Modular Permanent Magnet Machine Based o n Soft Magnetic Composite W e n Ouyang*, Surong Huang**, Anne Good***, T.A. Lipo* *Department of Electrical and Computer Engineering University of Wisconsin-Mad ison 1415 Engineering Drive Madison, W I 53706 " Department of Automation Shanghai U niversity Shanghai, 200072, P.R.China **Burgess-Norton 737 Peyton Street, Geneva, IL , 60134 Abstract With the improvement of soft magnetic composite (SMC) material, electric machine design i s n o longer limited to the traditional iron lamination technology. T h e single extrusion fabrication process of th e S M C material simplifies construction of machine armature core. Moreover, th e material property c a n be exploited for various machine structure design, compared with th e 2D flux distribution of typical iron laminations. In this paper, a drive system based o n a nov el m u lti phase modular perman ent magn et machine is proposed. T he concentric winding structure simplifies th e stator structure with th e benefit of less end winding loss, which also offers th e potential of fault tolerant capability. The performance of the drive system is analyzed discussed with th e simulation provided. Keywords Soft Magnetic Composite, Permanent Magnet (PM), Concentric Windings, Single Phase, Multiple Phase, Fault Tolerant INTRODUCTION T h e emergence of soft magnetic composite material has greatly changed th e nature of the electrical machine construction process. Th e possibility of a "one-punch" module reduces the work effort in lamination a n d stacking. Less copper loss c a n be ach iev ed with the concentric winding design d u e to the shorter e n d windings fo r the pole p ie ce modules.[1] T he progressive improvement of soft magnetic composite (SMC) material property as illustrated in Figure 1. T h e isotropic property to create a 3 D magnetic circuit creates possibilities fo r various novel electric machine designs. Some prototypes based o n S M C ha ve be e n reported[2-7], with[1] illustrating typical machine designs of surface permanent magnet motor, a n d [ 8 ] small induction motors. In this paper, novel single phase a n d multiphase permanent drive system based o n S M C modules are proposed a n d compared. T h e machine stator is assembled b y independent pole pieces fabricated from the S M C material, with ea ch pole piece mounted b y a n independent concentric phase winding, which also simplifies th e winding efforts in machine fabrication. T he rot or structure c a n be designed with surface permanentmagnet (SPM) o r internal perman en t magn et (1PM) for diffe ren t application requirement. Fo r the single phase design, th e machine winding achieves the maximum winding factor a n d minimum switching devices at the cost of air-gap length adjustment a n d current compensation fo r th e starting an d pulsating torque. Fo r the multiphase design, a five phase drive system is proposed with less torque ripple a n d potential for the phase fault operation capability, but at the cost of significant increase number of switching devices in th e driv e circuit. Fig. 1: Magnetic property of S M C I I MACHINE STRUCTURE In order to compare the effective usage of machine material, the winding factor K & is typically defined as in [9]. A higher winding factor means higher utilization of the stator module, which includes stator winding a n d stator iron volu me fo r th e energy conversion, thus higher power density when th e other factors are same. T h e general expression of K,,h with consideration of harmonic order h is expressed as: Kwh ::: KphKdhKXhKsh (1) Krh. Kdh. KAh. and K ~h are fa ct ors fo r pitch, distribution, slot opening, a n d skew. Fo r the surf ac e PM machine discussed in this paper, the distribution, skew a n d slot opening factors are unity d u e to th e concen tric winding, non-skew rotor structure a n d relative small slot opening design. Thus, the winding factor will be virtually determined b y the pole pitch factor, which is generally defined as (2 ) [9]: hWzT hz T K ph sin( - ) sin( ) T p 2 2 (2 ) T h e quantity W enotes the concentric winding span, a n d - r. is the pole pitch. Fo r th e fundamental component, the 23 5 S M C maeiaHCuv --I-- -- -- a - - Authorized licensed use limited to: Chaitanya Bharathi Institute of Technology. Downloaded on July 9, 2009 at 02:54 from IEEE Xplore. Restrictions apply.
Transcript
8/14/2019 Modular Permanent Magnet Machine Based on Soft Magnetic Composite
For the single phase design, the machine winding achieves
the maximumwinding factor andminimum switching devices
at the cost of air-gap length adjustment and current
compensation for the starting and pulsating torque. For the
multiphase design, a five phase drive system is proposed with
less torque ripple and potential for the phase fault operation
capability, but at the cost of significant increase number of
switching devices in the drive circuit.
