Search

The development of dual phase soft magnetic laminate for advanced electric machines at General Electric is summarized, including alloy development, properties, manufacturing trials, prototype experience, potential applications, and future material development. Dual phase soft magnetic laminates provide the flexibility to tune magnetic/non-magnetic state at the desired locations, using solution nitriding treatment with protective mask/coating. This enabling material technology benefits electric machine performance by reducing flux leakage in the laminates. It also decouples the electromagnetic and mechanical design, which opens up the design space for advanced electric machines. Magnetic and mechanical properties of dual phase laminates were compared to commercial FeSi and FeCo soft magnetic laminates. Driven by the market needs for high power density and high-speed electric machines, a synchronous reluctance (SynRel) machine without PMs using dual phase soft magnetic laminates was assessed in machine electromagnetic performance as well as rotor stress analysis by finite element simulation. Successful prototype build and testing further retired manufacturing risks and advanced the technology maturity level. Future material development with higher mechanical strength, higher saturation magnetization, higher permeability, and lower loss are highly desired for ground and air transportation electrification. [ABSTRACT FROM AUTHOR]

This article systematically compares two axial flux permanent magnet machines designed for a university student racing car application: a double-rotor single-stator yokeless and segmented armature (YASA) structure, and a single-stator single-rotor configuration. Both machines are optimized for minimum loss and active weight using three-dimensional finite element analysis and the highest performing candidate designs are compared in more detail. The studies indicate that the benefits offered by the YASA configuration over the single-stator single-rotor machine are achieved only for specific designs that are heavier. For the design space with lower mass, albeit with increased losses, the Pareto front designs overlap. In this envelope, the YASA configuration demonstrates higher efficiencies at higher speeds, whilst the single-stator single-rotor is more efficient in high torque duty cycles. This shows the performance of the two machines is very similar and the choice is application specific. To validate the finite element analysis used in the optimization, a prototype was built and tested. Results showed good alignment between simulation and experimental data. [ABSTRACT FROM AUTHOR]

Outer-rotor switched reluctance machines (SRMs) have drawn much attention as promising candidates for in-wheel direct-drive motors of future electric vehicles. This article presents a systematic performance comparison of three outer-rotor SRM topologies for in-wheel traction applications in terms of the specific torque, electromagnetic efficiency, torque ripple, radial force, and mechanical aspects. A generalized design optimization framework for SRMs is proposed to enable the fast evaluation of large numbers of designs generated from the differential evolution by incorporating an analytical current profile estimation into the transient finite element analysis. The relationship between the saliency ratio and converter volt-ampere rating is also discussed. The calculations are then benchmarked with the experimental results from an existing prototype. The effectiveness of the performance prediction method and the proposed optimization approach is validated. [ABSTRACT FROM AUTHOR]

This article proposes a new hybrid analytical and numerical finite element (FE) based method for calculating ac eddy current losses in wire windings and demonstrates its applicability for axial flux permanent magnet electric machines. The method takes into account three-dimensional (3-D) field effects in order to achieve accurate results and yet greatly reduce computational efforts. The new 3-D FE-based method is advantageous as it employs minimum simplifications and considers the end turns in the eddy current path, the magnetic flux density variation along the effective length of coils, and the field fringing and leakage, which ultimately increases the accuracy of simulations. This study is one of the first ones to compare meticulous 3-D finite element analysis (FEA) models with more approximate, but faster solution methods, which can be employed in the optimization process. The accuracy of the 3-D FEA calculations has been confirmed through tests on a prototype axial flux permanent magnet machine. The proposed method is applicable for cases with majority of ac copper losses induced due to external magnetic flux sources, such as permanent magnets. Examples of such machines designs are coreless or open slot PM machines with conductors sizes smaller than skin depth. [ABSTRACT FROM AUTHOR]

