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, i.e.
(4)
nd the current now known, the
calculated by numerically
tage and current over the
(5)
culated similarly with
(6)
lgorithm then receives the
as the goal function and the
straint and tries to iteratively
aintaining the output power
e.
ASS OPTIMISATION
erformed in accordance with
below in Table 1.
.
Value
50 Hz
30 mm
3000 W
0.96
Rare earth, N36
M-19
nfluence that the geometric
s on the design, three different
d with increasing geometric
ed in Table 2, using the
ted in Fig. 5.
imisations performed.
Opt. 2 Opt. 3
free free
free free
free free
free free
free free
free free
free free
= stroke length free
= stroke length free
etic active masses obtained
are shown in Table 3.
641
Table 3: Results obtained from the optimisations perf
Optimisation results (kg)
Mass Opt. 1 Op
Steel 12.0
Copper 5.9
Magnets 1.4
Total 19.3
Fig. 9 shows 3D representations of the t
with one quarter sectioned.
Fig.9: 3D representations of the optimisations with on
From left to right: Opt. 1, Opt. 2 and Opt. 3.
The optimised dimensions (from Fig
optimisations are listed in Table 4.
Table 4: Optimised dimension of the three optimisati
Dimensional
parameter
Opt. 1 Opt. 2
1 [mm] 18.2 37.
2 [mm] 37.6 21.
3 [mm] 9.3 9.
4 [deg] 44.0 43.
5 [deg] 36.0 32.
6 [mm] 40.1 36.
7 [mm] 25.2 22.
8 [mm] 30.0 30.
9 [mm] 30.0 30.
While the single additional degree of
second optimisation slightly reduced th
improvement was obtained when freedom
the z direction or direction of motion. Th
from the third optimisation yielded an ac
58.5 % of Schuttes previous design w
identical performance measures over a si
stroke length.
One reason for this substantial improve
to the thinner core thickness (dimension
diameter of the third optimisation is also
that of the first and second optimisatio
compared to 307.8 mm and 302.4 mm
second respectively).
To increase confidence in the optimi
third, 13.1 kg optimisation (Opt. 3
dimensional freedom) was re-run twice
different initial values but with iden
parameters. This was done to further e
space and address concerns regarding lo
convergence. Fig 10 illustrates the pro
minimisations and Fig 11, the output pow
their iterations. The results show
probability that the third, 13.1 kg optim
upon a global or near global optimum.
formed.
pt. 2 Opt. 3
10.5 6.2
6.4 4.9
1.4 2.0
18.3 13.1
three optimisations
ne quarter cut-out.
g. 5) of the three
ons.
Opt. 3
1 17.0
0 31.3
2 9.9
9 44.0
2 32.5
5 38.7
5 26.5
0 18.1
0 44.5
f freedom for the
he mass, the real
m was allowed in
he final dimensions
ctive mass of only
while maintaining
ignificantly shorter
ement is attributed
n 8). The overall
o slightly less than
ns (i.e. 289.0 mm
for the first and
isation results, the
with the most
e with completely
ntical optimisation
explore the design
ocal, sub-optimum
gress of the mass
wer with regard to
with satisfactory
misation converged
Fig. 10: Mass minimisation of t
optimisation parameters but from comp
Fig. 11: Power constraint of three optim
parameters but from completely differe
VII. TRANSIENT
A static simulation method
time that an optimisation requi
Considering that a single optim
of computational time, the us
technique is justified if it yields
Schutte employed a virtuall
technique in the design of his f
tests of this prototype yielded
with the simulation data [4]. H
to an operating frequency of
limitations. He also could not
mechanical power and cou
determine the efficiency of the
at 10 Hz the losses associated w
the flux linkage, e.g. eddy cur
much lower than at 50 Hz.
magnitude of core losses and
therefore exists and as a conse
the accuracy of a magnetostatic
A detailed transient simulat
on the final 13.1 kg design. Fi
the flux linkages and Fig. 13 of
for the magnetostatic and transi
three optimisations with identical
pletely different initial values.
misations with identical optimisation
nt initial values.
