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Hreczka, Marek; Kolano, Roman; Kolano-Burian, Aleksandra; Burlikowski, Wojciech; Hetmańczyk, Janusz
doi: 10.1108/compel-09-2022-0310
The purpose of this paper is to verify results related to losses in the core of a brushless DC prototype motor, obtained using its computer FE models, by experimental tests on manufactured machines. The paper focuses on the comparison of losses in the core of a machine with a classical stator core made of an iron–silicon material (Fe–Si) and a new one made of a modern METGLAS material.Design/methodology/approachComputer models of the prototype motors were created using FEM. The designed machines were manufactured, and experimental tests were performed. To achieve high frequencies in rotating magnetic fields, motors with a stator to rotor pole ratio of 9/12 were built. Twin rotor approach was applied, as two identical rotors were built along the two geometrically identical stators made of different core materials.FindingsExperimental studies have shown the superiority of the METGLAS material over the classical Fe–Si material. Material parameters were measured directly on the prepared cores as library data used in the simulation may be incorrect due to technological processes during core production, which was also verified. Problems related to twin rotor approach have been identified. Solution to the problem has been suggested. Necessity of 3D FEM modelling was identified.Originality/valueThe main source of originality is that METGLAS material used in the prototype machines was developed and manufactured by the authors themselves. Original approach to core parameter evaluation based on simplified methodology has been suggested. Another original part is a simplified methodology applied to loss measurement during no-load test.
Garmut, Mitja; Steentjes, Simon; Petrun, Martin
doi: 10.1108/compel-09-2022-0331
Small highly saturated interior permanent magnet- synchronous machines (IPMSMs) show a very nonlinear behaviour. Such machines are mostly controlled with a closed-loop cascade control, which is based on a d-q two-axis dynamic model with constant concentrated parameters to calculate the control parameters. This paper aims to present the identification of a complete current- and rotor position-dependent d-q dynamic model, which is derived by using a finite element method (FEM) simulation. The machine’s constant parameters are determined for an operation on the maximum torque per ampere (MTPA) curve. The obtained MTPA control performance was evaluated on the complete FEM-based nonlinear d-q model.Design/methodology/approachA FEM model was used to determine the nonlinear properties of the complete d-q dynamic model of the IPMSM. Furthermore, a fitting procedure based on the nonlinear MTPA curve is proposed to determine adequate constant parameters for MTPA operation of the IPMSM.FindingsThe current-dependent d-q dynamic model of the machine models the relevant dynamic behaviour of the complete current- and rotor position-dependent FEM-based d-q dynamic model. The most adequate control response was achieved while using the constant parameters fitted to the nonlinear MTPA curve by using the proposed method.Originality/valueThe effect on the motor’s steady-state and dynamic behaviour of differently complex d-q dynamic models was evaluated. A workflow to obtain constant set of parameters for the decoupled operation in the MTPA region was developed and their effect on the control response was analysed.
Albert, Dennis; Domenig, Lukas Daniel; Schachinger, Philipp; Roppert, Klaus; Renner, Herwig
doi: 10.1108/compel-09-2022-0303
The purpose of this paper is to investigate the applicability of a direct current (DC) hysteresis measurement on power transformer terminals for the subsequent hysteresis model parametrization in transformer grey box topology models.Design/methodology/approachTwo transformer topology models with two different hysteresis models are used together with a DC hysteresis measurement via the power transformer terminals to parameterize the hysteresis models by means of an optimization. The calculated current waveform with the derived model in the transformer no-load condition is compared to the measured no-load current waveforms to validate the model.FindingsThe proposed DC hysteresis measurement via the power transformer terminals is suitable to parametrize two hysteresis models implemented in transformer topology models to calculate the no-load current waveforms.Originality/valueDifferent approaches for the measurement and utilization of transformer terminal measurements for the hysteresis model parametrization are discussed in literature. The transformer topology models, derived with the presented approach, are able to reproduce the transformer no-load current waveform with acceptable accuracy.
