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C 2014 Veysel Tutku Buyukdegirmenci c 2014 Veysel Tutku Buyukdegirmenci A FRAMEWORK FOR DYNAMIC CHARACTERIZATION AND SHORT-TERM THERMAL CAPABILITY ASSESSMENT OF ELECTRIC MACHINES AND INVERTERS IN MOTOR DRIVES BY VEYSEL TUTKU BUYUKDEGIRMENCI DISSERTATION Submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy in Electrical and Computer Engineering in the Graduate College of the University of Illinois at Urbana-Champaign, 2014 Urbana, Illinois Doctoral Committee: Professor Philip T. Krein, Chair Professor Peter W. Sauer Professor Andrew G. Alleyne Professor Anthony Jacobi Assistant Professor Alejandro Dominguez-Garcia ABSTRACT The need for more powerful and compact motor drives is growing, especially in the fields of automotive traction and more-electric aircraft systems. These applications have peak-duty aspects that intermittently stress the drive. To account for this stress, conventional methods dating back to the 1940s have yielded oversized and expensive designs. This dissertation presents motor-drive characterizations to illuminate the full extent of their peak capabilities and control strategies to safely attain peak torque. Vector-controlled induction machine torque capabilities are assessed and limiting factors are investigated. Static and dynamic thermal characterizations are carried out through an- alytical and experimental approaches. Three decoupled heating regimes that characterize time ratings ranging from modest to severe overloads are identified. The characterizations show that recent general-purpose open-drip-proof induction machines can handle up to 25 times more heat dissipation than rated for 30 seconds and twice the rated heat dissipation for 60 minutes. A self-limiting control strategy is developed that exploits these capabilities and protects the drive from overheating. Results suggest that these machines may be safely overloaded even after the hot-spot temperature limit is reached, as long as internal temper- atures are below rated. Inverter sizing to accommodate peak duty is also addressed and design tradeoffs on size and short-term ratings are highlighted. These characterizations inform an energy-based and service time-aware design strategy which allows size reduction of up to 70% in automotive drives and 17% in aircraft actua- tors. Analyzing the general-purpose motors from a peak-duty perspective shows that they have significant time-limited peak capabilities—with no structural change, they provide high short-term power density. Once fully exploited, this peak capability makes possible inex- pensive and compact drive systems for the tomorrow’s advanced applications. ii To my parents, Mehmet Okay B¨uy¨ukde˘girmenci and Fazilet B¨uy¨ukde˘girmenci, for their love, confidence and support in every aspect of my life. iii ACKNOWLEDGMENTS I would like to express my greatest gratitude to my adviser, Professor Philip T. Krein, for allowing me to pursue a doctoral degree at the University of Illinois at Urbana-Champaign. The opportunity to work closely with him and learn from him has been absolutely life- changing. His practical and perceptive insights and suggestions are truly inspirational. I admire his ability to be succinct in communication. I would like to extend my acknowledgements to my doctoral committee and other profes- sors that made my graduate college experience delightful. Prof. Peter Sauer is one of the most remarkable and influential professors I have had the opportunity to get to know. His fatherly figure, which holds the power and energy group together, has been a true inspira- tion for me and will be my guide in my future voyages into academia. Prof. Kiruba Haran provided valuable insight and direction on my research, especially from the industry per- spective. I appreciate the effort and time he spent to discuss research and provide valuable feedback. Prof. Andrew Alleyne has taught me the importance of looking outside the box. I deeply appreciate his input and valuable suggestions on my research. Many thanks to other professors such as Alejandro Dom´ınguez-Garc´ıaand Anthony Jacobi as well. This research has been funded by the Grainger Center of Electric Machinery and Elec- tromechanics and Rolls-Royce 2012-05196. My graduate study would not be possible without their generous support. In addition, parts of the material discussed here resulted from col- laboration through the strategic partnership program between Kungliga Tekniska Hgskolan and University of Illinois at Urbana-Champaign. Many other people worked hard to enable this work. My undergraduate assistant, Kemal Emre Ercikti, helped me numerous hours. I would also like to thank Joyce Mast for her invaluable help with my writing skills, and Robin Smith from arranging reimbursements to iv addressing our administrative problems. I