Fig. 1: Magnetic property ofSMC
I I MACHINESTRUCTURE
In order to compare the effective usage ofmachine material,
the winding factor K & is typically defined as in [ 9 ] . Ahigher
winding factor meanshigher utilization of the stator module,
which includes stator winding and stator iron volume for the
energy conversion, thus higher power density when the other
factors are same. The general expression of K,,h with
consideration ofharmonic order h is expressed as:
Kwh:::
KphK dhKXhKsh (1)
K r h . Kdh. K A h . and K ~h are factors for p i t c h , distribution, slot
opening, and skew. For the surfacePMmachine discussed in
this paper, the distribution, skew and s lot opening factors are
unity due to the concentric winding, non-skew rotor structure
andrelative small slot opening design. Thus, the winding factor
will be virtually determined by the pole pitch factor, which is
generally defined as (2) [ 9 ] :
hWzT hzTK ph s i n ( -) s i n ( )
T p2 2(2)
The quantityWenotes the concentric winding span, and - r .
is the pole pitch. For the fundamental component, the
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S M C maeiaHCuv
--I-- -- -- a
- 4-
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8/14/2019 Modular Permanent Magnet Machine Based on Soft Magnetic Composite
F i g . 4 : S i m u l at io n o f s q u a r e wave c u r r e n t s u p p l y a n d m a c h i n e t o r q u e
F i g . 2 : S i n g l e p h a s e s u r f a c e PMm a c h i n e c o n c e p t
H o w e v e r , t h e i n t r i n s i c s t a r t i n g p ro b le m s o f t h e s i n g l e p h a s e
PM m o t o r m a k e i t n e c e s s a r y t o a p p l y s o m e v a r i a t i o n o n t h es t a t o r t e e t h s h a p e [ 1 0 ] . One o f t h e s u g g e s t e d t e c h n i q u e s i s t o
c r e a t e a t a p e r e d a i r - g a p l e n g t h b y s h a p i n g t h e t o o t h t i p d e p t h .By m a k i n g u s e o f t h e c o g g i n g t o r q u e g e n e r a t e d b y t h ea s y m m e t r i c r e l u c t a n c e c e n t e r s a r o u n d t h e t o o t h a x i s , t h e m o t o r
c a n pass t h e z e r o t o r q u e p r o d u c t i o n p o i n t a t t h e c o s t o f
f l e x i b i l i t y i n r o t a t i o n d i r e c t i o n . F i g u r e 3 g i v e s a n e x a m p l e
d e s i g n b as ed o n t h e s i n g l e p h a s e m a c h i n e c o n c e p t w i t h t a p e r e ds t a t o r t e e t h a n d t h e c o r r e s p o n d i n g c o g g i n g t o r q u e p r o p e r t y .T h e m a c h i n e s t a t o r i s a n a s s e m b l y o f e i g h t p o l e p i e c e sf a b r i c a t e d f r o m SMC m a t e r i a l o r e v e n s t e e l l a m i n a t i o n s . T h e
a i r - g a p l e n g t h b e t w e e n r o t o r r a r e e a r t h PMs a n d s t a t o r p o l e s i s
v a r i e d f r o m 0 . 7 mm t o 1 . 3 mm.
F i g . 3 : S i n g l e ph as e m a c h i n e e x a m p l e d e s i g n a n d t h e c o g g i n g t o r q u e p r o p e r t y
When t h e PM a x e s a r e a l i g n e d w i t h t h e s t a t o r p o l e p i e c e a x e s ,w h i c h c o r r e s p o n d s t o t h e r o t o r p o s i t i o n o f 2 2 . 5 d e g r e e s , t h em a c h i n e s t i l l d e v e l o p s s i g n i f i c a n t c o g g i n g t o r q u e t o r i d e o v e r
t h e p o i n t w i t h d i f f i c u l t y i n t h e a c t i v e t o r q u e p r o d u c t i o n , w h e r e
i s u s u a l l y t h e r o t o r p o s i t i o n p o i n t f o r c u r r e n t c o m m u t a t i o n .
W i t h a r a t e d s q u a r e w a v e f o r m c u r r e n t s u p p l y , t h e m a c h i n e t o t a lt o r q u e p r o p e r t y i s s i m u l a t e d a s s h o w n i n F i g u r e 4 . A l t h o u g h
t h e a v e r a g e t o r q u e i s s i g n i f i c a n t l y h i g h e r t h a n t h e r a t e d t o r q u e
o f a t y p i c a l 3 h p i n d u c t i o n m a c h i n e ( G E - 5 K I 8 2 B C 2 1 8 A ) a t
1 7 5 5 r p m f o r t h e s a m e e f f e c t i v e m a c h i n e v o l u m e , t h e m a c h i n e
t o r q u e f l u c t u a t i o n s a n d t h e c o r r e s p o n d i n g n o i s e a n d v i b r a t i o np r o b l e m s r e d u c e i t s s c o p e o f a p p l i c a t i o n . By p u s h i n g l i m i t o f
t h e w i n d i n g f a c t o r , t h e i n t r i n s i c p u l s a t i o n p r o b l e m t h a t c o m e s
w i t h t h i s m a c h i n e s t r u c t u r e c a n b e c o m p e n s a t e d b y t h e a c t i v ec o n t r o l o n t h e c u r r e n t s u p p l y [ 1 1 ] . T h e c o m p e n s a t i n g c u r r e n t
F i g . 5 : S i m u la t i o n o f c u r r e n t c o m p e n s a t i o n a n d m a c h i n e t o r q u e
A l t h o u g h t h e m a c h i n e t o r q u e c a n b e i m pr ov e d b y c u r r e n tc o m p e n s a t i o n , t h e t o r q u e c u r v e c o n t a i n s a s ag p o i n t w h e r e t h em a c h i n e s t a t o r c u r r e n t i s i n t h e c o m m u t a t i o n p r o c e s s . By
p r o p e r d e s i g n o f t h e m a c h i n e p o l e s h a p e , t h e t o r q u e v a l u e a t
t h i s s ag p o s i t i o n c a n s t i l l b e e n h a n c e d , b u t t h i s n e c e s s i t yd e p e n d s o n t h e a p p l i c a t i o n r e q u i r e m e n t . I n m o s t c a s e s , e f f o r t sa r e u s u a l l y f o c u s e d o n t h e r e d u c t i o n o f c o g g i n g t o r q u e . W h i l e
i n t h i s c a s e , t h e c o g g i n g t o r q u e h e l p s t h e o p e r a t i o n o f m a c h i n e .
