Wide bandgap (WBG) device-based power electronics converters are more efficient and lightweight than silicon-based converters. WBG devices are an enabling technology for many motor drive applications and new classes of compact and efficient motors. This paper reviews the potential applications and advances enabled by WBG devices in ac motor drives. Industrial motor drive products using WBG devices are reviewed, and the benefits are highlighted. This paper also discusses the technical challenges, converter design considerations, and design tradeoffs in realizing the full potential of WBG devices in motor drives. There is a tradeoff between high switching frequency and other issues such as high dv/dt and electromagnetic interference. The problems of high common mode currents and bearing and insulation damage, which are caused by high dv/dt , and the reliability of WBG devices are discussed.

Wide Bandgap Devices in AC Electric Drives: Opportunities and Challenges

Electrical machines are the hearts of many appliances, industrial equipment and systems. In the context of global sustainability, they must fulfill various requirements, not only physically and technologically but also environmentally. Therefore, their design optimization process becomes more and more complex as more engineering disciplines/domains and constraints are involved, such as electromagnetics, structural mechanics and heat transfer. This paper aims to present a review of the design optimization methods for electrical machines, including design analysis methods and models, optimization models, algorithms and methods/strategies. Several efficient optimization methods/strategies are highlighted with comments, including surrogate-model based and multi-level optimization methods. In addition, two promising and challenging topics in both academic and industrial communities are discussed, and two novel optimization methods are introduced for advanced design optimization of electrical machines. First, a system-level design optimization method is introduced for the development of advanced electric drive systems. Second, a robust design optimization method based on the design for six-sigma technique is introduced for high-quality manufacturing of electrical machines in production. Meanwhile, a proposal is presented for the development of a robust design optimization service based on industrial big data and cloud computing services. Finally, five future directions are proposed, including smart design optimization method for future intelligent design and production of electrical machines.

/pdf/a-review-of-design-optimization-methods-for-electrical-1uv2yxy6ns.pdf

A Review of Design Optimization Methods for Electrical Machines

Permanent magnet temperature (PMT) is crucial to high-performance control and condition monitoring of permanent magnet synchronous machines (PMSMs). This paper proposes a noninvasive PMT estimation approach based on the PMSM steady-state equation. First, a linear temperature model, dependent solely on the PMT, is derived from the steady-state equation and the PM thermal model. Thus, the PMT can be directly estimated from the measurements using the derived linear model. In order to improve the estimation performance, a linear state-space model is developed based on the derived model, and the Kalman filter is employed for PMT estimation. The inverter nonlinearity is considered and compensated in the proposed model to improve the estimation performance. Compared with the existing methods, the proposed approach is noninvasive and computationally efficient. More importantly, the derived model does not involve machine parameters such as winding resistance and self and mutual inductances, and thus, the proposed approach is independent of winding temperature rise, magnetic saturation, and cross-coupling effect. The proposed approach is evaluated with extensive experiments under various speed and load conditions.

Noninvasive Kalman Filter Based Permanent Magnet Temperature Estimation for Permanent Magnet Synchronous Machines

This paper is an effort to put together all the potential applications of Wide Bandgap (WBG) devices in AC electric drives. Low inductance motors, high speed motors, and electric drives operating in a high temperature environment are the main application areas of WBG devices. Low voltage permanent magnet motors and slotless motors have a low inductance and require a stringent high-bandwidth current regulation strategy to obtain an acceptable current ripple. Silicon (Si) devices cannot be used in this case due to their limited switching frequency. MW-level high speed motors have devices operating at high voltage and current levels and a high fundamental frequency (600–1200 Hz) that cause very high switching losses in Si IGBT devices. SiC devices have enabled the use of power electronic converters for MW-level high speed motors. Integrated motor drives (IMDs) are also benefitted by WBG devices as they reduce the size of the power converter and allow operation at a high junction temperature. Therefore, the inverter can be mounted on the motor itself which can be a significant heat source due to motor losses. Cooling requirements in high temperature environment applications such as hybrid Electric Vehicle (EV), ground vehicles in combat zones, and power converters used in space technology like land rovers etc., are greatly reduced due to low losses and high junction temperatures. Operation at high frequencies and high temperatures reduces the size of electric drive significantly.

