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Permanent Magnet Synchronous Machines with Fractional Slot and Concentrated Winding Configurations

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Permanent Magnet Synchronous Machines with Fractional Slot and Concentrated Winding Configurations CRANFIELD UNIVERSITY Defence Academy - College of Management and Technology Department of Engineering and Applied Science, Power and Drive Systems Group PhD Thesis 2011 Weizhong Fei Permanent Magnet Synchronous Machines with Fractional Slot and Concentrated Winding Configurations Supervisor: Dr Patrick Chi-Kwong Luk January 2011 c Cranfield University, 20101. All rights reserved. No part of this publication may be reproduced without the prior written permission of the copyright owner. Abstract The permanent magnet synchronous machines with fractional slot and con- centrated winding configuration have been steadily gaining traction in various applications in recent times. This is mainly driven by several advantages of- fered by this configuration such as high-torque density, outstanding efficiency, and easy and low-cost fabrication. The main focus of this thesis is dedicated to the investigation of three main topologies of fractional-slot and concentrated- winding permanent magnet synchronous machines specifically suited for partic- ular applications. Additionally, the cogging torque and torque ripple reduction technique based on a novel axial pole pairing scheme in two different radial-flux permanent magnet synchronous machines with fractional-slot and concentrated- winding configuration are investigated. First, an axial flux permanent magnet segmented-armature-torus machine with laminated stator is proposed for in-wheel direct drive application. Both simplified analytical method and three-dimensional finite element analysis model accounting for anisotropic property of lamination are developed to analyze the machine performance. The predicted and experimental results are in good agree- ment and indicate that the proposed machine could deliver exciting and excellent performance. The impact of magnet segmentation on magnet eddy current losses in the prototype is carried out by the proposed three-dimensional finite element analysis model. The results show that the eddy current losses in the magnet could be effectively reduced by either circumferentially or radially segmenting the mag- nets. Furthermore, a magnet shaping scheme is employed and investigated to reduce the cogging torque and torque ripple of the prototype. This is validated using the three-dimensional finite element analysis model as well. Second, a coreless axial flux permanent magnet machine with circular mag- nets and coils is proposed as a generator for man-portable power platform. Ap- proximate analytical and three-dimensional finite element analysis models are developed to analyze and optimize the electromagnetic performance of the ma- chine. Comprehensive mechanical stress analysis has been carried out by three- dimensional structural finite element analysis, which would ensure the rotor in- tegrity at expected high rotational speed. The results from both three-dimensional finite element analysis and experiments have validated that the proposed proto- type is a compact and efficient high speed generator with very simple and robust structure. Additionally, this structure offers simplified assembly and manufac- turing processes utilizing off-the-shelf magnets. Third, a novel radial flux outer rotor permanent magnet flux switching ma- chine is proposed for urban electric vehicle propulsion. Initial design based on the analytical sizing equations would lead to severe saturation and excessive magnet volumes in the machine and subsequently poor efficiency. An improved design is accomplished by optimizing the geometric parameters, which can significantly improve the machine efficiency and effectively reduce the overall magnet vol- umes. Magnet segmentations can be employed to further improve the machine performance. Finally, a novel axial pole pairing technique is proposed to reduce the cogging torque and torque ripple in radial flux fractional-slot and concentrated-winding permanent magnet synchronous machines. The implementation of the technique in outer rotor surface mounted permanent magnet synchronous machine shows that the cogging torque and torque ripple can be reduced very effectively with different magnet pairs. However, careful pair selection is of particular importance for compromise between cogging torque and torque ripple minimizations dur- ing the machine design stage. This technique is also employed to minimize the cogging torque in a permanent magnet flux switching integrated-stator-generator and it is compared with rotor step skewed technique. The estimated and exper- imental results show that the axial pole pairing technique can not mitigate the torque ripple of the machine as effectively as rotor step skewed approach although both