T h e c u r r e n t c o m p e n s a t i o n a l s o i n c r e a s e s t h e s t r e s s o n t h es w i t c h i n g d e v i c e s d u e t o t h e maximum v a l u e a n d t h es i g n i f i c a n t h a r m o n i c c o m p o n e n t s , w h i c h a l s o d i r e c t l y i m p a c t st h e h e a l t h o f t h e c a p a c i t o r s o n t h e DC b u s . M o r e o v e r , d u e t o t h ep u l s a t i n g MMF w h e n t h e m a c h i n e i s o p e r a t e d i n s i n g l e p h a s e
m a n n e r , t h e s y n c h r o n i s m o f t h e r o t o r a n d t h e e x c i t a t i o n p h a s e
a n g l e i s a c o nc er n . T h e i n f o r m a t i o n o n r o t o r p o s i t i o n i s
n e c e s s a r y f o r t h e p r o p e r l y a p p l i e d c u r r e n t p h a s e , w i t h t h ec u r r e n t a m p l i t u d e c o n t r o l l e d b y t h e f e e d b ac k f ro m c u r r e n t
t r a c k i n g d e v i c e s a s a common p r a c t i c e .
A s i n g l e p h a s e m a c h i n e b e n e f i t s f r o m i t s s i m p l e m a c h i n e
s t r u c t u r e b as e d o n SMC m o d u l e s . T h e p o l e p i e c e n u m b e r c a n
b e s e l e c t e d w i t h f l e x i b i l i t y f o r d i f f e r e n t p o w e r r a t i n gr e q u i r e m e n t s . From a n i n v e s t i g a t i o n o f a n e x a m p l e d e s i g n , t h eSMC b a s e d m o d u l a r s i n g l e p h a s e m a c h i n e c a n b e s h o w n t o
a c h i e v e s i g n i f i c a n t h i g h e r p o w e r d e n s i t y c o m p a r e d w i t h t h ec o m m e r c i a l i n d u c t i o n m a c h i n e . W i t h t h e l a r g e s c a l e f a b r i c a t i o nb a s e , t h e m a c h i n e co s t c a n b e f u r t h e r r e d u c e d . T h e d r i v e c i r c u i tc a n a l s o b e o p t i m a l l y i m p l e m e n t e d b y o n l y t w o s w i t c h i n gd e v i c e s . A l l t h e s e m e r i t s m a k e i t a t t r a c t i v e f o r t h e l o w c o s t
a p p l i c a t i o n s . H o w e v e r , a s m e n t i o n e d b e f o r e , t h e i n c r e a s e dc o m p l e x i t y o f c u r r e n t c o n t r o l l e r a n d t h e i n t r i n s i c m a c h i n e
t o r q u e p u l s a t i o n a n d t h e c o r r e s p o n d i n g n o i s e a n d v i b r a t i o np r o b l e m s may a l s o l i m i t i t s a p p l i c a t i o n r a n g e . T h u s , t h e
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8/14/2019 Modular Permanent Magnet Machine Based on Soft Magnetic Composite
m u l t i p h a s e m od u l ar m ac hi ne s t r u c t u r e i s p r o p o s e d a n d
c o m p a r e d w i t h t h e s i n g l e p h a s e m a c h i n e .
Due t o t h e f a c t o f m o d u l a r s t r u c t u r e o f s t a t o r , e a c h m o d u l e
c a n b e w o u n d e d b y a c o n c e n t r i c w i n d i n g s e p a r a t e l y , w h i c h n o t
o n ly s i m p l i f i e s t h e l a b o r e f f o r t o n w i n d i n g s , b u t a l s o o f f e r sf l e x i b i l i t y o f m u l t i p h a s e n u m b e r a n d c o n t r o l s t r a t e g i e s . I n
F i g u r e 6 , a s t a t o r m o d u l e i s i l l u s t r a t e d b a s e d o n t h i s d e s i g nc o n c e p t . T h e m o d u l e f u r t h e r b e n e f i t s f r o m t h e SMC's
f l e x i b i l i t y o f 3D f l u x p a t h f o r i t s e x t e n s i o n o f p o l e s h o e a n d
y o k e s e c t i o n s , a s d i s c u s s e d b y o t h e r r e s e a r c h e r s . W i t h t h e s a m e
t o t a l m a c h i n e v o l u m e , t h i s s t a t o r m o d u l e c a n m a k e f u l l u s a g e o f
t h e m a c h i n e a i r - g a p s p a c e , e n h a n c i n g m a c h i n e ' s t o r q u e
p r o d u c t i o n .
