Air Gap Elimination in Permanent Magnet Machines
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AIR GAP ELIMINATION IN PERMANENT MAGNET MACHINES By Andy Judge A Dissertation Submitted to the Faculty of the WORCESTER POLYTECHNIC INSTITUTE In partial fulfillment of the requirements for the Degree of Doctor of Philosophy In Mechanical Engineering by _________________________________________________________ March 2012 APPROVED: _________________________________________________________ Dr. James D. Van de Ven, Advisor _________________________________________________________ Dr. Cosme Furlong-Vazquez, Committee Member _________________________________________________________ Dr. Alexander E. Emanuel, Committee Member _________________________________________________________ Dr. Eben C. Cobb, Committee Member _________________________________________________________ Dr. David J. Olinger, Graduate Committee Representative ABSTRACT In traditional Permanent Magnet Machines, such as electric motors and generators, power is transmitted by magnetic flux passing through an air gap, which has a very low magnetic permeability, limiting performance. However, reducing the air gap through traditional means carries risks in manufacturing, with tight tolerances and associated costs, and reliability, with thermal and dynamic effects requiring adequate clearance. Using a magnetically permeable, high dielectric strength material has the potential to improve magnetic performance, while at the same time offering performance advantages in heat transfer. Ferrofluids were studied as a method for improved permeability in the rotor / stator gap with a combined experimental and computational approach. Results show promise for the ferrofluid technique. An off-the-shelf motor system showed improved performance with ferrofluids vs. fluids of equivalent viscosity, and improved performance vs. an air gap at low RPM. New generator designs showed design dependent performance gains, although some potential for negative performance effects. A proof of concept generator was built and tested, with increased voltage vs. RPM predicted through virtual prototyping, and validated through experimentation, showing ~10% improvement on voltage vs. RPM at the <600 RPM range. More repeatable engineering tests demonstrated a ~30% increase in the voltage / RPM relationship for designs with an isolated stator chamber and a large stator – rotor gap. However, the effects were negative for a similar system with a small stator-rotor gap due to leakage flux effects. i New contributions to the body of knowledge in this area include: • Application of the ferrofluid technique to axial flux designs. • Development of a virtual prototype, including variations in the fluid viscosity due to ferrohydrodynamic effects. • Consideration of negative effects of ferrofluid immersion, such as shear losses and increases in leakage flux. • Optimization of the design to eliminate increased viscous losses. The improved design has been designed, built, and tested, featuring isolation of the ferrofluid from the rotating region. This offers all of the performance gain of improved magnetic permeability, while minimizing the offsetting losses from increased shear effects. ii ACKNOWLEDGEMENTS To start, I would like to thank the faculty of Worcester Polytechnic Institute, including the members of my dissertation committee, and throughout the University. It had been a few years since I had last taken a class, and the overall graduate experience at WPI reminded me of why I became an engineer in the first place – my love of learning and technology. I am especially grateful to my advisor, Dr. James Van de Ven, who reminded me of what engineering research was all about, helping me get started, offering support whenever needed and giving me the freedom to make my own path throughout the process. None of this would have been possible without the financial support of my employers, ITT for the first three years of my PhD coursework and research, and DRS for the past few months. Also, I am appreciative of John Schneider and Mark St. Pierre, two former supervisors of mine, who wrote my recommendations to WPI, and were a pleasure to work for. I am also grateful to my co-workers, including those who helped me learn the basics of Permanent Magnet Machines when I started in the field, and those who taught me the fine points as my understanding of the topic grew. Of course, my most heartfelt thanks go to my family, including my father, for giving me his work ethic, and my mother, for giving me her love of life. To my children, Sawyer and Delaney, I am always grateful for, and want nothing more than to have you continue living happy, healthy lives. Finally, to my wife Wendy, thank you for supporting me in this, for loving me back, and for understanding me in such a complete way. iii TABLE OF CONTENTS Abstract……..