance, contradiction to determine and integration.the outer and The inner motor diameters design isofset stator as the with initial other design key parameters entrance, to as determine dynamic thedesign outer parameters. and inner diametersThen, MBs of design stator is with set otheras the keyinterface parameters for rotor, as dynamic with MBs’ design diameters parameters. and lengths Then, MBsdetermined. design isConst set asrains the interfaceabout rotor for rotor,diameters with MBs’among diameters MBs and and motor lengths are determined.established. ConstrainsWith rotor aboutdynamic, rotor strength diameters analysis among and MBs thermal and motor design are implemented, established. left With dynamic rotor dynamic, parameters strength are set. analysis Finite andelement thermal method design (FEM) implemented, is used for left validating dynamic parametersdesign model. are set.A prototype Finite element of maglev method BLDCM (FEM) isis usedmanufactured, for validating with design 1.21 kW/kg model. power A prototype density, of rotating maglev to BLDCM 33 kW, is 55 manufactured,,332 rpm under with load 1.21 with kW/kg drag powersystem. density, The contradictions rotating to 33 among kW, 55,332 various rpm requirements under load with and drag coupling system. effects Thecontradictions among multiphysics among variousare also requirements reflected. Finally, and coupling design results effects amongobtained multiphysics by above design are also methods reflected. are Finally, validated design by results drag obtainedtest and MBs’ by above stiffness design test methods [23–25] areto finish validated close byd loop drag of test the and whole MBs’ integration stiffness test design [23–25 procedure.] to finish closedIntegrated loop design of the wholemethod integration needs to be design reflected. procedure. Integrated design method needs to be reflected. Motor RMB CRAMB TDB Rotor Figure 1. The structure of the 30 kW MLBLDCM.MLBLDCM. 2. Determination of Structure and Design Process 2. Determination of Structure and Design Process The innovation of this work mainly focuses on comprehensive consideration of BLDCM and The innovation of this work mainly focuses on comprehensive consideration of BLDCM and magnetic bearings. The whole frame structure is determined based on mature experience. The design magnetic bearings. The whole frame structure is determined based on mature experience. The design procedure is initialized from electromagnetic torque of motor and suspending force of magnetic procedure is initialized from electromagnetic torque of motor and suspending force of magnetic bearings. The dynamic parameters are transferred among different design aspects to integrate Energies 2018, 11, 1236 3 of 25 Energies 2018, 11, x FOR PEER REVIEW 3 of 24 bearings.engineering The requirements dynamic parameters of BLDCM and are transferredmagnetic bearings. among The different
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