Benninger, Moritz; Liebschner, Marcus; Kreischer, Christian
doi: 10.1108/compel-09-2022-0327
Monitoring and diagnosis of fault cases for squirrel cage induction motors can be implemented using the multiple coupled circuit model. However, the identification of the associated model parameters for a specific machine is problematic. Up to now, the main options are measurement and test procedures or the use of finite element method analyses. However, these approaches are very costly and not suitable for use in an industrial application. The purpose of this paper is a practical parameter identification based on optimization methods and a comparison of different algorithms for this task.Design/methodology/approachPopulation-based metaheuristics are used to determine the parameters for the multiple coupled circuit model. For this purpose, a search space for the required parameters is defined without an elaborate analytical approach. Subsequently, a genetic algorithm, the differential evolution algorithm and particle swarm optimization are tested and compared. The algorithms use the weighted mean squared error (MSE) between the real measured data of stator currents as well as speed and the simulation results of the model as a fitness function.FindingsThe results of the parameter identification show that the applied methodology generally works and all three optimization algorithms fulfill the task. The differential evolution algorithm performs best, with a weighted MSE of 2.62, the lowest error after 1,000 simulations. In addition, this algorithm achieves the lowest overall error of all algorithms after only 740 simulations. The determined parameters do not completely match the parameters of the real machine, but still result in a very good reproduction of the dynamic behavior of the induction motor with squirrel cage.Originality/valueThe value of the presented method lies in the application of condition-based maintenance of electric drives in the industry, which is performed based on the multiple coupled circuit model. With a parameterized model, various healthy as well as faulty states can be calculated and thus, in the future, monitoring and diagnosis of faults of the respective motor can be performed. Essential for this, however, are the parameters adapted to the respective machine. With the described method, an automated parameter identification can be realized without great effort as a basis for an intelligent and condition-oriented maintenance.
Xiao, Xiao; Müller, Fabian; Nell, Martin Marco; Hameyer, Kay
doi: 10.1108/compel-09-2022-0328
The goal of this research is to investigate the convergence behavior of the Newton iteration, when solving the nonlinear problem with consideration of hysteresis effects. Incorporating the vector hysteresis model in the magnetic vector potential formulation has encountered difficulties. One of the reasons is that the Newton method is very sensitive regarding the starting point and states distinct requirements for the nonlinear function in terms of monotony and smoothness. The other reason is that the differential reluctivity tensor of the material model is discontinuous due to the properties of the stop operators. In this work, line search methods to overcome these difficulties are discussed.Design/methodology/approachTo stabilize the Newton iteration, line search methods are studied. The first method computes an error-oriented search direction. The second method is based on the Wolfe-Powell rule using the Armijo condition and curvature condition.FindingsIn this paper, the differentiation of the vector stop model, used to evaluate the Jacobian matrix, is studied. Different methods are applied for this nonlinear problem to ensure reliable and stable finite element simulations with consideration of vector hysteresis effects.Originality/valueIn this paper, two different line search Newton methods are applied to solve the magnetic field problems with consideration of vector hysteresis effects and ensure a stable convergence successfully. A comparison of these two methods in terms of robustness and efficiency is presented.
Haussmann, Norman; Mease, Robin; Zang, Martin; Stroka, Steven; Hensel, Hendrik; Clemens, Markus
doi: 10.1108/compel-09-2022-0312
Magneto-quasi-static fields emanated by inductive charging systems can be potentially harmful to the human body. Recent projects, such as TALAKO and MILAS, use the technique of wireless power transfer (WPT) to charge batteries of electrically powered vehicles. To ensure the safety of passengers, the exposing magnetic flux density needs to be measured in situ and compared to reference limit values. However, in the design phase of these systems, numerical simulations of the emanated magnetic flux density are inevitable. This study aims to present a tool along with a workflow, based on the Scaled-Frequency Finite Difference Time-Domain and Co-Simulation Scalar Potential Finite Difference schemes, to determine body-internal magnetic flux densities, electric field strengths and induced voltages into cardiac pacemakers. The simulations should be time efficient, with lower computational costs and minimal human workload.Design/methodology/approachThe numerical assessment of the human exposure to magneto-quasi-static fields is computationally expensive, especially when considering high-resolution discretization models of vehicles and WPT systems. Incorporating human body models into the simulation further enhances the number of mesh cells by multiple millions. Hence, the number of simulations including all components and human models needs to be limited while efficient numerical schemes need to be applied.FindingsThis work presents and compares four exposure scenarios using the presented numerical methods. By efficiently combining numerical methods, the simulation time can be reduced by a factor of 3.5 and the required storage space by almost a factor of 4.Originality/valueThis work presents and discusses an efficient way to determine the exposure of human beings in the vicinity of wireless power transfer systems that saves computer simulation resources and human workload.
