Improving Robotic Actuator Torque Density and Efficiency Through Enhanced Heat Transfer.
Abstract not provided.
Mazumdar, Anirban↗
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Advanced High Torque Density Magnetically Geared Generator
The objective of this research project was to investigate the fundamental torque density limitations of multistage flux focusing magnetic gears and magnetically geared direct-drive generators for wind turbines. Magnetic gears create non-contact speed amplification by modulating the air-gap magnetic field harmonics created by magnetic rotors. By integrating a stator into the magnetic gear structure a very high torque density direct-drive generator can be created. Magnetic geared systems offer unique capabilities that are currently not available using existing mechanically geared systems, such as overload protection. Magnetic gears also offer the potential for higher reliability, higher efficiency and quieter operation than is currently achievable using a mechanically geared generator. By increasing reliability and design life magnetic gears could decrease the overall life-cycle costs when compared with equivalent mechanical or direct-drive drivetrains. This research project investigated and experimentally testing two sub-scale magnetic gearboxes (0.12 m diameter) and two large diameter magnetic gearboxes (0.56m and 0.63m diameter). The goal of the project was to demonstrate a torque density >300Nm/L for a multistage magnetic gearbox with integrated stator. A nested multistage magnetic gear structure was first proposed and studied. However, it was shown that the nested design greatly increased mechanical complexity and therefore a two-stage series typology was utilized. A multi-stage magnetic gear with a 59:1 gear ratio was successfully experimentally tested. A peak torque of 4.25 kN·m was measured and this resulted in an overall active region torque density of 141 N·m/L (when including support rings). The torque density was significantly reduced from what was computed using 2-D electromagnetic analysis. This reduction was due to the 3-D edge effects, increased power losses and the inclusion of additional mechanical support rings as well as other mechanical assembly design changes. At large diameters contiguous lamination parts could not be fabricated and so a segmented laminated rotor design had to be used. This reduced the mechanical strength of the design when compared to small diameter magnetic gears and resulted in the need for the addition of mechanical support rings to prevent deflection. The final experimentally tested design also had a high torque ripple and the power loss within the magnetic gear did not change significantly with load. This therefore resulted in the efficiency being high only at peak loads. Despite not experimentally achieving the 2-D calculated high torque density the analysis has shown that the problems encountered with the scaling can be overcome with careful design changes. For example, understanding the unique mechanical deflection requirements during the electromagnetic design of the large diameter magnetic gears is key to achieving both a high torque density based on the electromagnetic analysis and a high torque density based on the mechanical support needs. Furthermore, ensuring that end plates are made of non-conductive material and minimizing other conductive support elements within the magnetic structure is a key requirement for reducing eddy current losses. In summary, if the mechanical design can be made more robust and eddy current loss mitigation strategies are used in the mechanical design phase then the magnetic gear is capable of being scaled up whilst operating at a very high torque density. This will then enable it to be potentially performance and cost competitive with alternative direct-drive and mechanically geared wind turbine drivetrains.
17 WIND ENERGY↗
MADE3D: Enabling the next generation of high-torque density wind generators by additive design and 3D printing
Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments—especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technolgies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.
17 WIND ENERGY↗
MADE3D: Enabling the Next-Generation High-Torque- Density Wind Generators by Additive Design and 3D Printing
Direct-drive wind turbine generators are increasing in popularity, thanks to recent project developments - especially offshore, where reliability and efficiency are major cost drivers. Yet, high capital costs are forcing many original equipment manufacturers to consider lightweight, high-torque density generators for next-generation multi-megawatt turbines that may be difficult to realize by traditional design or manufacturing methods. In this study, we present a new design framework enabled by advanced machine learning and multimaterial additive manufacturing to perform a magnetic topology optimization that maximizes the torque per rotor active mass for a 15-megawatt direct-drive permanent magnet wind generator. A comparison of the proposed approach against conventional topology optimization demonstrated a significant increase in computational efficiency and accuracy in performance predictions. Results using single and multimaterial compositions for rotor core and magnets identify a wider choice of 3D printable designs for a given specification. A hybrid combination of sintered and dysprosium-free polymer-bonded magnets shows good potential for torque performance by saving material costs up to 8.75%. More than 30% improvement in rotor torque densities is identified which can marginally improve the overall generator torque density. With the rapid evolution of multipowder deposition technologies, this study can greatly inspire a new paradigm for design-driven manufacturing with novel material compositions and lightweight, low-cost, high-strength multimaterial geometries that were previously unexplored for direct-drive generators.