F i g . 6 : S t a t o r m o d u l e c o n c e p t
I n F i g u r e 7 , a f i v e p h a s e m a c h i n e c o n c e p t i s i l l u s t r a t e db as e d o n t h e m o d u l a r m a c h i n e s t r u c t u r e . T h e t h e o r e t i c a l f l u xl i n k a g e a n d b ac k EMF c u r v e s a r e a l s o d e p i c t e d f o r t w o o f t h ep h a s e s , w i t h 2 t 5 e l e c t r i c a l a n g l e s h i f t b e t w e e n p h a s e s . T h e
f u n d a m e n t a l w i n d i n g f a c t o r 0 . 9 5 1 c a n b e d i r e c t l y o b t a i n e d
A l t h o u g h t h e w i n d i n g f a c t o r i s n o t a s h i g h a s t h e f u l l p i t c hs i n g l e p h a s e m a c h i n e s u g g e s t e d b e f o r e , t h e m a c h i n e c a n b e
o p e r a t e d m o r e e a s i l y w i t h a c c e p t a b l e p o w e r d e n s i t yp e r f o r m a n c e . ( 3 ) - ( 6 ) d e s c r i b e t h e m a c h i n e ' s g o v e r n i n g
e q u a t i o n s o f g e n e r a l o p e r a t i o n .
[ v ] = [ e ] + [ r ] [ i ] + d [ A ]dt
( 3 )
w h e r e v , e , i , i d e n o t e s t h e v e c t o r o f p h a s e t e r m i n a l v o l t a g e ,b a c k EMF ( e m f ) , c u r r e n t , a n d f l u x l i n k a g e .
[ i ] = I L I [ i d ( 4 )
L 1 l L 1 2 L 1 3 L 1 4 L 1 5
L 2 1 L 2 2 L 2 3 L 2 4 L 2 5[ L ] = L 3 1 L 3 2 L 3 3 L 3 4 L 3 5 ( 5 )
L 4 1 L 4 2 L 4 3 L 4 4 L 4 5
L 5 1 L 5 2 L 5 3 L 5 4 L 5 5 -
B a s e d o n t h e c l a s s i c e n e r g y c o n v e r s i o n , t h e m a c h i n e t o r q u e
a n d s p e e d p r o d u c t i o n e q u a l s t h e p o w e r i n p u t f r o m t h e i n v e r t e rs i d e a s ( 6 ) , i f t h e r e s i s t a n c e a n d o t h e r l o s s e s a r e n e g l e c t e d .
T e * m= [ e ] [ i ] ( 6 )
I n t h i s s t u d y , t w o t y p i c a l r o t o r s t r u c t u r e s , s u r f a c e p e r m a n e n t
m a g n e t ( S P M ) a n d i n t e r n a l p e r m a n e n t m a g n e t ( I P M ) , a r ed i s c u s s e d , a s t h e s e t w o t y p i c a l m a c h i n e t o p o l o g i e s i l l u s t r a t e d i nF i g u r e 8 . T h e SP M m a c h i n e s a r e w id el y u se d i n i n d u s t r ya p p l i c a t i o n s f o r i t s l o w c o s t a n d h i g h p e r f o r m an c e , b u t w i t h t h ed i f f i c u l t i e s i n t h e e x p e n d e d s p e e d o p e r a t i o n f o r i t s l i m i t e d f i e l d
w e a k e n i n g c a p a b i l i t y , d u e t o t h e f a c t t h e f l u x f r o m t h e PMs
c a n n o t b e t u r n e d o f f a n d t h e c u r r e n t c a p a b i l i t y l i m i t e d b y t h es u p p l y . H o w e v e r , t h e IPM m a c h i n e e x h i b i t s i m p r e s s i v e f i e l d
w e a k e n i n g c a p a b i l i t y f o r t h e r e l a t i v e l y h i g h e r m a c h i n e
i n d u c t a n c e d u e t o t h e l e s s e f f e c t i v e a i r - g a p l e n g t h .