Tolentino, Guilherme; Parent, Guillaume; Ninet, Olivier; Rossi, Mathieu; Leite, Jean Vianei; Blaszkowski, Jonathan
doi: 10.1108/compel-09-2022-0298
The horizontal rotational single-sheet tester (RSST) suffers from weaknesses such as the reduced size of test samples, measurement disturbances due to magnetic flux leakage and nonhomogeneity of field in the measurement area. Although the vertical RSST allows to overcome the first two aforementioned drawbacks, the heterogeneity of the field in the test sample remains an issue. In addition, there is still a lack of device standardization to ensure test repeatability, as already is well established with the Epstein frame. This paper aims to investigate the influence of several parameters on the field homogeneity in the test sample.Design/methodology/approachA fully 3D finite element model of a vertical RSST is developed and used to perform a sensibility study on several geometrical parameters.FindingsThe influence of several parameters on the field homogeneity in the test sample, such as the geometrical dimensions of the yokes, the presence or not of holes drilled inside the test sample for B-coil placement as well as the size of the H-coils and B-coils, is addressed.Originality/valueIt is expected that this study will contribute to the optimization and standardization vertical RSSTs.
Hebri, Mohamed Amine; Rebhaoui, Abderrahmane; Bauw, Gregory; Lecointe, Jean-Philippe; Duchesne, Stéphane; Zito, Gianluca; Abdenour, Abdelli; Mediavilla Santos, Victor; Mallard, Vincent; Maier, Adrien
doi: 10.1108/compel-09-2022-0318
The purpose of this paper is to exploit the optimal performances of each magnetic material in terms of low iron losses and high saturation flux density to improve the efficiency and the power density of the selected motor.Design/methodology/approachThis paper presents a study to improve the power density and efficiency of e-motors for electric traction applications with high operating speed. The studied machine is a yokeless-stator axial flux permanent magnet synchronous motor with a dual rotor. The methodology consists in using different magnetic materials for an optimal design of the stator and rotor magnetic circuits to improve the motor performance. The candidate magnetic materials, adapted to the constraints of e-mobility, are made of thin laminations of Si-Fe nonoriented grain electrical steel, Si-Fe grain-oriented electrical steel (GOES) and iron-cobalt Permendur electrical steel (Co-Fe).FindingsThe mixed GOES-Co-Fe structure allows to reach 10 kW/kg in rated power density and a high efficiency in city driving conditions. This structure allows to make the powertrain less energy consuming in the battery electric vehicles and to reduce CO2 emissions in hybrid electric vehicles.Originality/valueThe originality of this study lies in the improvement of both power density and efficiency of the electric motor in automotive application by using different magnetic materials through a multiobjective optimization.