T SIMULATION
was employed to reduce the
ires to successfully converge.
misation requires several days
e of such a simplified static
s accurate results.
ly identical static simulation
first prototype. Experimental
d results that correlated well
However, Schutte was limited
f 10 Hz due to mechanical
accurately measure the input
uld therefore not properly
generator. Even if he could,
with the time rate of change of
rrents in the core, should be
No real indication of the
ohmic losses in the magnets
equence no real indication of
c approximation exists.
tion was therefore performed
ig. 12 shows a comparison of
f the derived terminal voltages
ient simulations.
642
Fig.12: Flux linkage of one of the coils for the magne
simulations.
Fig.13: Terminal voltages for the magnetostatic and t
The flux linkages of the two simulat
identical as is the terminal voltages ob
processing.
The instantaneous input mechanical
from the product of the total instantaneous
of the magnets) is shown in Fig. 14.
output electrical power (calculated as th
instantaneous current and terminal voltage
15.
Fig.14: Instantaneous mechanical input power from th
transient simulations.
etostatic and transient
transient simulations.
tions are close to
btained from post-
power (calculated
s force and velocity
The instantaneous
he product of the
e) is shown in Fig.
he magnetostatic and
Fig.15: Instantaneous electrical output p
transient simulations.
An increase in the average v
power obtained from the
compared to the mechanical
magnetostatic simulation is cle
electrical power remains fairly
increased losses obtained from t
The instantaneous copper lo
magnets (due to eddy currents
copper losses derived for the m
for reference purposes. The cor
plot against time, i.e. only
provided.
The ohmic losses in the
substantially higher than the c
present a significant problem
magnets may increase to le
occurs, even under normal ope
could be partially addressed by
proposed by Wills and Kam
manufacturing technique reduc
presents certain mechanical dif
is compromised since the magn
in motion. Further investigatio
issue.
Fig.16: Losses from the magnetostatic a
of time.
The values of the different lo
the magnetostatic and transient
power from the magnetostatic and
value of the mechanical input
transient simulation when
l power obtained from the
early visible, while the output
y similar. This is a result of
transient simulation.
osses and ohmic losses in the
) are shown in Fig. 16. The
magnetostatic case is included
re losses were not available to
time averaged values are
magnets are shown to be
copper losses and are sure to
m. The temperature in the
vels where demagnetisation
erating conditions. This issue
y segmenting the magnets as
mper [10]. While such a
ces losses in the magnets, it
fficulties. Structural integrity
nets are the only components
on is required to resolve this
and transient simulation as a function
osses are listed in Table 5 for
case.
643
Table 5: Losses from the transient and magnetostatic simulations.
Simulated output Magneto-
static
Transient
Copper losses [W] 125 158
Ohmic losses in the magnets [W] - 230
Core: Hysteresis losses [W] - 15
Core: Eddy current losses [W] - 6
Total losses [W] 125 409
While uncertainty exists regarding the accuracy of the
simulated losses, it is clear that the efficiency of the
generator will be degraded by several percentage points to
below 90 %. The main loss mechanism that needs to be
addressed is that of ohmic losses in the magnets.
VIII. CONCLUSION
The process of optimising a transverse flux linear
generator by means of a 3D FEM in combination with an
optimisation algorithm has been demonstrated. One of the
advantages of such a process is that it often yields counter-
intuitive results that can, in turn, lead to design changes
which previously would not have been envisioned.
Unfortunately it is a computationally expensive method.
A single optimisation can run for days or even weeks on
well capable computers. This relatively long optimisation
time makes debugging a tiring process. The stability of the
analytical mass calculations as well as the scripting process
requires careful consideration, as all possible combinations
of the geometric dimensions need to be realised in all three
physical dimensions.
Overall satisfactory results have been obtained.
Optimised designs of this generator topology compare well
with other topologies with regard to the mass.
Further investigation is however required to address the
issue of excessive losses related to the time rate of change of
the flux linkage. As a first step an efficient method should
be developed to include the influence of these losses as part
of the optimisation process, without having to run transient
simulations during optimisation.