( a ) ( b )F i g . 8 : S i x p o l e f i v e p h a s e m a c h i n e c o n c e p t . ( a ) S P M . ( b ) IP M
F o r t h e SP M r o t o r d e s i g n a s i l l u s t r a t e d i n F i g u r e 8 , t h ei n d u c t an c e m a t r i x L e x h i b i t s l o w c o u p l i n g b e t w e e n p h a s e s d u e
t o t h e l o w m u t u a l i n d u c t a n c e , w h i c h b e n e f i t s d e a l i n g w i t h
p h a s e f a u l t o p e r a t i o n . T h i s t y p i c a l d e s i g n l e a d s t o t h e L m a t r i x
( m H ) a s d e s c r i b e d i n ( 7 ) s i m u l a t e d b y s o f t w a r e p a c k a g e
M a x w e l l . O n t h e d i a g o n a l o f t h e m a t r i x L i n ( 7 ) , t h e s e l fi n d u c t a n c e e x h i b i t s q u i t e s i m i l a r v a l u e s d u e t o t h e l a r g e a i r g a p
t a k e n b y t h e P M s . W h i l e f o r t h e o f f - d i a g o n a l t e r m s , t h e m u t u a l
i n d u c t a n c e s a r e r e l a t i v e l y c o u p l e d s t r o n g e r w i t h t h e a d j a c e n tp ha s e w i n d i ng s f o r t h e s h o r t e r f l u x p a t h , a l t h o u g h t h i s k i n d o f
c o u p l i n g i s s t i l l w e a k w i t h t h e c o u p l i n g c o e f f i c i e n t o f 0 . 2 3 6 a n d
0 . 1 7 4 f o r t h e a d j a c e n t a n d n o n - a d j a c e n t p h a s e c o u p l i n g .
7 . 8 9 1 . 8 91 . 8 9 8 . 1 3
[ L S P M ] = 1 . 4 2 2 . 0 9
1 . 4 5 1 . 5 0
1 . 9 7 1 . 4 6
1 . 4 22 . 0 9
8 . 4 2
2 . 1 4
1 . 5 9
1 . 4 51 . 5 0
2 . 1 4
8 . 4 8
2 . 2 2
1 . 9 71 . 4 6
1 . 5 9
2 . 2 2
8 . 4 7
( 7 )
W i t h a n i n t e r n a l p e r m a n e n t m a g n e t d e s i g n f o r t h e r o t o r
s t r u c t u r e , t h e e f f e c t i v e a i r - g a p l e n g t h c o u l d b e r e d uc e d
s i g n i f i c a n t l y , r e s u l t i n g i n a r e l a t i v e l y h i g h e r m a c h i n e
i n d u c ta n c e m a t r i x a s s h o w n i n ( 8 ) . I t c a n b e o b se rv e d t h a t t h es e l f - i n d u c t a n c e s o f t h e IPM r o t o r d e s i g n ar e s i g n i f i c a n t l yi n c r e a s e d . M o r e o v e r , t h e s e l f i n d u c t a n c e v a r i e s n o t i c e a b l y d u e
t o t h e d - q a x i s e f f e c t , w h i c h c a n b e n e g l e c t e d i n t h e SP M r o t o rs t r u c t u r e . T h e d - a x i s i n d u c t a n c e L q = 2 6 . 2 2 m H , w i t h L d =
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8/14/2019 Modular Permanent Magnet Machine Based on Soft Magnetic Composite
1 8 . 1 ImH f o r t h i s t y p i c a l d e s i g n . T h e a d j a c e n t p h as e c ou pl in g
i s q u i t e s i m i l a r w i t h SP M f o r t h e c o u p l i n g c o e f f i c i e n t 0 . 2 6 6 ,a l t h o u g h t h e i nd u c ta n ce v a l u e i s n e a r l y t r i p l e d . T h e c o u p l i n g
b e t w e e n t h e n o n- a d j a ce n t p h a se s i s f u r t h e r r e d u c e d t o a r o u n d
0 . 1 6 4 .
1 8 . 1 1
5 . 1 8
[ L I P M ] = 3 . 4 1
3 . 2 8
5 . 2 0
5 . 1 8
2 1 . 0 1
6 . 7 1
3 . 9 0
3 . 9 8
3 . 4 1
6 . 7 1
2 3 . 9 7
8 . 7 5
3 . 8 2
3 . 2 8
3 . 9 0
8 . 7 5
2 4 . 7 1
7 . 4 2
5 . 2 0
3 . 9 8
3 . 8 2
7 . 4 2
2 1 . 6 6
( 8 )
A s d i s c u s s e d b e f o r e , i t i s d i f f i c u l t t o o p e r a t e SP M m a c h i n e i n
t h e e x t e n d e d s p e e d r a n g e d u e t o t h e l i m i t e d f i l e d w e a k e n i n g
c a p a b i l i t y o f t h i s m a c h i n e d u e t o t h e l i m i t e d c o n t r o l l a b i l i t y o f
f l u x w h i c h d e p e n d s o n t h e i n d u c t a n c e a n d c u r r e n t p r o d u c t L i .
W i t h a n IPM d e s i g n , t h e hig he r i n d u c t a n c e m a k e s i t f e a s i b l e t o
o b t a i n a n e x t e n d e d s p e e d o p e r a t i o n i n f i e l d w e a k e n i n g r a n g e .