3D printing↗
Ideal Radial Permanent Magnet Coupling Torque Density Analysis
This paper derives here the closed form 3-D analytical torque equations for an ideal radial Halbach rotor magnetic coupling. The performance of the radial Halbach coupling is then compared with an ideal axial Halbach rotor coupling. The closed form equations and comparison gives insight into the upper torque density limits of Nd-Fe-B based magnetic devices.
42 ENGINEERING↗
Comprehensive Report on Design and Development of a 100-kW DSSRM
Switched reluctance machines (SRMs) are low cost and fault tolerant alternatives for traction applications. Due to their relatively low torque density and high torque ripple, these machines have not been used in commercialized electrified power trains yet. The double-stator magnetic configuration, where a segmental rotor shared between two stators, is proven to have superior torque density, lower acoustic noise, and torque pulsation. The double-stator SRM (DSSRM) has a high potential of being the next generation of traction motors since it combines the advantages of permanent magnet-free machines, such as low cost and independence from supply chain issues associated with rare metals, while providing high torque and power densities. In this paper, we introduce the complete design process of a 100-kW DSSRM including electromagnetic, structural, thermal, and system level design. The performance of the developed DSSRM is verified with the experimental data. This paper presents overall study of DSSRM and describes merits of DSSRM drive system.
42 ENGINEERING↗
Evaluation of Torque-Dense Electric Machine Technology for Off-Highway Vehicle Electrification
Electrification of off-highway vehicles offers the benefits of improved energy efficiency, enhanced control, and reduction in greenhouse gas emissions. However, progress towards electrification has been limited by the low torque density (30 kNm/m 3 ) of conventional electric machines compared to mobile hydraulic machines (up to approximately 1000 kNm/m 3 ). This paper reviews emerging variants of electric machines that offer a step improvement in torque density and potential pathway to enable electrified off-highway vehicles. First, sizing approaches for electric and hydraulic machines are developed, and torque-dense electric machines reviewed in literature are compared to commercial hydraulic machines to identify design trends in terms of speed, torque density, and power density. Next, key metrics are identified for the electric machine, based on which the following four emerging electric machine variants that promise to improve torque density are reviewed: i) multi-harmonic machines injection, ii) combined radial-axial flux machines, iii) magnetic gears, and iv) magnetically-geared machines. Here, the findings from this review show that these new electric machines can achieve upwards of 300% improvement in electric machine torque density, with several designs exceeding 100 kNm/m 3 , making them worthy candidates for further research to bridge the torque density gap with hydraulic machines.
33 ADVANCED PROPULSION SYSTEMS↗
A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor
There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.
47 OTHER INSTRUMENTATION↗
Comparison of electro-thermal performance of advanced cooling techniques for electric vehicle motors
Permanent magnet synchronous motors are commonly used in the powertrain of electric vehicles because of their high power and torque densities. Attempts to increase power and torque densities beyond the state-of-the-art often suffer from thermal limitations of the adopted winding-wire insulation class. In this paper, overall effectiveness of four different cooling technologies, namely conventional stator jacket cooling, embedded circular and rectangular cooling channels within stator core, and direct winding heat exchangers have been studied numerically. Here, by realizing temperature dependent magnetic and material properties, winding and core losses, a two-way coupling algorithm has been utilized to study the detailed electro-magnetic and thermal performance of BMW i3 motor with aforementioned cooling techniques. The numerical results illustrated that the direct winding heat exchangers approach provides better electro-thermal performance in comparison to the other cooling techniques analyzed. On the contrary, embedded rectangular and circular channel in stator core adversely affect the electro-magnetic performance and overall efficiency of the motor, despite their superior thermal performance compared to the jacket cooling
42 ENGINEERING↗
Quantifying vorticity in magnetic particle suspensions driven by symmetric and asymmetric multiaxial fields.
