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Interior permanent-magnet synchronous machines are widely spreading in automotive and vehicle traction applications, because of their high efficiency over a wide speed range. This capability can be achieved by appropriated control strategies: Maximum Torque per Ampere (MTPA), Flux Weakening (FW) and Maximum Torque per Volt (MTPV). However, these control trajectories are often based on an simplified magnetic model of the electrical machine. In order to improve the evaluation of machine output capabilities, nonlinear magnetic behavior must be modeled. This is not only related to the final application with a given drive and control structure, but also during the design process of the electric machine. In the design process, the output torque Vs. speed characteristic must be calculated following MTPA, MTPV and FW in the most accurate way to avoid significant error. This paper proposes a set of algorithms to compute MTPA, FW and MTPV curves for interior permanent-magnet synchronous machines taking into account the machines’ nonlinearities caused by iron saturation and compares differed approaches to highlight the torque–speed capabilities for the same machine following different methods. The algorithms are based on the maps of the equivalent inductances of a reference interior permanent-magnet synchronous machine and inductances maps were obtained via 2-D Finite Element Analysis over the machine’s operating points in id−iq reference plane. The effects of different 2-D finite element methods are also computed by both standard nonlinear magnetostatic simulations and Frozen Permeability simulations. Results show that the nonlinear model computed via frozen permeability is more accurate than the conventional linear and nonlinear models computed via standard magnetostatic simulations; for this reason, during the electrical machine design, it is important to check the expected performance employing a complete inductance map and frozen permeability.

Energy storage is an emerging technology that can enable the transition toward renewable-energy-based distributed generation, reducing peak power demand and the time difference between production and use. The energy storage could be implemented both at grid level (concentrated) or at user level (distributed). Chemical batteries represent the de facto standard of storage systems for performance and maturity; however, batteries feature a quite large environmental footprint and use precious raw materials. Mechanical storage technologies could represent a viable alternative to chemical batteries, because of their reduced impacts on the environment and on raw materials. This article presents the design of a motor/generator for a flywheel energy storage at household level. Three reference machines were compared by means of finite element analysis: a traditional iron-core surface permanent-magnet (SPM) synchronous machine, a synchronous reluctance machine (SynchRel), and an ironless SPM synchronous machine. Simulation shows that the ironless machine is good candidate for distributed energy storage, because of its high efficiency, high discharge duration, and low losses. A prototype ironless machine was designed and manufactured. Experiments confirm the simulation results.

Energy storage is an emerging technology that can enable the transition towards renewable-energy-based distributed generation, reducing peak power demand and the time difference between production and use. The energy storage could be implemented both at grid level or at user level and nowadays different technologies are available for this purpose. In particular chemical batteries represent the de facto standard of storage systems for performance and maturity, however batteries feature a quite large environmental footprint and use precious raw materials. As an alternative to chemical batteries, mechanical storage technologies could be evaluated because of their reduced impacts on the environment and on the exploitation of raw materials. This paper presents the design, the prototyping and the experimental results of an ironless surface permanent-magnet (SPM) synchronous machine for a flywheel energy storage at household level. The electrical machine can work either as a motor or as a generator and it is the main item to fulfill the major challenges of a household application: high discharge duration and compatible size/dimension. The performance of the proposed ironless SPM machine are also compared with traditional iron core SPM synchronous machine by means of Finite Element Analysis (FEA).