M o r e o v e r , t h e l o w e r a i r g a p f l u x d i s t r i b u t i o n f a v o r s IPMm a c h i n e f o r i n t h e h ig h s pe ed r a n g e a s s h o w n i n F i g u r e 9 . I nt h e s e t w o t y p i c a l SP M a n d IPM r o t o r d e s i g n s , r a r e e a r t h( N d F e B ) i s u s e d f o r t h e s i m u l a t i o n . T h e t h i c k n e s s o f PMs i n t h eSP M d e s i g n v a r i e s f r o m 3.5mm t o 6mm, w h i l e f o r I P M , 3mmPMs a r e i n s e r t e d i n t o t h e s l o t s . T h e a v e r a g e a i r g a p f l u x d e n s i t yp e r p o l e o f IPM d e s i g n i s n e a r l y h a l v e d c o m p a r e d w i t h t h eSP M d e s i g n . Due t o t h e e x i s t e n c e o f s a t u r a t e d b r i d g e s o n t h er o t o r s i d e s t r u c t u r e , s i g n i f i c a n t f l u x b y p a s s e d t h e m a i n f l u xp a t h a s p u r e l y l e a k a g e . To d e s i g n a n IPM r o t o r w i t h s p e c i f i e dd - q a x i s r e a c t a n c e u n d e r w i d e r a n g e o p e r a t i o n i s s t i l l ac h a l l e n g i n g t a s k f o r t h e v a r i a b l e l o a d c o n d i t i o n s a n d
c o r r e s p o n d i n g s a t u r a t i o n l e v e l . T h e s a t u r a t i o n b r i d g e s a r ed e s i g n e d w i t h c o n s i d e r a t i o n s f o r b o t h e l e c t r o m a g n e t i c a n d
m e c h a n i c a l s t r e s s e s , e s p e c i a l l y w h e n t h e m a c h i n e i s o p e r a t e d i nt h e h i g h s p e e d r a n g e .
1 - - - - - - r - - - - - - -- - t t - - - - - - T - - - -- ----- T - - - - - T - -- - - - - - - - T
O . S 0 l t - - - - - - - u - - - - + 5 - o ; \ - - - - - - - - - - - l -- - - - - - - - - -
n° ----- X---t--.-i-1
-L - --------- -X.
S M r d a f l u d e n s t5 -PM r a d r i a l f l u x e n s [ l y
0 5 1 ' 1 0 0 C C 1 5 0 2 2 0 0 1 2 5 0 C 3 0 0 1 3 5 0 2
a n g l e ( m q e c h )
F i g . 9 . A i r g a p r a d i a l f l u x d i s t r i b u t i o n f o r SPM a n d IPM
One o f t h e m a i n m e r i t s o f t h i s m o d ul ar m a ch i ne s t r u c t u r e i s
i t s f a u l t t o l e r a n t c a p a b i l i t y a n d e a s y r e p l a c e m e n t o f m o d ul es .
T h e c o n c e n t r i c w i n d i n g i s w o u n d o n e ac h s t a t o r SMC m o d u l e ,
r e s u l t i n g i n a n i n d e p e n d e n t c o n t r o l u n i t w i t h t h e f e a t u r e o f
r e p l a c e m e n t i n c as e o f u n i t f a i l u r e . E a c h u n i t i s a l s o c o n t r o l l e d
b y t h e i n d e p e n d e n t s w i t c h i n g d e v i c e s , w i t h t h e o p t i o n o f
m o u n t i n g c o n t r o l m o d u l e w i t h t h e m a c h i n e m o d u l e a t
a c c e p t a b l e c o s t . I n n o r m a l o p e r a t i o n , t h e m a c h i n e ' s s q u a r e
w a v e c u r r e n t i s i n p h as e w i th t h e b a c k EMF. I n ca s e o f p h as e
w i n d i n g f a i l u r e , a c o m p e n s a t i o n i mp le m e nt ed b y c o n t r o l
s t r a t e g y h e l p s t o m a i n t a i n t h e m a c h i n e t o r q u e .
M o s t o f t h e p h a s e f a u l t s a r e d i r e c t l y r e l a t e d w i t h t h ew i n d i n g f a i l u r e , i . e . , o p e n c i r c u i t a n d s h o r t c i r c u i t . O p e n c i r c u i t
i s q u i t e common f o r t h e t e r m i n a l c o n n e c t i o n f a i l u r e , a n d a l s o ,
t h e s w it c hi n g d e v i c e f a i l u r e . I n F i g u r e 1 0 , t h e f i v e - p h a s e SP Mm a c h i n e w i t h d i f f e r e n t o p e n c i r c u i t c a s e s a r e s i m u l a t e d .G e n e r a l l y , t h e a v e ra ge t or q ue i s d i r e c t l y p r o p o r t i o n a l t o t h ep h a s e n u m b e r i n s e r v i c e w i t h t h e s a m e c o n t r o l s t r a t e g ya s s u m e d f o r t h e n o r m a l o p e r a t i o n . I t i s a common p r a c t i c e t ob o o s t t h e t o r q u e l o s s b y a p p l y i n g c o m p e n s a t i n g c u r r e n t i n t h en o r m a l p h a s e s .
. ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ T o n.-oae p h a e l o s s , ,0_ +______L_____X_L_______L_______L___
4 0 6 0 8 0ror p g s
1 4 0 lb 0 Th
P e g r
F i g . 1 0 : S q u a r e w a v e p h a s e c u r r e n t a n d m a c h i n e t o r q u e u n d e r v a r i o u s o p e n
c i r c u i t f a i l u r e s
H o w e v e r , w h e n t h e w i n d i n g f a i l u r e i s s h o r t c i r c u i t e d ,w h i c h i s u s u a l l y r e l a t e d w i t h t h e i n s u l a t i o n d e f e c t , i t i s s t i l l a
t o u g h t a s k t o m i t i g a t e t h e f a i l u r e f o r t h e h u g e c u r r e n t
c i r c u l a t i n g i n t h e s h o r t e d w i n d i n g . W i t h t h e IPM d e s i g n , i t i s
p o s s i b l e m a k e u s e o f t h e s p e c i f i c a l l y i n j e c t e d c u r r e n t o f t h e
n o r m a l p ha s e w i n d i ng s t o r e d u c e t h e f l u x l i n k a g e o f t h e s h o r t e d
2 3 8
11
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8/14/2019 Modular Permanent Magnet Machine Based on Soft Magnetic Composite
w i n d i n g . T h u s , t h e f a i l u r e c o u l d b e t o l e r a t e d a n d t h e m a c h i n e
c a n s t i l l b e o p e r a t e d u n d e r l i m i t e d c o n d i t i o n s .
I I I . CONCLUSION
I n t h i s p a p e r , a n o v e l m o d u l a r PMm a c h i n e w i t h f a u l t t o l e r a n tc a p a b i l i t y i s d i s c u s s e d . T h e s i n g l e p h a s e d es ig n c an m a k e f u l l
u s a g e o f t h e m a c h i n e m a t e r i a l f o r i t s h i g h e s t w i n d i n g f a c t o r , b u t
i t i s v u l n e r a b l e t o s t a r t i n g p r o b l e m s w h i c h c a n n o t b e a v oi d e d
b y n o r m a l m a c h i n e d e s i g n . T h e m a c h i n e c a n b e o p e r a t e d w i t h at r a d e - o f f b e t w e e n s p e c i a l l y d e s i g n e d a i r - g a p l e n g t h a n d
c o m p l e x i t y o f t h e c o n t r o l c i r c u i t . T h u s , t h e m u l t i - p h a s em o d u l a r c o n c e p t i s p r o p o s e d f o r t h e a p p l i c a t i o n s r e q u i r e f a u l t
t o l e r a n t c a p a b i l i t y w i t h c o m p a r a b l e p o w e r d e n s i t y . A f i v ep h a s e m o d ul ar m a ch in e w i t h SP M a n d IPM r o t o r s t r u c t u r e i s
s t u d i e d . From t h e p r e l i m i n a r y s i m u l a t i o n r e s u l t s , 5 p h a s e
m o d u l ar m a c h in e e x h i b i t s s a t i s f a c t o r y t o r q u e c a p a b i l i t y b o t h i n
n o r m a l o p e r a t i o n c o m p a r e d w i t h a t y p i c a l 3 H I P i n d u c t i o nm a ch in e a nd u n d e r a f a u l t c o n d i t i o n w i t h o n e o r t w o p h a s e l e gl o s s . T h e p r o t o t y p e m a c h i n e i s u n d e r c o n s t r u c t i o n . T h e t e s t i n gr e s u l t s w i l l b e r e p o r t e d i n a f u t u r e p a p e r .
P o w e r E l e c t r o n i c s , M a c h i n e s a n d D r i v e s , 2 0 0 2 . I n t e r n a t i o n a l C o n f e r e n c e ,
J u n e 2 0 0 2 , p p . 6 4 4
[ 7 ] J . C r o s a n d P . V i a r o u g e , "New s t r u c t u r e s o f po l y ph as e c l a w - p o l e
m a c h i n e s " , I n d u s t r y A p p l i c a t i o n s C o n f er e n ce , 3 7 t h I A S A n n u a l M e e t i n g ,
O c t . 2 0 0 2 , p p . 2 2 6 7 , v o l . 4[ 8 ] R . Q u , G . B . K l i m a n , a n d R . C a r l , " S p l i t - p h a s e c l a w - p o l e i n d u c t i o n
m a c h i n e s w i t h s o f t m a g n et i c c o m po s i te c o r e s " , I n d u s t r y A p pl ic at io n sC o n f e r e n c e , 3 9 t h I A S A n nu al M e e t i n g , O c t . 2 0 0 4 , p p . 2 5 1 4 , v o l . 4
[ 9 ] T . A . L i p o , " I n t r o d u c t i o n t o AC M a c h i n e D e s i g n " , ( b o o k ) , U n i v e r s i t y o f
W i s c o n s i n , 2 0 0 4 .
[ 1 0 ] S . B e n t o u a t i , Z . Q . Z h u, a nd D . H o w e , " I n f l u e n c e o f d e s i g n p a r a m e t e r s o n
t h e s t a r t i n g t o r q u e o f a s i n g l e - p h a s e PM b r u s h l e s s DC m o t o r , " M ag n e t ic s ,
IEEE T r a n s a c t i o n s o n , v o l . 3 6 , p p . 3 5 3 3, 2 0 0 0 .
