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In the high-speed flux-switching permanent magnet (FSPM) machine, the ac copper loss issue in the armature winding conductor is very prominent, due to the high-frequency leakage magnetic field in stator slot, which seriously affects the machine performance. To model and calculate ac copper loss more accurately, a coupled electric circuit-magnetic field model is constructed based on 2D-finite element method, and consequently the influence of modeling methods and winding types on ac copper loss calculation of a 12-slot/10-pole (12/10) 54.7 kW/10 kr/min FSPM machine is investigated. First, ten simplified ac copper loss calculation models are established to deal with the problem of large consumption of calculation time and computer resources caused by the excessive number of wires, small size of winding conductors, high precision modeling, and mesh refinement. Second, the influences of voltage-/current-source and steady/rotating rotor are considered, and the ten models are evaluated in terms of computing time and accuracy. Third, based on the preferred model from the ten models, the effects of frequency, round/flat wires, and wire sizes on ac copper loss are further studied. Fourth, to investigate the influence of flux leakage at the end of winding on ac copper loss, a 3-D ac copper loss calculation model with different axial lengths of winding end space is established. Fifth, the change process of ac copper loss and transient temperature of winding under short time overload condition are obtained combined with the bidirectional coupling model between electromagnetic and thermal field method through multiple iterations of electromagnetic loss and temperature. Finally, the stator modules of round and flat copper wires are manufactured, respectively, and an experimental modular device is built to measure the ac copper loss, which confirms the improved accuracy of the predictions by the proposed model. [ABSTRACT FROM AUTHOR]

In this article, an axial-flux permanent-magnet (PM) Vernier machine with the triple-stator, spoke-type PM rotor, and toroidal winding wound on the innerstator is proposed. Benefited from the flux focusing spoke-type PM rotor and short end length toroidal winding, the proposed machine has a high torque density and the improved power factor. Based on the air-gap permeance function, the analytical expression of the proposed machine is derived to qualitatively analyze the machine's performance. The quasi-three-dimensional (3-D) finite element analysis (FEA) is adopted to optimize the design parameters, such as innerstator diameter, PM thickness, and slot opening width. The quasi-3-D FEA results match well with the 3-D FEA. The 3-D FEA results show the torque densities of the proposed machine reach 49.4 Nm/L and 11.4 Nm/kg, respectively, under the 232 A/cm average electrical loading. The performances, such as overload capacity, PM demagnetization, and PM and core losses, are also analyzed by 3-D FEA. The comparison with the other axial-flux PM Vernier machine is conducted, and the results reveal that the proposed machine has the great advantages of the torque density and power factor. Since the prototype is not built, in this article, the assembly scheme and thermal behavior of the proposed machine are discussed. [ABSTRACT FROM AUTHOR]

In high performance electric machines, the increase of fundamental frequency leads to additional losses in the winding due to parasitic effects such as the associated skin and proximity effects. In the first part, this paper presents an investigation into accurate modelling of AC losses in the winding using numerical methods and their experimental verification. Then, using experimental motorette setups, this research provides a comparative study between fixed strand positioning and fixed conductor shapes on the AC losses in the winding. It is shown that the exact position of strands in the conductor is not a critical factor; however, it is very important to control the conductor shape inside the slot. In the final section of this paper, an investigation into the relationship between AC losses in the winding and copper filling factor is presented. It is shown experimentally that counter-intuitive design choices such as using a lower copper fill factor and thicker strand diameters may be beneficial in achieving the highest overall efficiency. [ABSTRACT FROM AUTHOR]

In this article, slot-PM-assisted consequent-pole-PM machine (SPMA-CPMM) is proposed. The key is that the consequent-pole ferrite PMs are employed in the stator yoke to reduce the PM material cost largely, while a small amount of tangential magnetized rare-earth PMs is placed in the slot opening to improve the torque production. This proposed hybrid magnet design can greatly enhance the PM utilization ratio and reduce the PM cost while maintaining a relatively large torque density. In this article, the configurations of ferrite-PM machine (FPMM), consequent-pole ferrite-PM machine (CFPMM), and SPMA-CPMM are illustrated, while equivalent magnetic circuits (EMCs) of them are compared. Then, the electromagnetic performances of three machines are investigated and compared, which verifies the validity of the proposed machine. [ABSTRACT FROM AUTHOR]

It is well known that permanent magnet Vernier machine (PMVM) has multiple flux field harmonics, which can produce stable torque. However, some flux field harmonics would create torque that undermines the total torque output. Such as the 6 slots 26 poles split-tooth PMVM here, of which modulated flux field outputs torque while fundamental flux field undermines torque output. In this article, a 26 pole PMVM with coding-shaped tooth is proposed. The coding-shaped tooth can introduce permeance harmonics with specific phase and amplitude, thus modulating flux fields that all output torque. Air-gap permeance harmonics of the proposed and the regular split-tooth PMVM are obtained via FEA. Based on MMF-permeance model, flux fields of two machines and their contributions to average torque are investigated, proving that the proposed machine has multiple flux fields that all output torque. Moreover, by optimizing geometric parameters of coding-shaped tooth, the proposed machine could obtain largest average torque and smallest torque ripple simultaneously. Electromagnetic performances of the optimized machines are studied comparatively in semianalytical way and FEA. It is proved that with same overall size, PM usage, and copper loss, the proposed machine could achieve 30% larger torque density, 86% smaller cogging torque, and 62% lower torque ripple than its counterpart. Finally, a 16-N·m (rated) prototype is built and tested. [ABSTRACT FROM AUTHOR]

In this article, an improved surrogate-assisted design optimization method is proposed and applied to the torque performance optimization of a five-phase surface-mounted permanent magnet machine with quasi-trapezoidal permanent magnets. It integrates the Taguchi and surrogate-assisted methods; the training data for surrogate models are generated by the Taguchi method to reduce reliance on the finite-element analysis (FEA), in turn, the local optimum problem caused by the Taguchi method is tackled by the surrogate model. The generalization ability of surrogate models is enhanced by the parameter transfer technique. Using the fuzzy best-worst method, the decision process of multiple solutions is placed before optimization so that the multiobjective optimization can be transformed into a single objective to facilitate the search process for the optimal design. The optimization results are validated by the test results from a prototype. Compared with the FEA-based parametric scanning method, the optimization cycle is shortened by 94% and a globally optimal design can be obtained. [ABSTRACT FROM AUTHOR]

Based on the electromagnetic-structural coupling analysis, this article proposes the comparative study of three double-stator interior- permanent magnet vernier (DS-IPMV) machines, including the spoke-PM, V-shape-PM (V-PM), and H-shape-PM (H-PM) rotor structures. DS cooperation strategies are adopted in the machine design for the performance improvement. Firstly, the rotor optimization of the proposed machines is carried out, with consideration of the tooth-slot cooperation between the rotor and stators. The electromagnetic- structural coupling-simulation is adopted for comprehensive evaluation. Then, the specific performance comparison is carried out, including the magnetic, structural and cost analysis. Consequently, the spoke-PMV machine accommodates the highest torque output, efficiency and cost-effectiveness; meanwhile, the V-PMV machine possesses the highest torque per PM volume with the better ripple performance. Accordingly, prototype experiments are carried out for the validation of the proposed machine design and comparison. [ABSTRACT FROM AUTHOR]