Building energy consumption accounts for a large fraction of the total global energy usage, and considerable energy savings are expected to be achieved in this respect through residential electrical load monitoring. Due to the limitations on the practical implementation of in-depth and expensive monitoring systems, non-intrusive load monitoring (NILM) is becoming a hot topic. In this paper, an overview of the state of the art residential electrical load monitoring is presented. Different from previous reviews, the applications of load monitoring are particularly addressed, based on which, technical challenges of load monitoring techniques, including NILM, are identified and thoroughly discussed, together with possible developments and trends predicted from the authors' perspective. [ABSTRACT FROM AUTHOR]

Net zero energy (NZE) houses purchase zero net metered electricity from the grid over a year. Technical challenges brought forth by NZE homes are related to the intermittent nature of solar generation, and are due to the fact that peak solar generation and load are not coincident. This leads to a large rate of change of load, and in case of high PV penetration communities, often requires the installation of gas power plants to service this variability. This article proposes a hybrid energy storage system including batteries and a variable power electric water heater which enables the NZE homes to behave like dispatchable generators or loads, thereby reducing the rate of change of the net power flow from the house. A co-simulation framework, INSPIRE+D, which enables the dynamic simulation of electricity usage in a community of NZE homes, and their connection to the grid is enabled. The calculated instantaneous electricity usage is validated through experimental data from a field demonstrator in southern Kentucky. It is demonstrated that when the operation of the proposed hybrid energy storage system is coordinated with solar PV generation, the required size and ratings of the battery would be substantially reduced while still maintaining the same functionality. Methodologies for sizing the battery and solar panels are developed. [ABSTRACT FROM AUTHOR]

Axial-flux permanent-magnet machines are used particularly in applications requiring a compact structure. Their disc-shaped topology and axial airgap have led to a variety of configurations including two popular ones: the yokeless and segmented armature (YASA), and the single-stator single-rotor or single-sided machine. In this study, a comprehensive comparative analysis of these configurations is conducted at different magnetic and electric loadings. It is found that at lower loadings, typically employed for air-cooled machines, the torque/ampere characteristics of the YASA machine are almost identical to those of a single-sided machine constructed with half the magnet volume. On the other hand, the single-sided machine outperforms the YASA machine when the magnet volumes in both machines are maintained equal. However, for higher electric loadings, the torque/ampere characteristics of the YASA machine droop significantly less than those of the single-sided machine. This article includes analytical estimations, which are verified with experimentally validated finite element analysis (FEA) simulations. In addition, the impacts of the armature reaction on saturation and the magnetic flux linkage, the magnet losses, and eddy current losses in both machines are also explored. [ABSTRACT FROM AUTHOR]

Typically, solar inverters curtail or “clip” the available power from the photovoltaic (PV) system when it exceeds the maximum ac capacity. This article discusses a battery system connected to the dc link of an inverter to recuperate this PV energy. Contrary to conventional approaches, which employ two dc–dc converters, one each for the battery and solar PV system, the proposed configuration utilizes a single dc–dc converter capable of simultaneously operating as a charge controller and a maximum power point tracking (MPPT) device. In addition to improving the overall system capacity factor, increasing the conversion efficiencies, and ensuring MPPT stability, the proposed configuration offers a simple solution for adding energy storage to existing PV installations. With this configuration, the excess power that will otherwise be curtailed due to inverter rating limitations is stored in the battery and supplied to the grid during periods of reduced irradiance. Moreover, a systematic methodology for sizing a dc-bus connected battery to minimize total PV energy curtailed was developed using an annual PV generation profile at the Louisville Gas and Electric and Kentucky Utilities E. W. Brown solar facility at Kentucky. The detailed behavior of the proposed system and its power electronics controls and operations were validated with case studies developed in PSCAD/EMTDC software for variable power generation and PV output power smoothing. [ABSTRACT FROM AUTHOR]

