Geometrical and dimensional tolerance analysis for the radial flux type of permanent magnet generator design

Mechanical tolerance is something that should be carefully taken into consideration and cannot be avoided in a product for manufacturing and assembly needs, especially in the design stage, to avoid excessive dimensional and geometric deviations of the components made. This paper discusses how to determine and allocate dimensional and geometric tolerances in the design of a 10 kW, 500 rpm radial flux permanent magnet generator prototype components. The electrical and mechanical design results in the form of the detailed nominal dimensions of the generator components, and the allowable air gap range are used as input parameters for tolerance analysis. The values of tolerance allocation and re-allocation process are carried out by considering the capability of the production machine and the ease level of the manufacturing process. The tolerance stack-up analysis method based on the worst case (WC) scenario is used to determine the cumulative effect on the air gap distance due to the allocated tolerance and to ensure that the cumulative effect is acceptable so as to guarantee the generator's functionality. The calculations and simulations results show that with an air gap of 1 ± 0.2 mm, the maximum air gap value obtained is 1.1785 mm, and the minimum is 0.8 mm. The smallest tolerance value allocation is 1 µm on the shaft precisely on the FSBS/SRBS feature and the rotor on the RPMS feature. In addition, the manufacturing process required to achieve the smallest tolerance allocation value is grinding, lapping, and polishing processes.

The Analytical Comparative Analysis of Electromagnetic Characteristics of Four Typical Radial Flux Permanent Magnet Eddy Current Couplers

The analytical model of a permanent magnet eddy current coupler (PMECC) is mainly used for evaluation of its characteristics and the initial optimization of design. Based on the equivalent magnetic circuit method, this paper carries out analytical modeling for four typical PMECCs composed of surface-mounted and interior permanent magnet, slotted and non-slotted conductor rotors, which provides a theoretical basis for the subsequent research in this paper. The basic electromagnetic characteristics of the PMECCs are investigated by the established analytical model. Simultaneously, the analytical results about permeance, flux density, torque and power are verified by FEA simulation. The analysis results show that the slotted CR will obtain a much higher power density, and the iron loss mainly exists in the CRs. In addition, the analytical and FEA results agree well, which proves the reliability of the proposed, nearly unified analytical model.

Design and simulation of 5kW BLDC motor with half-buried permanent magnets using an existing stator body

<span lang="EN-US">This paper proposes a design of a 5 kW, 100 volts brushless direct current (DC) (BLDC) motor using an existing stator connected to an inverter and equipped with Hall sensors. The stator is a radial flux motor-type with 54 slots positioned at the outer side of the machine. In this case, the design is focused on the rotor components and winding configuration. However, the inverter aspects are also taken into account. At the same time, it considers the expected outputs: voltage, power, speed; and some limitations: maximum current and flux density. Finite element magnetic-based simulation is performed to extract the magnetic flux distribution, and analytical calculations are then conducted to obtain the output values and characteristics. The results show the BLDC motor at nominal speed produces 5.1 kW output power with 122.34 V voltages, 97.09% efficiency, and torque of 32.82 Nm. The maximum torque and rotation speeds are 51.39 Nm and 4,150 rpm respectively, while the peak-to-peak cogging force is 1.35 Nm. It can be concluded that the BLDC motor has a good performance and is compatible with the connected inverter.</span>

Experimental verification of theoretical approaches for radial gravity currents draining from an edge