Applications of Wide Bandgap (WBG) devices in AC electric drives: A technology status review

A slotless, lightweight permanent-magnet (PM) motor with high pole count is designed and analyzed for a drone system that requires four motors of 0.5 kW each for a 2-kW propulsion power to attain the required torque–speed profile. The design optimization was carried out using finite-element analysis that lead to a slotless stator with outer rotor Halbach PM configuration achieving high power density, zero cogging torque, low torque ripple, sinusoidal back electromotive force, and good system efficiency. The Halbach configuration is found to have superior power density and torque ripple over the conventional concepts for the aerial applications. The power density and efficiency of the slotless motor can be enhanced through the use of nonconventional thermoplastic material and Halbach segmentation. The resulting low inductance of the slotless machine introduces a controls challenge, but it can be overcome with today's enabling technology of wide bandgap devices. A comprehensive analysis and comparison of the slotless design with an equivalent slotted-radial version showed the superiority of the former. An optimum slotless design has been prototyped and test results along with analysis are presented.

Slotless Lightweight Motor for Aerial Applications

Direct-drive generators to be used in off-shore wind farms are very large low-speed electric machines, which pose remarkable design and manufacturing challenges. Demand forecasts for this kind of machines are urging manufacturers to work out design and technological solutions capable of facilitating series production at competitive costs. This paper presents the development of an interior permanent-magnet generator design and technology aimed at reducing series manufacturing costs while preserving good performance levels. The focus is on two of the most critical issues in the machine design and analysis, namely, the prediction and reduction of eddy-current losses in stator conductors and in permanent magnets. The proposed design solutions are validated through the construction and testing of a 780 kVA generator prototype conceived for easy scalability to higher power ratings (up to around 2.5 MVA) by core length increase.

Design for Manufacturability of an Off-Shore Direct-Drive Wind Generator: An Insight Into Additional Loss Prediction and Mitigation

To meet the needs of the ongoing expansion in the gas industry, common requirements such as high reliability, efficiency, and dynamic performance must be satisfied while still keeping costs competitive. This article reports on an industrial research and development (R&D) project to find the best compromise between performance and production cost targets for a special direct-drive turbomachinery application. The development and testing of a 640-kW 10,000-r/min motor prototype characterized by a slotless stator and a Halbach-magnetized, magnetically levitated permanentmagnet (PM) rotor is discussed, including the technology selection, the design optimization processes, the machine manufacturing, and testing results.

Design Optimization and Testing of High-Performance Motors: Evaluating a Compromise Between Quality Design Development and Production Costs of a Halbach-Array PM Slotless Motor

This paper reports the optimization process of a MW-size, medium voltage, squirrel cage induction motor for industrial applications. Starting from an existing construction, the aim of the optimization is to maximize the induction machine power density, while fulfilling high demanding, specific international Oil&Gas industry regulations. For every considered design, the motor performance is estimated by means of an algorithm based on T-type equivalent circuit. The circuit parameters are determined with a combination of magnetostatic and time harmonic Finite Elements Analysis (FEA), together with analytical formulas. This approach allows the evaluation of the precise parameters dependency on punctual current and frequency values, and allows good performance prediction ability. The multi-objective optimization process input are geometrical variables related to the motor electromagnetic configuration having direct impact on the output performance, is based on Genetic Algorithms (GA), and has been developed with the commercial software ModeFRONTIER®.

Numerical multi-objective optimization of a squirrel cage induction motor for industrial application

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Papers

Design for Manufacturability of an Off-Shore Direct-Drive Wind Generator: An Insight Into Additional Loss Prediction and Mitigation

Design Optimization and Testing of High-Performance Motors: Evaluating a Compromise Between Quality Design Development and Production Costs of a Halbach-Array PM Slotless Motor

Numerical multi-objective optimization of a squirrel cage induction motor for industrial application