Optimizing the design of electric machines is a vital step in ensuring the economical use of active materials. The three-dimensional (3-D) flux paths in axial flux permanent magnet (AFPM) machines necessitate the use of computationally expensive 3-D electromagnetic analysis. Furthermore, a large number of design evaluations is required to find the optimum, causing the total computation time to be excessively long. In view of this, a two-level surrogate assisted algorithm capable of handling such expensive optimization problems is introduced, which substantially reduces the number of finite element analysis (FEA) evaluations to less than 200 while conventional algorithms require thousands of designs to be analyzed. The proposed algorithm is employed to optimally design an AFPM machine within a specified envelope, and to identify the limits of cost and efficiency. In order to obtain these limits, the variables' ranges are assigned to be as wide as possible, resulting in a vast design space, the study of which was enabled by the developed special algorithm. Additionally, optimized designs with different rotor polarities are systematically compared in order to form the basis for a set of generalized design rules. [ABSTRACT FROM AUTHOR]

Equivalent circuit parameters serve as the basis for performance estimation and implementation of power electronic drives controls and therefore their accurate evaluation is very important. Specified in the newly approved IEEE Std 1812, a short-circuit test can be employed, in combination with an open-circuit measurement, in order to determine the back emf and the synchronous inductance. In the case of interior permanent magnet (IPM) machines, this approach can be used only to determine the d-axis inductance and additional and separate measurements are required for the q-axis inductance. In this respect, various methods, inclusive of dc step response tests, on-load tests, and a widely used test in industry, which involves locked-rotor measurements at variable voltage and constant frequency supply, are studied in detail, based on two-dimensional finite element analysis. Locked-rotor methods based on dc current supply and static torque versus rotor position measurements are introduced for determining the q-axis inductance in combination with the standardized open-circuit and short-circuit tests. A critical study of the inductances determined from different tests is conducted, and experimental results on an IPM motor design with non-sinusoidal back emf, relatively high torque ripple, and low leakage are presented. [ABSTRACT FROM AUTHOR]

This paper analyzes the configuration, design, and operation of multi-MW grid connected solar photovoltaic (PV) systems with practical test cases provided by a 10-MW field development. In order to improve the capacity factor, the PV system operates at its maximum power point during periods of lower irradiance, and the power output is limited to a rated value at high irradiance. The proposed configuration also incorporates a utility scale battery energy storage system (BESS) connected to the grid through an independent inverter and benefits of the experience gained with a 1-MW 2-MWh BESS large demonstrator. The BESS power smoothing and frequency regulation capabilities are illustrated though combined theoretical and experimental studies. The behavior of the grid connected PV and BESS combined system is studied using a modified IEEE 14 bus test system implemented in PSCAD/EMTDC. This paper also includes a sizing exercise for energy storage in order to provide dispatchable PV power. [ABSTRACT FROM AUTHOR]

Axial flux permanent magnet (AFPM) motors are suitable options for solar-powered vehicles due to their compact structure and high torque density. Furthermore, certain types of AFPM machines may be configured without stator cores, which eliminates associated losses and cogging torque and simplifies the manufacturing and assembly. This paper examines two machine designs for use in the solar-powered vehicle of the challenger class—a single rotor, single stator conventional AFPM machine, and a coreless AFPM machine with multiple stator and rotor disks. The response surface methodology (RSM) is utilized for the systematic comparison of the conventional and coreless topologies and to select the optimum designs among several hundreds of candidates. Designs with minimum losses and mass producing required torque with larger air-gap are favored. The performance of the selected designs has been studied via three-dimensional finite element analysis (FEA). The FEA parametric modeling methodology is validated by measurements on three AFPM machines of the conventional and coreless type. [ABSTRACT FROM AUTHOR]

Switched reluctance (SR) machines are attractive because they present relatively high efficiency and torque density in spite of lacking permanent magnets. This paper focuses on a two-objective optimization of an external rotor SR motor with a stator that has concentrated coils and a rotor with magnetically isolated modules. The objectives are minimum loss and mass, and 11 independent dimensionless geometric variables are considered as inputs that affect them. A combined design of experiments (DOE) and differential evolution (DE) approach is proposed. The DOE methodology is used to reduce the search space by eliminating from consideration input variable values, leading to poor-performing designs. Following this initial DOE study, an optimization study based on DE is run over the reduced search space, which leads to significant savings in computation time. Furthermore, a directed graph-based method for comparing different designs on the Pareto front to rank the best compromise designs is proposed. [ABSTRACT FROM AUTHOR]