We present an experimental study of inertial gravity currents (GCs) propagating in a cylindrical wedge under different drainage directions (inward/outward), lock-release (full/partial gate width) and geometry (annulus/full cylinder). We investigate the following combinations representative of operational conditions for dam-break flows: (i) inward drainage, annular reservoir, full gate; (ii) outward drainage, full reservoir, full gate; and (iii) outward drainage, full reservoir, partial gate. A single-layer shallow-water (SW) model is used for modelling the first two cases, while a box model interprets the third case; the results of these approximations are referred to as “theoretical”. We performed a first series of experiments with water as ambient fluid and brine as intruding fluid, measuring the time evolution of the volume in the reservoir and the velocity profiles in several sections; in a second series, air was the ambient and water was the intruding fluid. Careful measurements, accompanied by comparisons with the theoretical predictions, were performed for the behaviour of the interface, radial velocity and, most important, the volume decay $${\mathcal {V}}(t)/{\mathcal {V}}(0)$$ V ( t ) / V ( 0 ) . In general, there is good agreement: the theoretical volume decay is more rapid than the measured one, but the discrepancies are a few percent and the agreement improves as the Reynolds number increases. Velocity measurements show a trend correctly reproduced by the SW model, although often a delay is observed and an over- or under-estimation of the peak values. Some experiments were conducted to verify the role of inconsistencies between experimental set-up and model assumptions, considering, for example, the presence or absence of a top lid, wedge angle much less than $$2\pi $$ 2 π , suppression of the viscous corner at the centre, reduction of disturbances in the dynamics of the ambient fluid: all these effects resulted in negligible impacts on the overall error. These experiments provide corroboration to the simple models used for capturing radial drainage flows, and also elucidate some effects (like oscillations of the radial flux) that are beyond the resolution of the models. This holds also for partial width lock-release, where axial symmetry is lost.

Influence of a Winding Short-Circuit Fault on Demagnetization Risk and Local Magnetic Forces in V-Shaped Interior PMSM with Distributed and Concentrated Winding

This paper presents a comparison of 30/8 and 12/8 AC permanent magnet motors with distributed (DW) and concentrated winding (CW) designed for electric vehicle traction. Both prototypes are based on an interior permanent magnet (IPM) motor topology and contain V-shape magnets. The radial flux AC IPM motors were designed for an 80 kW propulsion system to achieve 125 N·m. Finite element models (FEM) used to design the geometry of IPM motors and the required useful parameters of electric motors are widely investigated. The accuracy of finite element models is verified and validated on the basis of test data. Numerical simulations of healthy and faulty operation states, and studies of winding faults based on the FEM offer a deeper understanding of the associated phenomena. Therefore, in this paper, a short-circuit fault in a stator winding was simulated to investigate the transient currents under an external load collapse, for all winding phases. These simulations were used to define other important machine parameters to improve mechanical reliability of the motors and to assess the potential risk of permanent magnet (PM) demagnetization. Furthermore, the analysis of local magnetic forces affecting the PMs in the rotor and their possible displacement in a short-circuit situation were performed, also taking into account the centrifugal force. Lastly, it is demonstrated that the choice of winding configuration has a significant impact on the uncontrolled displacement of magnets in the rotor.

Design and Analysis of a Novel Axial-Radial Flux Permanent Magnet Machine with Halbach-Array Permanent Magnets

Electric machines with high torque density are needed in many applications, such as electric vehicles, electric robotics, electric ships, electric aircraft, etc. and they can avoid planetary gears thus reducing manufacturing costs. This paper presents a novel axial-radial flux permanent magnet (ARFPM) machine with high torque density. The proposed ARFPM machine integrates both axial-flux and radial-flux machine topologies in a compact space, which effectively improves the copper utilization of the machine. First, the radial rotor can balance the large axial forces on axial rotors and prevent them from deforming due to the forces. On the other hand, the machine adopts Halbach-array permanent magnets (PMs) on the rotors to suppress air-gap flux density harmonics. Also, the Halbach-array PMs can reduce the total attracted force on axial rotors. The operational principle of the ARFPM machine was investigated and analyzed. Then, 3D finite-element analysis (FEA) was conducted to show the merits of the ARFPM machine. Demonstration results with different parameters are compared to obtain an optimal structure. These indicated that the proposed ARFPM machine with Halbach-array PMs can achieve a more sinusoidal back electromotive force (EMF). In addition, a comparative analysis was conducted for the proposed ARFPM machine. The machine was compared with a conventional axial-flux permanent magnet (AFPM) machine and a radial-flux permanent magnet (RFPM) machine based on the same dimensions. This showed that the proposed ARFPM machine had the highest torque density and relatively small torque ripple.