L1 Introduction

B Design of electrical machines

Avo Reinap
Industrial Electrical Engineering and Automation, LTH
Industrial Electrical Engineering and Automation Lund University, Sweden
Industrial Electrical Engineering and Automation

Power of understanding energy conversion material properties machine construction

F
Creativity

I
Power of imagination integration production

Machine Design
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Design process
Industrial Electrical Engineering and Automation Industrial Electrical Engineering and Automation

Design of electrical machines in Lund

separation disk lower half of claw-pole ring phase coil

Component and system thinking

Performance and controllability Cost and manufacturability

coil

upper half of claw-pole ring housing

shaft housing magnet inner core half outer core half

housing magnet claw-pole ring

Dimensioning and modelling

Multi-dimensional multi-physics Supply, electronics, application, drive cycle,

Optimizing
Objective vs design parameters Sensitivity analysis
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Powder core motors simple electric circuit and unconventional magnetic circuit Different moulding techniques integrability and manufacturability
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EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

Design of electrical machines in Lund

Industrial Electrical Engineering and Automation Industrial Electrical Engineering and Automation

Need for electrical actuator

Electrified traction drive Integrated pump and fan drives Wind generators Mechatronics, robotics

Material and production development Machine design and evaluation

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Maintenance As long we going to have electricity there is always an electrical machine around
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Motivation
Industrial Electrical Engineering and Automation

L1: Introduction

Employed by being creative engineering challenges to think creatively Improve your power of understanding and power of imagination Actual trends integrability, manufacturability, sustainability, Design challenges new technology, new materials, computational power,
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Course overview Machine construction overview

Industrial Electrical Engineering and Automation Lund University, Sweden

EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

About course I
Industrial Electrical Engineering and Automation Industrial Electrical Engineering and Automation
Borrowed from Ice Age I

About Course II
Design of electrical machines
14x2 lectures (LP3) 5 weekly home assignments (LP3) Course project (LP4)

Motivation (U): 6 credits + knowledge (as bonus) Requirements (R):

28 hours of lectures 42 hours of project 90 hours of self-studies

Course literature
T.A. Lipo Introduction to AC Machine Design WEMPEC A. Reinap Numerical modelling and Design of Electrical Devices LTH/TTH

Easiness (I): I=U/R

Course responsible Avo Reinap

E-mail: avo.reinap@iea.lth.se eSkype: avo.reinap Cell: 070 563 9097

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Course goal
Industrial Electrical Engineering and Automation Industrial Electrical Engineering and Automation

Lectures
L1 introduction L2 survey of machines:1 L8 design of PMSM L9 losses

objective of this course is to gain experience covering the overall design process: design, actual construction and testing of an electromagnetic device Understand the electromechanical design behind the classical electromagnetic devices

L3 calculation method: EC L10 thermal circuits L4 calculation method: FE L11 design issues L5 energy conversion L6 magnetic circuits L7 electric circuits L12 optimization L13 survey of machines:2 L14 home design

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EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

Home assignments
Industrial Electrical Engineering and Automation Industrial Electrical Engineering and Automation

Design task 2007

Design and prototyping of an electromagnetic toy DC drive (2007)
Rotating machine whos is fastest Linear machine whos is strongest Creativity drive who is most innovative

Introduction to computational techniques and software optimization of a transformer Thermal analysis of PMSM Magnetic analysis of PMSM Design model and optimization of PMSM Estimation of machine characteristics

Supply 1.5 V battery Design documentation

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Number of modulator poles, N

6
BM

RP

and gear ratio

20 22 24

Number of magnet pole-pairs, N

5
4

4
16 18 20
1
2

8 6

10 8

12 10

14 12

16 14

18

22

3
4

2
1

8
6
2

16

18

20

10

12
10

14

10

12

14
AM

16

18

20

Number of magnet pole-pairs, N

Design task 2008

Industrial Electrical Engineering and Automation

Design task 2009

93 550
@120 @200

Goal of hands on project: Study magnetomechanical energy conversion Complex theory vs simple experimentation

Industrial Electrical Engineering and Automation

92 500 91 90 efficiency \ny [%] 450 power Pm [W]

Design machine for an axial wind turbine Use an existing stator & Select a number of poles that gives highest power and smallest ripple!
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89 400 88 87 86 300 85
@120 @200

350

84 20

25

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Design of Electrical Machines

30 35 number of poles, Np

250 40

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EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

Design Task 2010

Industrial Electrical Engineering and Automation

Design Task 2011

Industrial Electrical Engineering and Automation

Hands on project that requires a good theoretical understanding Focus on winding layout and manufacturing

Understanding Equivalent circuits

Magnetic Thermal

Measurements
Magnetic Thermal

Analyses

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Course Plan
Industrial Electrical Engineering and Automation

Electrical machine in a nutshell

Industrial Electrical Engineering and Automation

Preliminary course plan for lectures After two lectures a weekly home assignment will be given and this suppose to be handed in within a week Design task is a parallel process with additional meetings
W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 W15 W16 W17 W18 W19 W20 W21

Cause-effect, action-reaction
Understanding observation (physics) expression (maths) creation (innovation)

Classification based on magnet origin (?)