IX. REFERENCES
[1] I. Boldea and S.A. Nasar, Linear Electric Actuators and Generators.
Cambridge University Press, New-York, 1997, pp. 210-223
[2] J. Schutte and J Strauss, Optimisation of a transverse flux linear PM
generator using 3D Finite Element Analysis, in Proc. ICEM 2010,
Rome, 19
th
International conference on Electrical Machines.
[3] W.M. Arshad, A Low-Leakage Linear Transverse-Flux Machine for
a Free-Piston Generator, Doctoral dissertation, Dept. Elec. Eng.,
Royal Institute of Technology, Stockholm, 2003. pp 70 73.
[4] J. Schutte, Optimisation of a transverse flux linear PM generator
using 3D Finite Element Analysis, Masters thesis, University of
Stellenbosch, 2011.
[5] A. Cosic, Analysis of a Novel Transverse Flux Machine with a
Tubular Cross-section for Free Piston Energy Converter Application
Doctoral Thesis, KTH School of Electrical Engineering, Stockholm,
2010. pp. 43 51.
[6] S. Qiu, D.L. Redinger and J.E. Augenblick, The next generation
Infinia free-piston Stirling engine for micro-chip applications, in
Proc. 12
th
International Stirling Engine Conference and Technology
Exhibition, 2005. pp. 158 160.
[7] N. W. Lane and W.T. Beale, Free-piston Stirling Design Features,
Proc. 8
th
International Stirling Engine Conference, Ancona, Italy,
1997.
[8] G. Venter, Review of Optimization Techniques, Encyclopedia of
Aerospace Engineering. John Wiley & Sons, Ltd. Edited by R.
Blockley and W. Shyy, 2010.
[9] K. Schittkowski and Y. Yuan, Sequential Quadratic Programming
Methods, Academic article, Dept. of Computer Science, University
of Bayruth, Germany & AMSS, Chinese Academy of Sciences,
Beijing, China, 2010.
[10] D.A. Wills and M.J. Kamper, Reducing PM Current Rotor Losses by
Partial Magnet and Rotor Yoke Segmentation, in Proc. ICEM 2010,
Rome, 19
th
International conference on Electrical Machines.
X. BIOGRAPHIES
Louis H. Joubert received the BEng degree in Mechatronic
Engineering from the University of Stellenbosch in 2010. He is currently
doing a MScEng in the field of linear electric machinery at the University of
Stellenbosch.
Jacques Schutte received the BEng (Electrical and Electronic
Engineering with Computer Science) and MScEng (Electrical and
Electronic Engineering) degrees from the University of Stellenbosch in
2008 and 2011 respectively.
Johannes M. Strauss received the BEng (cum laude) and MScEng
(cum laude) degrees in Electrical and Electronic Engineering from the
University of Stellenbosch in 1996 and 1998 respectively. In 1999 he was
appointed as research engineer in the field of power system dynamics and
synchronous generator modelling at the university and in 2001 he became a
fulltime lecturer at the university. His main fields of interest include
generator modelling and dynamic behaviour and efficient energy
conversion. He is currently busy with his PhD in the field of linear
generator technology for high speed short stroke applications.
Robert T. Dobson received a National Diploma (Mechanical
Engineering) from Pretoria Technicon in 1965, BScEng (Mechanical) from
the University of the Witwatersrand in 1969, MScEng (Nuclear
Engineering) from the University of Cape Town in 1970 and an MBL from
the University of South Africa in 1985. In 1988 he took up a post as
lecturer in the Thermodynamics Division of the Department of Mechanical
Engineering at the University of Stellenbosch. In this capacity he has
specialised as undergraduate lecturer in Heat Transfer and Food
Engineering. At postgraduate level he has specialised in two-phase flow and
heat transfer and thermal management and control. He has published both
locally and internationally on heat pipes, thermosyphons and two-phase
flow devices and is a founder member of the South African Heat Pipe
Association SAPHA.
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