Energy efficient design and implementation of electric machines in air transport propulsion system

Interior permanentmagnet (IPM) motors have been the most promising solutions for electric vehicles (EV) drives in terms of torque/power density, compactness, and efficiency. However, IPM motors are vulnerable to large torque ripple and high-level electromagnetic vibrations due to the differences of <italic xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">d-&amp;q -axis inductance and abundant spectrum of exciting forces. This article presents an intensive comparison of IPM motors with three design approaches to reduce cogging torque, torque ripple, and electromagnetic vibration. The design approaches compared cover skewing slot and segmented rotor approaches commonly used in industry, as well as a new asymmetric pole approach. A commercial 10 kW 8-pole/ 48-slots V-shaped IPM motor for EV traction is taken as the reference base. Extensive performance comparisons, including cogging torque, back-EMF, load current, load torque profiles, PM reliability, and torsional force were carried out. Besides, vibration aspects in terms of exciting force, modal property, and electromagnetic vibration response were also analyzed and compared. Finally, the prototypes with the mentioned three design approaches are produced, respectively, and intensive experimental tests were done to verify the analysis and comparison.

Comparison and Experimental Verification of Different Approaches to Suppress Torque Ripple and Vibrations of Interior Permanent Magnet Synchronous Motor for EV

Interior permanentmagnet (IPM) motors have been the most promising solutions for electric vehicles (EV) drives in terms of torque/power density, compactness, and efficiency. However, IPM motors are vulnerable to large torque ripple and high-level electromagnetic vibrations due to the differences of d-&q-axis inductance and abundant spectrum of exciting forces. This article presents an intensive comparison of IPM motors with three design approaches to reduce cogging torque, torque ripple, and electromagnetic vibration. The design approaches compared cover skewing slot and segmented rotor approaches commonly used in industry, as well as a new asymmetric pole approach. A commercial 10 kW 8-pole/ 48-slots V-shaped IPM motor for EV traction is taken as the reference base. Extensive performance comparisons, including cogging torque, back-EMF, load current, load torque profiles, PM reliability, and torsional force were carried out. Besides, vibration aspects in terms of exciting force, modal property, and electromagnetic vibration response were also analyzed and compared. Finally, the prototypes with the mentioned three design approaches are produced, respectively, and intensive experimental tests were done to verify the analysis and comparison.

Permanent magnet synchronous motor (PMSM) for electric vehicles is developing higher frequency and speed but triggering a significant increase of eddy current loss. To resolve the eddy current loss issue, a novel flat wire transposed winding composed of double-row multiple parallel strands is proposed. Transposed winding techniques have been proved to be efficient in reducing eddy current loss by preventing the uneven leakage magnetic field induced by high frequency. The proposed transposition further improved this technique in reducing circulating current loss. Taking a 60-kW PMSM as an example, the novel flat wire transposed winding arrangement is carried out. The 3-D field-circuit coupled finite-element models of 360° complete transposed and incomplete transposed winding PMSM are established, and circulating current losses are compared. The analysis results show that incomplete transposed winding has a better performance in reducing the circulating current loss. The transposition method suitable for novel flat wire transposed winding is obtained, and the feasibility of PMSM with novel flat wire transposed winding to reduce winding losses is proven. 

Research on Novel Flat Wire Transposed Winding of PMSM for Electric Vehicle

By measuring the open-circuit radial stray magnetic flux density (RSMFD) of three spatial points, a novel diagnostic method for the eccentricity of interior permanent magnetic motors (IPMSMs) in electric vehicles is proposed. Outperforming traditional methods, the proposed method can noninvasively diagnose not only the severities of static eccentricity (SE), dynamic eccentricity (DE), and mixed eccentricity (ME), but also the eccentricity location. In this article, diagnosis results are described through three eccentricity parameters: SE ratio, DE ratio, and SE angle. First, an analytical model of the open-circuit RSMFD of the IPMSM is proposed, with its accuracy validated by experiments. The pattern of the impact of the eccentricity parameters on the open-circuit RSMFD is analyzed to form the basis of the proposed method. Then, an eccentricity prototype motor, which can continuously emulate the eccentricity according to any listed eccentricity parameters, is developed. A test rig is built to collect the open-circuit RSMFD and validate the analytical calculation results. Finally, an eccentricity diagnostic model based on the open-circuit RSMFD is established. The diagnosis results proved the noninvasiveness, effectiveness, and viability of the proposed method.

Open-Circuit Radial Stray Magnetic Flux Density Based Noninvasive Diagnosis for Mixed Eccentricity Parameters of Interior Permanent Magnet Synchronous Motors in Electric Vehicles

To accurately and quickly predict the open-circuit air-gap magnetic field in interior permanent magnet synchronous machines (IPMSMs), an analytical model based on magnetic equivalent circuit (MEC) method is proposed. The analytical model can provide radial and tangential components of open-circuit magnetic field in the slotless air gap. The radial component is obtained from the MEC model, and the tangential component is obtained from boundary conditions of macroscopic equations. Then, a complex relative air-gap permeance is applied to take the effect of slots into account. As a result, an accurate solution of both radial and tangential components of the flux density in the slotted air gap is obtained. Additionally, the no-load back electromotive force (EMF) and cogging torque are calculated based on the open-circuit air-gap magnetic field. All the analytical results are verified by the finite element (FE) analysis and they are well matched. In the end, a direct measurement experiment of open-circuit air-gap magnetic field is proposed to verify the validity of both radial and tangential open-circuit air-gap magnetic fields.

Analytical Model of Open-Circuit Air-Gap Field Distribution in Interior Permanent Magnet Machines Based on Magnetic Equivalent Circuit Method and Boundary Conditions of Macroscopic Equations

A 3-D analytical model of armature reaction field (ARF) of interior permanent magnet synchronous motor (IPMSM) with multi-segmented skewed poles (MSP) and multi-layered flat wire winding (MFWW) considering current harmonics is proposed in this paper. Firstly, based on the MFWW distribution analysis and the coil magnetic field vector superposition method, the ideal ARF functions of the MFWW considering low-order current harmonics and high-order sideband current harmonics are derived. Secondly, 3-D relative permeance functions caused by the stator slotting effect and the multi-segmented rotor magnetic barriers are presented. Thirdly, 3-D analytical expressions of ARF are obtained by multiplying the ideal ARF functions and the 3-D relative permeance functions. Additionally, the effects of low-order current harmonics, high order sideband current harmonics, MSP, and stator slotting on the spatial orders and frequencies of ARF are analyzed. Finally, the proposed model is verified by finite element method (FEM) and experiment.

/pdf/3-d-analytical-model-of-armature-reaction-field-of-ipmsm-2pqlmannwq.pdf

3-D Analytical Model of Armature Reaction Field of IPMSM With Multi-Segmented Skewed Poles and Multi-Layered Flat Wire Winding Considering Current Harmonics

Physical-Knowledge-Guided and Interpretable Deep Neural Networks for Gear Fault Severity Level Diagnosis

Review of intelligent fault diagnosis for rotating machinery under imperfect data conditions

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