Excitation vs armature

Understanding energy conversion

Thermodynamic arguments (conservation of energy) Field analysis (Maxwell stress tensor)
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L1 L2

L3 L4

L5 L6

L7 L8

L9 L11 L13 L10 L12 L14

P1

P2

P3

P4

P5

P6

P7

LP3 LP3 LP3 LP3 LP3 LP3 LP3 T4 LP4 LP4 P

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T5 LP4 LP4 LP4 LP4 LP4 LP4 T6

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Design of Electrical Machines

EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

Prior knowledge
Industrial Electrical Engineering and Automation

Developed knowledge
Industrial Electrical Engineering and Automation

Ohms Law 1 / 3 Cause of electromagnetic force (torque) Magnetic flux vs. electromotive force, electric current vs. magnetomotive force Maxwells equations Power electronic control

Computer aided design

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Construction, calculation and dimensioning of nding electromechanical devices ersta d

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Design of Electrical Machines

un etic Good ctromagn n o e on el conversi y energ

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Actuator
Industrial Electrical Engineering and Automation Industrial Electrical Engineering and Automation

Main parts
Motion Force
Coil or winding to produce variable magnetic flux Permanent magnet to produce invariable magnetic flux Soft magnetic core to provide an easy path for the flux in order to facilitate flux linkage or magnetic coupling between sources and loads
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(Controlled) electric power

Geometry Materials

Electro-mechanical energy converter Electromagnetism intermediates energy conversion Electric side: DC, AC, pulsed Mechanic side: linear, rotary motion
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EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

Introduction to magnetism
Industrial Electrical Engineering and Automation

Magnetic interaction vs attraction

Industrial Electrical Engineering and Automation
M F M F M M

Before we control or construct an electrical machine we play with permanent magnets The energy conversion between the electric and mechanic energy takes place in presence of the magnetic field
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The traditional five senses of a human being exclude ability to achieve a direct response from magnetic field that intermediates the electromechanical energy conversion in an electrical machines

N40 NdFeB magnets 5x20x20 mm Attraction or repulsion ca 40 N Shear ca 27 N including ca 7 N attraction/repulsion Attraction ca 8 N Shear 4 N attraction 3 N
26

M F M

M F

F F M M

Design of Electrical Machines

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Maxwells Stress Tensor

B
Industrial Electrical Engineering and Automation

Force components
Industrial Electrical Engineering and Automation
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Magnetic force on a surface according to magnetic pressure

Bn t Bt tt

Attraction between ferrous material and exciting magnetic fields due to permanent magnet(s) or coil(s) resulting in reluctance force/torque Interaction between electromagnet(s) or/and permanent magnet(s) cause magnetic force/torque

1 2 tn Bn Bt2 2 0 B B tt n t

tn

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EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

Electromagnet vs PM
Industrial Electrical Engineering and Automation
A+ I
A+ I M F

How machines work

Industrial Electrical Engineering and Automation

A+ I

A-

Magnetic field around current carrying coil The principle of operation of any rotating electric motor is derived from Lorenz force. Replace PM by EM NI=Hl= ca 5kA

Electrical machines exploit magnetic interaction

Two magnets one in stator the other with the rotor displacement of these two magnets will create a torque The magnets can be created directly or induced The bigger the torque the bigger the machine

A+ I M F A+ I M
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AF

A+ I M F

A-

No new topology
The principles of machine design are more than 100 years old

AF

A+ I

AM

Design of Electrical Machines

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Types of machines
Industrial Electrical Engineering and Automation

Control of machines
Industrial Electrical Engineering and Automation

According to excitation
EM and PM Reluctance and inductance

Field oriented control

Maximise torque product Consider the limits And keep losses down

According to supply According to geometrical arrangement

The goal for the design is quite the same as for the control

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EIE050 Design of Electrical Machines, IEA, 2012

L1 Introduction

Size of machines
Industrial Electrical Engineering and Automation

Machine=Generator&Motor
Industrial Electrical Engineering and Automation

Torque is proportional to size and weight Power is proportional to torque and speed

Can you figure out when the animation machine operates as a generator and when as a motor?
i u

T w
w= =T iu= Pe

Pm

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Questions
Industrial Electrical Engineering and Automation

Course participants12
Industrial Electrical Engineering and Automation
35 Avo R

What are you expecting from the course?

How would you like to study the course?

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Design of Electrical Machines

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EIE050 Design of Electrical Machines, IEA, 2012