We recently reported two methods of inducing vigorous fluid vorticity in magnetic particle suspensions. The first method employs symmetry-breaking rational fields. These fields are comprised of two orthogonal ac components whose frequencies form a rational number and an orthogonal dc field that breaks the symmetry of the biaxial ac field to create the parity required to induce deterministic vorticity. The second method is based on rational triads, which are fields comprised of three orthogonal ac components whose frequency ratios are rational (e.g., 1 : 2 : 3). For each method a symmetry theory has been developed that enables the prediction of the direction and sign of vorticity as functions of the field frequencies and phases. However, this theory has its limitations. It only applies to those particular phase angles that give rise to fields whose Lissajous plots, or principal 2-d projections thereof, have a high degree of symmetry. Nor can symmetry theory provide a measure of the magnitude of the torque density induced by the field. In this paper a functional of the multiaxial magnetic field is proposed that not only is consistent with all of the predictions of the symmetry theories, but also quantifies the torque density. This functional can be applied to fields whose Lissajous plots lack symmetry and can thus be used to predict a variety of effects and trends that cannot be predicted from the symmetry theories. These trends include the dependence of the magnitude of the torque density on the various frequency ratios, the unexpected reversal of flow with increasing dc field amplitude for certain symmetry-breaking fields, and the existence of off-axis vorticity for rational triads, such as 1 : 3 : 5, that do not have the symmetry required to analyze by symmetry theory. As a result, experimental data are given that show the degree to which this functional is successful in predicting observed trends.
36 MATERIALS SCIENCE↗
Design Considerations of a Transverse Flux Machine for Direct-Drive Wind Turbine Applications
This paper presents the design considerations of a double-sided transverse flux machine (TFM) for direct-drive wind turbine applications. The TFM has a modular structure with quasi-U stator cores and ring windings. The rotor is constructed with ferrite magnets in a flux-concentrating arrangement to achieve high air gap flux density. The design considerations for this TFM with respect to initial sizing, pole number selection, key design ratios, and pole shaping are presented in this paper. Pole number selection is critical in the design process of a TFM because it affects both the torque density and power factor under fixed magnetic and changing electrical loading. Several key design ratios are introduced to facilitate the design procedure. The effect of pole shaping on back-emf and inductance is also analyzed. These investigations provide guidance toward the required design of a TFM for direct-drive applications. The analyses are carried out using analytical and three-dimensional finite element analysis. A prototype is under construction for experimental verification.
17 WIND ENERGY↗
Novel Transverse Flux Machine for Vehicle Traction Applications: Preprint
A novel transverse flux machine topology for electric vehicle traction applications using ferrite magnets is presented in this paper. The proposed transverse flux topology utilizes novel magnet arrangements in the rotor that are similar to the Halbach array to boost flux linkage; on the stator side, cores are alternately arranged around a pair of ring windings in each phase to make use of the entire rotor flux that eliminates end windings. Analytical design considerations and finite-element methods are used for an optimized design of a scooter in-wheel motor. Simulation results from finite element analysis (FEA) show that the motor achieved comparable torque density to conventional rare-earth permanent magnet (PM) machines. This machine is a viable candidate for direct-drive applications with low cost and high torque density.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Electromagnetic analysis and experimental testing of a flux focusing wind turbine magnetic gearbox
The electromagnetic design of the second stage of a 59:1 multistage magnetic gearbox for a wind turbine demonstrator is presented here. The multistage series connected magnetic gearbox is composed of a 6.45:1 first stage and 9.14:1 second stage magnetic gear. The magnetic gears utilize a flux focusing spoke type rotor typology with a unique segmented fully laminated design. The electromagnetic impact of structural design changes on the second stage gearbox is considered with respect to torque density. Severe 3-D edge effects were encountered that greatly reduced the expect torque density of the stage 2 magnetic gear. Experimental testing of the multistage magnetic gear highlight unexpected problems associated with eddy current loss and torque ripple.