the techniques could reduce the cogging torque to the same level. ii PhD Thesis: Weizhong Fei To my parents Shunrong Fei and Yuewen Zhang! Acknowledgements I would like to acknowledge everyone who has knowingly and unknowingly helped me and wished me the best in successfully accomplishing this research. I would like to express particular thanks to my supervisor, Dr Patrick Chi-kwong Luk. His supportive encouragement and supervision over the whole study have been extremely helpful and essential. A special thanks goes out to Professor Jianxin Shen from Zhejiang University, China, for his valuable helps and discussions during the research. I would also like to thank Mr Chen Yuan from Wujiang Nanyuan Electrical Co., Ltd, China for his professional advices on the prototype design as well as prompt and excellent prototype manufacture services. Thanks also to all my family and friends whose support and wishes have been of essential importance through this entire study. Contents Abstract i Acknowledgements v Nomenclature xxiii 1 Introduction 1 1.1 Introduction ................................ 1 1.2 Main Contributions ............................ 13 1.3 Outline ................................... 14 1.4 Publications ................................ 14 2 AFPM SAT Machine for In-Wheel Direct Drive Applications 19 2.1 In-Wheel Direct Drive and AFPM Machine .............. 19 2.2 AFPM SAT Machine with Laminated Stator .............. 26 2.3 Analytical Modeling of AFPM SAT Machine ............. 28 2.3.1 No Load Air-Gap Flux Density Distribution ......... 30 2.3.2 Armature Reaction Field Prediction .............. 32 2.3.3 Cogging Torque .......................... 33 2.3.4 Back EMF ............................. 34 2.3.5 Resistance ............................. 35 2.3.6 Inductance ............................. 36 2.3.7 Losses ............................... 37 2.4 3-D FEA Modeling of AFPM SAT Machine .............. 40 2.5 Design of AFPM SAT Machine ..................... 42 2.6 Loss Evaluation and Efficiency Map .................. 51 PhD Thesis: Weizhong Fei vii Contents 2.6.1 Stator Losses ........................... 51 2.6.1.1 Winding Resistive Losses ............... 52 2.6.1.2 Stator Core Losses ................... 52 2.6.1.3 Eddy Current Losses in the Aluminium Alloy Rings 53 2.6.2 Rotor Losses ............................ 55 2.6.2.1 Rotor Back Iron Core Losses ............. 55 2.6.2.2 Magnet Eddy Current Losses ............ 56 2.6.3 Efficiency Map of the Proposed Machine ........... 58 2.7 Prototype and Experimental Validation ................ 59 2.8 Magnet Segmentation .......................... 64 2.9 Torque Ripple Reduction ......................... 67 2.9.1 Scope of Magnet Variation .................... 69 2.9.2 Cogging Torque and Back EMF Harmonics Modeling .... 70 2.9.3 Optimization with Armature Reaction ............. 77 2.10 Summary .................................. 79 3 Coreless AFPM Machine for Man-Portable Power Platform 81 3.1 Man-Portable Power Platform ...................... 81 3.2 Coreless AFPM Machines ........................ 84 3.3 Machine Topology ............................ 85 3.4 Analytical Modeling ........................... 88 3.4.1 Electromagnetic Modeling .................... 88 3.4.2 Loss Modeling .......................... 92 3.4.2.1 Stator losses ...................... 92 3.4.2.2 Rotor losses ....................... 93 3.5 Machine Design .............................. 94 3.6 Magnet Holder Design .......................... 98 viii PhD Thesis: Weizhong Fei Contents 3.7 Loss and Efficiency Evaluations .....................102 3.8 Prototype and Experimental Validation ................107 3.9 Summary ..................................113 4 Novel Outer Rotor PMFS Machine for Electric Vehicle Propulsion 115 4.1 Introduction ................................115 4.2 Topology ..................................117 4.3 Operation Principle ............................119 4.4 Sizing Equations ..............................121 4.5 Determination of Rotor Pole Number .................123 4.6 Design and Analysis of Prototype Machine ..............124 4.6.1 Machine Design ..........................124 4.6.2 Losses and Efficiency Map ....................132 4.7 Improved Design of the Prototype Machine ..............135 4.7.1 Impact of the Design Parameters ................135 4.7.2 Improved Prototype .......................139 4.7.3 Losses and Efficiency Map of the Improved Machine ....142 4.8 Summary ..................................148 5 Torque Ripple Suppression in Direct Drive FSCW PMSM by Axial Pole Pairing 149 5.1 Introduction ................................149 5.2 Analytical Torque Ripple Modeling ...................151 5.2.1 Open Circuit Magnetic Field Distribution ...........151 5.2.2 Cogging Torque ..........................152 5.2.3 Flux Linkage and Back EMF ...................153 5.2.4 Instantaneous Torque ......................154 5.3 Outer Rotor
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