Ryndzionek, Roland; Michna, Michal; Kutt, Filip; Kostro, Grzegorz; Blecharz, Krzysztof
doi: 10.1108/compel-09-2022-0333
The purpose of this paper is to provide an analysis of the performance of a new five-phase doubly fed induction generator (DFIG).Design/methodology/approachThis paper presents the results of a research work related to five-phase DFIG framing, including the development of an analytical model, FEM analysis as well as the results of laboratory tests of the prototype. The proposed behavioral level analytical model is based on the winding function approach. The developed DFIG model was used at the design stage to simulate the generator’s no-load and load state. Then, the results of the FEM analysis were shown and compared with the results of laboratory tests of selected DFIG operating states.FindingsThe paper provides the results of analytical and FEM simulation and measurement tests of the new five-phase dual-feed induction generator. The use of the MATLAB Simscape modeling language allows for easy and quick implementation of the model. Design assumptions and analytical model-based analysis have been verified using FEM analysis and measurements performed on the prototype. The results of the presented research validate the design process as well as show the five-phase winding design advantage over the three-phase solution regarding the control winding power quality.Research limitations/implicationsThe main disadvantage of the winding function approach-based model development is the simplification regarding omitting the tangential airgap flux density component. However, this fault only applies to large airgap machines and is insignificant in induction machines. The results of the DFIG analyses were limited to the basic operating states of the generator, i.e. the no-load state, the inductive and resistive load.Practical implicationsThe novel DFIG with five phase rotor control winding can operate as a regular three-phase machine in an electric power generation system and allows for improved control winding power quality of the proposed electrical energy generation system. This increase in power quality is due to the rotor control windings inverter-based PWM supply voltage, which operates with a wider per-phase supply voltage range than a three-phase system. This phenomenon was quantified using control winding current harmonic analysis.Originality/valueThe paper provides the results of analytical and FEM simulation and measurement tests of the new five-phase dual-feed induction generator.
Liebrich, Johannes; Kreischer, Christian
doi: 10.1108/compel-09-2022-0308
Superconductors offer several advantages compared with conventional conductors. However, it is not clear at this stage whether these types of conductors provide the same durability. For this reason, tape conductors under mechanical forces need to be studied in detail. The purpose of this paper is to investigate the relationship between critical temperature and axial mechanical stress of GdBaCuO tape conductors.Design/methodology/approachThe paper investigates the influence of axial mechanical stresses on the critical temperature of superconductors. For these investigations, a multi-physical test rig was developed, which makes it possible to perform these types of investigations. With the presented measurement methodology, the influence of mechanical stresses on the tape conductor can be determined.FindingsThe investigations show a correlation between the critical temperature and the acting mechanical stresses. The analytically presented approach to describe the transition temperature is valid for the investigated samples. In addition, it is determined that the effects are not reversible, and therefore, permanent damage to the tape conductor is observed.Originality/valueThe presented investigations make it possible to create more accurate models of GdBaCuO tape conductors. This enables to extend the superconducting state space, which so far depends on three critical quantities, by the quantity of the axial stress.
Kostro, Grzegorz; Michna, Michal; Kutt, Filip; Ryndzionek, Roland
doi: 10.1108/compel-09-2022-0330
Calculating the stator end-winding leakage inductance, taking into account the rotor, is difficult due to the irregular shape of the end-winding. The end-winding leakage may distribute at the end of the active part and the fringing flux of the air gap. The fringing flux belongs to the main flux but goes into the end-winding region. Then, not all the magnetic flux occurring in the end region is the end-winding leakage flux. The purpose of this paper was to find a method to accurately separate the leakage from the total flux, taking into account the rotor.Design/methodology/approachIn this paper, two methods based on energy calculation are presented. Both methods require the assumption that the machine is symmetrical. The first method depends on the total leakage inductance and the machine’s active region length. The second method is based on the energy stored in the end region of the machine. In this case, removing the energy produced by the fringing flux of the air gap is necessary. The model should have a volume-closing fringing flux to remove the part of energy belonging to the end of the air gap.FindingsThe method presented in the paper does not require rotor removal. The values of the end-winding leakage inductance computed based on the proposed method were compared with values computed using the method with the removed rotor. The computations show that the proposed method is closest to the results from the method presented in the literature. Results obtained in the first method present that rotor influence on the value of end-winding leakage inductance exists. The model of the stator end-winding described in the paper is general. Therefore, the proposed methods are suitable for calculating the end-winding leakage inductance of other electric machines.Originality/valueThe method presented in the paper considers the rotor in end-winding leakage inductance calculation. It is not necessary to remove the rotor as in the similar method presented in the literature. The authors elaborated a parametric model with a volume-closing fringing flux to remove the part of energy belonging to the end of the air gap. The authors also elaborated their 3D model of the machine winding for calculations in Opera 3D.