…………………………..…………………………….…………………...i Acknowledgements………………………………………………………………………ii Table of Contents………………………………………..…………………….………...iii List of Tables…………………………………………………..………………………..vii List of Figures………………………………………………………..………………...viii Nomenclature………………………………………………………..……………….…xv Chapter 1…………………………………………………………………………………1 1.1 Background………………………………………………………………......1 1.2 Literature Review ……………………………………………….………..…2 1.2.1 Primary Sources …………………………………………………...3 1.2.2 Secondary Sources ……………………………………………….15 1.2.3 Citation Summary.………………………………………………..21 1.3 Overview….…………………………………………………………………22 Chapter 2 - Fundamentals of Magnetics….……………………..…………………….25 2.1 Magnetics……………………………………………………………………25 2.2 Fundamentals of Electromagnetism..……………………………………...32 iv 2.3 Permanent Magnet Machines – Air Gaps.………………………………..43 2.4 Fundamentals of Ferrofluids...…………………………………………….47 2.4.1 Tradeoffs to Ferrofluid Immersion..……………………….……50 Chapter 3 - Computational Model…………………………………………………….60 3.1 Background.………………………………………………………………...60 3.2 Computational Model…...………………………………………………….60 3.2.1 Macro-Scale Model..……………………………………………...61 3.2.2 Finite Element Analysis….……………………………………….66 Chapter 4 - Experiment 1 – Off the Shelf Motor……………………………………..83 4.1 Background…………………………………………………………………83 4.2 Experimental Results....…………………………………………………….83 Chapter 5 - Experiment 2 – Proof of Concept Generator……………………………97 5.1 Background…………………………………………………………………97 5.2 Experimental Results....…………………………………………………...101 Chapter 6 - Experiment 3 – Large Gap Ferrofluid Experiment..………………….109 6.1 Background………………………………………………………………..109 v 6.2 Experimental Results....…………………………………………………...109 Chapter 7 - Experiment 4 – Small Gap Ferrofluid Experiment...………………….119 7.1 Background..……………………………………………………………....119 7.2 Experimental Results......………………………………………………….119 Chapter 8 – Conclusions.....………………………………………………………..….129 8.1 Review....………………………………………………………...............…129 8.2 Conclusion......………...………………………………………............…...132 8.3 Recommendations for Future Work...…………………………………...135 References.……………………………………………………………………………..137 Appendix A: Magnetic Gears and Couplings.……………………………………….142 Appendix B: Experimental Part Drawings….……………………………………….148 vi LIST OF TABLES 2.3-1 – Losses in Permanent Magnet Machines. ………………………………..44 2.4.1-1 – Ferrofluid Viscosity and Density. ……...……………………………...51 3.2.2-1 – Summary, Mesh Sensitivity Study. …………………………………...73 3.2.2-2 – FEA Results, Increased Gap Permeability. …………………………...74 3.2.2-3 – FEA Results, Increased Permeability, Complete Immersion. ………...77 3.2.2-4 – FEA Results, Complete Immersion, 2.0” Leg Width.…………………80 3.2.2-5 – FEA Results, Increased Gap Permeability, Varying C-Channel Geometry…………………………………………………………………………82 6.2-1 – Experimental Data, Experiment 3. …………………………………….117 7.2-1 – Experimental Data, Experiment 4. ……………………………….........127 vii LIST OF FIGURES 1.2.1-1 - Nethe, et al. Magnetic Circuit. ……....…………………………….........6 1.2.1-2 - Nethe, et al. Force vs. Permeability for Various Air gap Distances….....7 1.2.1-3 – Nethe, et al. Analytical Model for Force vs. Relative Permeability for Various Air gap Distances………………………………………………………...8 1.2.1-4: Nethe, et al. Torque vs. Various Air Gap Distance for Various Maximum Levels of Magnetic Saturation. ……………………..…………………………….9 1.2.1-5 – Nethe, et al. Heat Flux Delta Versus Gap Width for Various Thermal Coefficients and Speed Ranges. …………………………………………….…...10 1.2.1-6 – Nethe, Et al. Linear Permanent Magnet Machine Experimental Fixture. ..…………................................................................................................11 1.2.1-7 –Nethe, Et al. Linear Permanent Magnet Machine Experimental Results....................................................................................................................12 1.2.1-8 – Nethe, et al. Rotating Permanent Magnet Machine CAD Model...........13 1.2.1-9 – Nethe, et al. Rotating Permanent Magnet Machine Experimental Results. …………………………………………………………………………..14 1.2.2-1 – Torque vs. Relative Angular Offset and Air gap Distance. …………...15 1.2.2-2 – Thingap Manufacturing Process. ………………………………….......16 viii 1.2.2-3 – Flux Guide for Permanent Magnet Machines. ………………………...17 1.2.2-4 – Ferrofluidic Generator, Heat Powered. ………………………………..18 1.2.2-5 - Ferrofluidic Generator, Rotary Motion Powered. …………………..…19 1.2.2-6 – Standard Halbach Array. ………………………………………….......20 1.2.2-7 – Extended Halbach Array………………………...……………...…......21 2.1-1 – Magnetic Element. ………………………………………………………26 2.1-2 – PMM Resistor Network. ………………………………………………...28 2.1-3 - Magnetic Flux Density vs. Magnetic Field Strength, D6ac Steel…..........30 2.2-1 - Traditional Brushed Motor / Generator. …………………………………33 2.2-2 - Demagnetization Curve for