[ 1 1 ] T . M . J a h n s , Wen L . S o o n g , " P u l s a t i n g T o r q u e M i n i m i z a t i o n T e c h n i q u e s
f o r P e r m a n e n t M a g n e t AC M o t o r D r i v e s - A R e v e w " , I n d u s t r i a lE l e c t r o n i c s , IEEE T r a n s a c t i o n s o n , v o l . 4 3 , p p . 3 2 1 , A p r i l , 1 9 9 6 .
[ 1 2 ] B . A . W e l c h k o , J . W a i , T . M . J a h n s , T . A . ; L i p o , , " M a g n e t f l u x c o n t r o l o f
i n t e r i o r PM m a c h i n e d r i v e s f o r i m p r o v e d r e s po n s e t o s h o r t - c i r c u i t f a u l t s " ,I A S 2 0 0 4 , IEEE c o n f e r e n c e , V o l u m e 1 , p p . 3 . 2 0 0 4 .
APPENDIX5 p h a s e SP M m a c h i n e p a r a m e t e r s
P a r a m e t e r s IM ( G E / 3 H P ) 5 P h a s e SP M M o t o r
OD 190mm 120mm
I D 120mm 72mm
RPM 1 7 5 0 1 8 0 0
M a c h i n e L en g t h 7 0 mm ( i r o n ) / 15 0 mm ( f u l l ) 140mm
T o r q u e ( T ) 1 1 . 8 7 N m 1 3 . 2 6 N m
E f f e c t i v e V o l u m e 4 . 2 5 2 9 x I 0 3 m 3 1 . 5 8 3 4 x 0 - 3 m 3
T o r q u e D e n s i t y 2 . 7 9 1 x I 0 3 N m / m 3 8 . 3 7 4 x I 0 3 N m / m 3
C o g g i n g T o r q u e 0 3 . 0 1 % o f r a t e d
T o r q u e D e n s i t y R a t i o 5 ph as e PM / IM = 3 . 0
REFERENCE
[ 1 ] L . 0 . H u l t m a n a n d A . G . J a c k , " S o f t m a g n e t i c c o m p o s i t e s - m a t e r i a l s a n d
a p p l i c a t i o n s , " 2 0 0 3 . I E M D C ' 0 3 , v o l . 1 , p p : 5 1 6 , J u n e 2 0 0 3.
[ 2 ] A . J a c k , " E x p e r i e n c e w i t h u s i n g s o f t m a g n e t i c c o m p o s i t e s f o r e l e c t r i c a lm a c h i n e s " , New M a g n e t i c M a t e r i a l s - B o n d e d I r o n , L a m i n a t i o n S t e e l s ,S i n t e r e d I r o n a n d P e r m a n e n t M a g n e t s , I E E C o l l o q u i u m o n 2 8 , May1 9 9 8 p p : 3 / 1 - 3 / 4 .
[ 3 ] A . G . J a c k , B . C . M e c r o w , C . P . M a d d i s o n , a n d N . A . W a h a b , " C l a w p o l ea r m a t u r e p e r m a n e n t m a g n e t m a c h i n e s e x p l o i t i n g s o f t i r o n p o w d e rm e t a l l u r g y , " E l e c t r i c M a c h i n e s a n d D r i v e s C o n f e r e n c e R e c o r d , 1 9 9 7 ,IEEE I n t e r n a t i o n a l , p p . 1 8 - 2 1 , May 1 9 9 7 .
[ 4 ] A . G . J a c k , B . C . M e c r o w , P . G . D i c k i n s o n , D . S t e p h e n s o n , J . S . B u r d e s s ,N . F a w c e t t , a n d J . T . E v a n s , " P e r m a n e n t - m a g n e t m a c h i n e s w i t h
p o w d e r e d ir o n c o r e s a n d p r e p r e s s e d w i n d i n g s , " I n d u s t r yA p p l i c a t i o n s , IEEE T r a n s a c t i o n s o n , v o l . 3 6 , p p . 1 0 7 7 , 2 0 0 0 .
[ 5 ] Y . G . G u o , J . G . Z h u , P . A . Wat t e r s o n , a n d W. Wu, " C o m p a r a t i v e s t u d y o f
3D f l u x e l e c t r i c a l m a c h i n e s w i t h s o f t m a g n e t i c c o m p o s i t e c o r e s " , I n d u s t r yA p p l i c a t i o n s C o n f e r e n c e , 2 0 0 2 . 3 7 t h I A S A n n u a l M e e t i n g , p p . 1 1 4 7 v o l . 2
[ 6 ] B . C . M e c r o w , A . G . J a c k , D . J . A t k i n s o n , P . G . D i c k i n s o n , a n d S .
S w a d d l e , " H i g h t o r q u e m a c h i n e s f o r p o w e r h a n d t o o l a p p l i c a t i o n s " ,
2 3 9
Authorized licensed use limited to: Chaitanya Bharathi Institute of Technology. Downloaded on July 9, 2009 at 02:54 from IEEE Xplore. Restrictions apply.