would like to extend my special thanks to my foster brother, Dr. Ali M. Bazzi. It has been a great pleasure to get to know him as a friend, as a colleague and as a brother. There are not enough words to describe how intellectually stimulating it is to collaborate and brainstorm with him. My colleagues and fellow graduate students have helped me significantly during my studies. I especially want to thank Matthew P. Magill, my office mate, for the countless hours he spent to help me articulate my thoughts and improve my communication skills. I deeply appreciate the interesting discussions we had on each other’s research direction over the years. I also express my great appreciation to Srikanthan Sridharan, who is one of the most passionate researchers I have had chance to collaborate with. He sacrificed his experimental work so I could complete this dissertation in a timely manner. It has been a terrific experience to work with him and discuss the philosophy of meditation. I would also like to thank Shafigh Nategh. Collaborating with him has been a pleasure. I would like to say thank you to my dear friends in the power and energy area, Kai Van Horn, Dimitra Apostolopulou, Christopher Barth, and Enver Candan. My journey began with the motivation from Sevim Engin and Murat Kacar. I cannot thank them enough. They are among the most important people in my life. Their influence was indispensable for my accomplishments. Lastly, I would like to thank my loving parents for their incredible support and confidence in me. They have sacrificed more from their lives than anyone else to bring me to where I am today. All my accomplishments would be impossible without their guidance. v TABLE OF CONTENTS CHAPTER1 INTRODUCTION ............................ 1 1.1 AutomotiveSystems ............................... 2 1.2 AircraftSystems ................................. 6 1.3 ElectromagneticLaunchers. 7 1.4 Protection Systems and Safety Applications . ... 9 1.5 Organization ................................... 9 CHAPTER 2 LITERATURE REVIEW AND BACKGROUND INFORMATION . 12 2.1 Drive Torque Capabilities . 12 2.2 MachineRatings ................................. 17 2.3 MachineThermalAnalysis............................ 19 2.4 TransientThermalTrackingStrategies . ... 21 2.5 ElectrothermalInverterModels . .. 25 2.6 Impact of Thermal and Power Cycling on Motor Drive Lifetime . ... 34 2.7 ConcludingRemarks ............................... 38 CHAPTER 3 MOTOR DRIVE ELECTRICAL LIMITATIONS . 40 3.1 Torque Capabilities of Vector Controllers . .. 40 3.2 Alternative Field Weakening Strategies . 46 3.3 ExperimentalResults............................... 50 3.4 Torque Capability Projections on Higher Power and Voltage Drives ..... 53 3.5 Vector-Controlled Drives in the Limit of Zero Leakage . .... 56 3.6 ConcludingRemarks ............................... 57 CHAPTER 4 DEVELOPMENT OF ANALYTICAL MODELS FOR FAST AND FLEXIBLE THERMAL ANALYSIS OF ELECTRIC MACHINES . 60 4.1 ALinearStatorThermalModel . 60 4.2 A Layer-based Thermal Model of a Rotational Machine Stator . ....... 75 4.3 ConcludingRemarks ............................... 87 CHAPTER 5 MACHINE CHARACTERIZATION FOR PEAK DUTY . 88 5.1 Electric Machine Heating Modes . 88 5.2 Estimating Material Properties . 98 5.3 Unified Model for Time Rating Estimates . 99 5.4 Experimental Validation . 102 vi 5.5 ExpandingTimeRatings............................. 104 5.6 Using PCM in Electric Machines . 106 5.7 ConcludingRemarks ............................... 112 CHAPTER 6 INVERTER CHARACTERIZATION FOR PEAK DUTY . 114 6.1 Developed Electrothermal Inverter Model . ..... 115 6.2 InverterTimeRatingEstimates . 119 6.3 Experimental Results on Time Ratings . 122 6.4 Inverter Characterization for Periodic Duty . ..... 122 6.5 Energy-BasedInverterRatings. 126 6.6 FaultOperationCaseStudy ........................... 128 6.7 ConcludingRemarks ............................... 129 CHAPTER 7 SELF-LIMITING CONTROL OF INDUCTION MACHINES . 131 7.1 Self-Limiting Control . 132 7.2 Developed Transient Thermal Tracker . 137 7.3 Induction Machine Loss Estimation under Vector Control . ...... 139 7.4 Implementation of Self-Limiting Algorithm . 144 7.5 ExperimentalResults............................... 146 7.6 SafeOverloadMargins .............................. 150 7.7 Impact of Initialization Errors . 151 7.8 ConcludingRemarks ............................... 154 CHAPTER 8 CASE STUDIES ON MACHINE SIZING . 156 8.1 Machine Sizing for Periodic Intermittent Duty . 156 8.2 Machine Sizing for Automotive Duty . 159 8.3 Lifetime and Service Time Aware Designs . 165 CHAPTER 9 CONCLUSIONS AND FUTURE WORK . 173 9.1 FutureWorkandOpenResearchTopics . 176 APPENDIX A CLOSED-FORM SOLUTION COEFFICIENTS FOR LINEAR MACHINEMODEL .................................. 178 A.1 Closed-form
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