Coreless axial flux machines are of interest because of the absence of stator core losses and cogging torque. These machines generally employ concentrated windings. One of the challenges with such a winding is that the torque producing MMF component that corresponds to the fundamental of the magnet excitation is accompanied by substantial asynchronous components. These harmonics cause losses in the rotor core and magnets, which can become significant at high speeds. This paper proposes a new multilayer winding arrangement to eliminate the non-torque producing MMF components. This winding is applied to a 12-coil 16-pole coreless axial flux machine. The efficacy of the winding is established by 3-D finite-element analysis. [ABSTRACT FROM AUTHOR]

Coreless axial flux permanent magnet (AFPM) machines are attracting increasing attention due to their compact structure and high torque density. The torque to weight ratio can be further enhanced by the use of alternate conductor materials, such as carbon nanotube (CNT), or aluminum windings in place of the copper material coils. This paper proposes a coreless AFPM synchronous motor with CNT windings. Analytical equations are developed to allow a systematic comparison of machine designs with different conductor materials. The performance of machine designs with different coil materials, namely, copper, aluminum, and CNT, is evaluated and compared. The calculations are also backed by 3-D finite-element analysis. [ABSTRACT FROM AUTHOR]

A novel automated design optimization procedure based on the application of an ultrafast computationally efficient finite-element analysis (CE-FEA) for current-regulated synchronous reluctance machines supplied from power electronic converters is proposed. The CE-FEA uses only a minimum number of magnetostatic solutions in order to comprehensively evaluate performance, including ripple torque and core losses. The optimization algorithm is based on differential evolution, and uses as independent variables the torque angle and ratios for a generic rotor topology with four flux barriers. Two problems, one with two and the other with three objectives, are studied and results are compared. Global performance indices and objectives incorporate the effect of average torque output, losses, torque ripple, and power factor at fixed cost. It is shown that through optimal studies with more than 5000 candidate designs, high output power, high efficiency, and low torque ripple can be achieved, while the relatively low power factor remains an inherent limitation of synchronous reluctance technology. Simulations are validated versus tests from a 10-hp 1800-r/min prototype. [ABSTRACT FROM AUTHOR]

Switched reluctance motors (SRM) are becoming increasingly popular because of the rising cost of permanent magnets. It was reported that segmented rotor construction improves the torque output and efficiency. This study discusses an SRM with segmented rotor construction designed for direct drive application. Such a motor has an outer rotor. It is found that in such machines, the torque output increases when there are higher number of rotor segments than stator poles. A segmented rotor SRM with 12 stator poles and 26 rotor segments is discussed here. It has unique pole tip shape, which improves torque output. Design procedure of the motor is presented. Moreover, limitations of segmented rotor SRMs having a higher number of rotor segments than stator poles are also identified, and possible solutions are suggested. Experimental results on the prototype of a three‐phase 12/26 motor are presented. [ABSTRACT FROM AUTHOR]

A motor for in-wheel electric vehicle (EV) requires high efficiency and specific torque. In view of this, permanent-magnet brushless dc (PM BLDC) motor is most commonly employed for this application. However, due to the increasing cost of PMs, machines that do not use PMs are attracting interest. Switched reluctance motor (SRM), with its simple and robust construction, along with fault tolerant operation, is a viable option for in-wheel EV application. However, the SRM has low specific torque as compared with BLDC. Therefore, design improvements are required to make SRM a viable alternative to BLDC motor. In this paper, a new 12/26 pole SRM with high specific torque is proposed for in-wheel EV application. This machine has segmented-rotor-type construction. Also, concentrated-winding arrangement is used, ensuring low end-winding volume and copper loss. The developed machine also has high efficiency. In order to verify the design, the prototype of the machine is fabricated, and experimental results are presented. [ABSTRACT FROM AUTHOR]