17 WIND ENERGY↗
Electromagnetic and Mechanical Design of a Hermetically Sealed Magnetic Gear for a Marine Hydrokinetic Generator
This article presents a new type of hermetically sealed magnetically geared generator typology for a marine hydrokinetic application. The proposed magnetically geared generator is composed of two series connected magnetic gearbox stages with the second stage having an integrated stator. This paper focuses only on presenting the electromagnetic design for the first stage magnetic gearbox with a 5kW (at 40RPM) rating. A volumetric and mass torque density tradeoff analysis is utilized in order to arrive at a high torque density design. The designed magnetic gearbox uses a unique laminated flux concentration inner rotor and Halbach array outer rotor typology with a 6.67:1 gear ratio. Furthermore, a mechanical deflection analysis is performed to verify that the proposed magnetic gearbox is mechanically robust.
16 TIDAL AND WAVE POWER↗
Investigating the Performance of a Fully Laminated Flux-Focusing Magnetic Gearbox
This paper presents here the design investigation and experimental testing of a flux-focusing magnetic gearbox with a fully laminated rotor structure. The unique feature of this flux-focusing magnetic gearbox design is that the three rotors are each made of a single lamination stack, and the central modulation structure is retained in place without the use of a resin filler such as epoxy. Ferromagnetic bridges are used to connect individual pole pieces together. It is shown that the use of the ferromagnetic bridges reduces the calculated torque density from 156 Nm/L to 139 Nm/L (a reduction of 11%). The experimentally measured torque density is, however, only 97 Nm/L. The reason for this discrepancy is associated with the demagnetization of the magnets.
42 ENGINEERING↗
A Novel Transverse Flux Machine for Vehicle Traction Applications
A novel transverse flux machine topology for electric vehicle traction application using ferrite magnets is presented in this paper. The proposed transverse flux topology utilizes novel magnet arrangements in the rotor that are similar to Halbach-array to boost flux linkage; on the stator side, cores are alternately arranged around a pair of ring windings in each phase to make use of the entire rotor flux that eliminates end windings. Analytical design considerations and finite element methods are used for an optimized design of a scooter in-wheel motor. Simulation results from Finite Element Analysis (FEA) show the motor achieved comparable torque density to conventional rare-earth permanent magnet machines. This machine is a viable candidate for direct drive applications with low cost and high torque density.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Calculation of AC Magnetizing Loss of ReBCO Superconducting Tapes Subjected to Applied Distorted Magnetic Fields
In recent years, there are fast-increasing concerns on the utilizations of superconducting rotating electrical machines in different application areas, such as ship propulsion systems, aircraft drivers, and wind turbine generators, since these machines exhibit the merits of high current density, compact design, high power density, light weight, high torque density as well as high efficiency. One of the main limitations in front of the vast use of superconducting tapes in the fabrication of electrical machineries is AC magnetizing loss when tapes are exposed to an external magnetic field, which can decrease the critical current density of wires, as well. In the literature, most of the research works have been done on calculation of the AC magnetizing loss under a pure external magnetic field, while in reality, magnetic flux lines in AC electrical machines are usually distorted with harmonics because of different reasons such as distorted leakage flux, distributed coils of a winding in several slots, cogging fields, mechanical faults, etc. Since these distorted fields contain harmonics, then in this paper, the AC magnetizing loss of superconducting tapes has been electromagnetically modeled and calculated when they are subjected to nonsinusoidally distorted external magnetic fields. The magnetic field dependency of critical current density has been considered in a proposed finite element model. The results have shown that the AC magnetizing loss increases significantly under a distorted applied field compared with a sinusoidal one. In addition, the loss increase depends on the harmonic content which would increases drastically with total harmonic distortion of the applied magnetic field.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
Analysis and Testing of a Coaxial Magnetic Gearbox With Flux Concentration Halbach Rotors
Halbach array magnetic gearboxes have been discussed as being able to create high torque density. However, Halbach arrays are difficult to mechanically assemble, and often the effective air gap must be made larger to provide space for a retaining sleeve. This paper investigates here the benefits of using an additional ferromagnetic retaining pole within the Halbach array structure. It is shown that utilizing this flux concentration ferromagnetic pole improves the torque density and can also help retain the magnets in place.
42 ENGINEERING↗