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Analysis and Development of a Halbach Array Motor for Application Analysis and Development of a Halbach Array Motor for Application into a Novel Delivery Drone Driving Cycle for Powertrain Optimization and Maximization of Delivery Radius by Maxime Perreault A thesis submitted in conformity with the requirements for the degree of Master of Applied Science Graduate Department of Applied Science and Engineering University of Toronto © Copyright by Maxime Perreault 2020 Analysis and Development of a Halbach Array Motor for Application into a Novel Delivery Drone Driving Cycle for Powertrain Optimization and Maximization of Delivery Radius Maxime Perreault Master of Applied Science Graduate Department of Applied Science and Engineering University of Toronto 2020 ABSTRACT Large companies such as Amazon and Google are currently testing deliveries using unmanned drones, with the intent of using these drones on the market. Topics tackled in this field of research include delivery routing optimization, object collision routing optimization, battery management optimization, and the addition of solar panels on the drones. Little publicly available research has been found to have been conducted on the developing methods to optimize the powertrain of the drones to maximize their delivery radii. To achieve this end, this work puts forth a delivery drone driving cycle simulation written in MATLAB with which to monitor their performance and fine- tune their properties. A halbach array motor is designed and analyzed in ANSYS Maxwell, and a data processing tool is written in MATLAB to manipulate the halbach array motor and propeller data into useable states for the simulation. The driving cycle simulation is tested on fifty-four drone configurations. ii ACKNOWLEDGMENTS The short time I have spent in my graduate research has been a crucial moment in my personal progress, augmented in no small part by the experience and mentorship of my supervisor, Professor Kamran Behdinan. His care and attention to my professional development have imparted wisdoms that will reverberate within me and from which I will keep learning as I move forward. This work has been funded in part by the Natural Sciences and Engineering Research Council of Canada under Grant CRDPJ 514905-17, to whom I would like to extend my appreciation for their support. I thank Doctor Ali Hameed Radhi for his friendship and camaraderie over these last years. It was a welcome boon to work alongside someone who is always willing to engage in stimulating discussions or provide guidance as .I often needed. I extend a deep gratitude to both of my parents, for the love they have shared, their stalwart devotion to my welfare, and unwavering support for my choices in life. Without the opportunities, comforts, and freedom to grow that they have provided, I would never have managed to be the person I am. To my dog, Remi, whose playfulness and unappeasable desire for cuddles has helped keep my sanity in check. I wish her many years of joy to come. To Mengqi, my muse. You have stayed by me these many years, your ardent presence never showing any signs of relent through both sickness and health. I only hope to be as good to you as you are to me. iii TABLE OF CONTENTS List of Tables ................................................................................................................................................ v List of Figures .............................................................................................................................................. vi Nomenclature ............................................................................................................................................... xi 1 Introduction ............................................................................................................................................. 1 1.1 Motivation ........................................................................................................................................... 3 1.2 Outline................................................................................................................................................. 4 2 Literature Review – Halbach Array Motors............................................................................................ 5 2.1 The Halbach Array .............................................................................................................................. 5 2.2 Applications of Halbach Arrays .......................................................................................................... 8 2.3 Halbach Arrays in Motors ................................................................................................................. 10 3 Governing Equations ............................................................................................................................ 15 3.1 Electromagnetic Equations ............................................................................................................... 15 3.2 Electric Motor Characteristic Behavior ............................................................................................ 18 3.3 Drone Kinetics .................................................................................................................................. 25 4 Methodology of Halbach Motor Design ............................................................................................... 30 4.1 ANSYS Maxwell Simulations .......................................................................................................... 30 4.2 Powertrain Data Processing .............................................................................................................. 47 5 Driving Cycle of Delivery Drone .......................................................................................................... 54 6 Results of Delivery Drone Driving Cycle ............................................................................................. 58 6.1 Delivery Drone Parameters ............................................................................................................... 58 6.2 Driving Cycle Simulation Result Analysis ....................................................................................... 60 7 Conclusion ............................................................................................................................................ 75 7.1 Contributions..................................................................................................................................... 76 8 Future Work .......................................................................................................................................... 77 References ................................................................................................................................................... 78 Appendices .................................................................................................................................................. 85 Appendix A: Produced MATLAB Code ................................................................................................ 85 Appendix B: Propeller Experimental Data Curve-Fitting ....................................................................... 88 Appendix C: Detailed Powertrain Operating Point Figures .................................................................... 89 Appendix D: Detailed Ideal Pitch Angle Figures ................................................................................... 90 iv LIST OF TABLES Table 4.1.1: General Machine Properties of the Halbach Array Motor in ANSYS Maxwell RMxprt. ...................... 31 Table 4.1.2: Circuitry Properties of the Halbach Array Motor in ANSYS Maxwell RMxprt. ................................... 32 Table 4.1.3: Material Properties of Iron in the Halbach Array Motor in ANSYS Maxwell RMxprt.......................... 32 Table 4.1.4: Stator Properties of the Halbach Array Motor in ANSYS Maxwell RMxprt. ........................................ 33 Table 4.1.5: Rotor Properties of the Halbach Array Motor in ANSYS Maxwell RMxprt. ......................................... 33 Table 4.1.6: Armature Slot Properties of the Halbach Array Motor in ANSYS Maxwell RMxprt. ........................... 34 Table 4.1.7: General Winding Properties of the Halbach Array Motor in ANSYS Maxwell RMxprt. ...................... 36 Table 4.1.8: Winding End/Insulation Properties of Halbach Array Motor in ANSYS Maxwell RMxprt. ................. 36 Table 4.1.9: Material Properties of N50M in the Halbach Array Motor in ANSYS Maxwell RMxprt. ..................... 37 Table 4.1.10: Magnet Pole Properties of the Halbach Array Motor in ANSYS Maxwell RMxprt............................. 37 Table 4.1.11: Mass Breakdown by Component of the Halbach Array Motor. ........................................................... 38 Table 4.1.12: Mesh Operations of the Halbach Array Motor in ANSYS Maxwell 2D Design. ................................. 43 Table 4.1.13: Motion Setup of the Halbach Array Motor in ANSYS Maxwell 2D Design........................................ 43 Table 6.1.1: Simulation Delivery Drone Properties. ................................................................................................... 58 Table 6.1.2: Propeller Characteristic Curves of Lift and Torque as Functions of rpm. .............................................. 59 Table 6.1.3: Simulation Powertrain Component Masses. ..........................................................................................
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