Impact of Manufacturing Tolerances on a Low-Reactance Slotless PM Synchronous Machine

Lee, Dong Su; Yoon, Andy; Sirimanna, Samith; Salon, S.J.; Haran, Kiruba S.

doi:10.1109/tec.2019.2938144

Cited by 23 publications

(7 citation statements)

References 18 publications

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“…The Joule loss is usually calculated in proportion to the square of the current, which is also known as the dc cooper loss [14]- [18]. In [19]- [20], the thermal characteristics of a high-speed PM machine with slotted and slotless stators were evaluated and compared. In [21], the static thermal analysis is discussed in order to validate the proposed cooling system functionality of a coreless PM machine used for flywheel energy storage system.…”

Section: Introductionmentioning

confidence: 99%

Thermal Analysis of Stator Iron-Core-Less PMBLDC Motors Considering Both Winding Eddy and Circulating Current Losses

Yang,

Gao,

et al. 2024

IEEE Access

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Thermal analysis of three stator iron-core-less PMBLDC motors considering winding eddy and circulating current losses is investigated. First, the effects of strand diameter, permanent magnet (PM) magnetization and rotating speed on the above mentioned two winding losses and thermal characteristics are investigated by 3D finite element method (FEM). It is found that both strand diameter and rotating speed have great impacts on the temperature rise, parallel and radial magnetizations have almost identical temperature rise results. Then, influence of eddy and circulating current losses on the thermal characteristics of the three PMBLDC motors are further studied, separately. Furtherly, comprehensive study of the two winding losses on the thermal characteristics is carried out. Results show that thermal analysis considering both winding eddy and circulating current losses in parallel thin strands is vital during motor primary design process considering the limited insulation level of wires and PMs. Finally, three prototypes with different combinations of strand diameters and parallel numbers are selected for the calculation of eddy current losses and temperature rise experiment. Experimental results demonstrate the effectiveness of the developed 3D FEM models and validate the obtained simulation results. This paper clarifies the key influence factors, i.e., windings of different wire diameters, PM magnetization and rotation speed, on temperature rise characteristics of such iron-core-less motors, which provides guidance for the subsequent design of such three types of motors. INDEX TERMSStator iron-core-less PMBLDC motor, thermal analysis, winding eddy current loss, winding circulating current loss.

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Section: Introductionmentioning

confidence: 99%

Thermal Analysis of Stator Iron-Core-Less PMBLDC Motors Considering Both Winding Eddy and Circulating Current Losses

Yang,

Gao,

et al. 2024

IEEE Access

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“…Further, it is also possible with the Halbach array to make the rotor without a back iron. Lee et al [4] used the Halbach array slotless motor as a propulsion motor for light weight aircraft, since it required high power density and high efficiency.…”

Section: Introductionmentioning

confidence: 99%

Analytic Optimization of the Halbach Array Slotless Motor Considering Stator Yoke Saturation

2021

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Hybrid subdomain analysis is utilized to optimize the design of a high speed compressor motor. Permanent magnets (PMs) are arranged in Halbach array, and bounded by a carbon fiber sleeve. The stator core does not have a slot structure, so that it is advantageous in reducing the iron loss. Since the core saturation takes place, magnetic equivalent circuit (MEC) is used to find the permeability depending on flux density of stator yoke. Furthermore, since the core is not infinitely permeable in subdomain analysis, the solution is obtained in the whole subdomain regions: shaft, PM, air-gap, coil, and stator yoke. The results of hybrid analysis are compared with those of finite-element analysis (FEA). Very close matching results are obtained in flux density and torque even under yoke saturation. The stator yoke height is optimized against the rotor outer radius so that torque, power density and efficiency are maximized, while stator outer radius, stack length and coil area are fixed.

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“…Recently, numerous intelligent optimization algorithms, e.g., multi-objective differential evolution with a ranking-based mutation operator, sequential nonlinear programming, and genetic algorithms, have been successfully applied in deterministic design [16][17][18] , exhibiting high accuracy and efficiency. Although the electromagnetic performance can be significantly improved by appropriate optimization algorithms, the noise factors, such as uncontrollable manufacturing tolerances of design variables, deviations in material characteristics, and imperfections in assembly, are inevitable (particularly in mass production), resulting in perturbations to the electromagnetic performance and affecting the reliability and manufacturing cost of the machine [19] . Therefore, it is vital to adopt robust optimization design to reduce the sensitivity of design variables, which is challenging for most machines.…”

Section: Introduction1mentioning

confidence: 99%

Multi-objective optimization design of inset-surface permanent magnet machine considering deterministic and robust performances

Jia

Zhao

et al. 2021

Chin. J. Electr. Eng.

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The inset-surface permanent magnet (ISPM) machine can achieve the desired electromagnetic performance according to the traditional deterministic design. However, the reliability and quality of the machine may be affected by the essential manufacturing tolerances and unavoidable noise factors in mass production. To address this weakness, a comprehensive multi-objective optimization design method is proposed, in which robust optimization is performed after the deterministic design. The response surface method is first adopted to establish the optimization objective equation. Afterward, the sample points are obtained via Monte Carlo simulation considering the design-variable uncertainty. The Design for Six Sigma approach is adopted to ensure the robustness of the design model. Furthermore, the barebones multi-objective particle swarm optimization algorithm is used to obtain a compromise solution. A prototype is manufactured to evaluate the effectiveness of the proposed method. According to the finite-element analysis and experimental tests, the electromagnetic performance and reliability of the machine are significantly enhanced with the proposed method.

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Impact of Manufacturing Tolerances on a Low-Reactance Slotless PM Synchronous Machine

Cited by 23 publications

References 18 publications

Thermal Analysis of Stator Iron-Core-Less PMBLDC Motors Considering Both Winding Eddy and Circulating Current Losses

Thermal Analysis of Stator Iron-Core-Less PMBLDC Motors Considering Both Winding Eddy and Circulating Current Losses

Analytic Optimization of the Halbach Array Slotless Motor Considering Stator Yoke Saturation

Multi-objective optimization design of inset-surface permanent magnet machine considering deterministic and robust performances

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