Electrical Machine Design Pdf
Cherly Fleitas
Abstract:Electrical machines are the hearts of many appliances, industrial equipment and systems. In the context of global sustainability, they must fulfill various requirements, not only physically and technologically but also environmentally. Therefore, their design optimization process becomes more and more complex as more engineering disciplines/domains and constraints are involved, such as electromagnetics, structural mechanics and heat transfer. This paper aims to present a review of the design optimization methods for electrical machines, including design analysis methods and models, optimization models, algorithms and methods/strategies. Several efficient optimization methods/strategies are highlighted with comments, including surrogate-model based and multi-level optimization methods. In addition, two promising and challenging topics in both academic and industrial communities are discussed, and two novel optimization methods are introduced for advanced design optimization of electrical machines. First, a system-level design optimization method is introduced for the development of advanced electric drive systems. Second, a robust design optimization method based on the design for six-sigma technique is introduced for high-quality manufacturing of electrical machines in production. Meanwhile, a proposal is presented for the development of a robust design optimization service based on industrial big data and cloud computing services. Finally, five future directions are proposed, including smart design optimization method for future intelligent design and production of electrical machines.Keywords: electrical machines; multi-level optimization; multi-objective optimization; system-level optimization; manufacturing variations; manufacturing quality; robust optimization; industrial big data; cloud computing
This work presents a finite element analysis-based, topology optimization (TO) methodology for the combined magnetostatic and structural design of electrical machine cores. Our methodology uses the Bi-directional Evolutionary Structural Optimization (BESO) heuristics to remove inefficient elements from a meshed model based on elemental energies. The algorithm improves the average torque density while maintaining structural integrity. To the best of our knowledge, this work represents the first effort to address the structural-magnetostatic problem of electrical machine design using a free-form approach. Using a surface-mounted permanent magnet motor (PMM) as a case study, the methodology is first tested on linear and nonlinear two-dimensional problems whereby it is shown that the rapid convergence achieved makes the algorithm suitable for real-world applications. The proposed optimization scheme can be easily extended to three dimensions, and we propose that the resulting designs are suitable for manufacturing using selective laser melting, a 3D printing technology capable of producing fully dense high-silicon steel components with good soft magnetic properties. Three-dimensional TO results show that the weight of a PMM rotor can be slashed by 50% without affecting its rated torque profile when the actual magnetic permeability of the 3D-printed material is considered.
Through a building-block teaching approach, you will develop a basic understanding of AC electric machine design. By learning the core concepts of electromagnetic laws for machine design, magnetic circuit calculations, loss mechanisms, analytical design techniques, and other essential topics, you will improve your skills, and ultimately, your work. Recent developments in AC electric machine design also will be covered in this course.
Dan M. Ionel, PhD, FIEEE, is currently Chief Engineer for Regal Beloit Corp., and Visiting Professor at the University of Wisconsin in Milwaukee. After completing post-doctoral research in the SPEED Laboratory, University of Glasgow, UK, Dr. Ionel worked in industrial R&D for large corporations in the UK and the US, most recently as Chief Scientist for Vestas. His design experience covers a wide range of electric machines and drives for various applications with power ratings between 0.002 hp and 10,000 hp. Dr. Ionel published more than 100 technical papers, including two winners of Best Paper Awards from the IEEE Industry Applications Society Electric Machines Committee, and holds more than 30 patents. An IEEE Fellow, he is the Chair-Elect of the IEEE Power and Energy Society Electric Motor Sub-committee, Chair of the Milwaukee IEEE Power Electronics Chapter, and Editor-in-Chief of the Electric Power Components and Systems Journal.
Dr. Jahns joined the faculty of the University of Wisconsin-Madison in 1998 in the Department of Electrical and Computer Engineering. He served for 14 years as a Co-Director of the Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC), a world-renowned university/industry consortium in the electrical power engineering field. Since 2021, he is the Grainger Emeritus Professor of Power Electronics and Electrical Machines.
Darren Tremelling, Ph.D. is currently a Principal Scientist in ABB Corporate Research.
After completing his doctorate in WEMPEC, University of Wisconsin - Madison, Dr. Tremelling has worked in ABB Corporate Research. His research experience covers a range of electric machines for various applications with power ratings between 1 [kW] to 7 [MW].
The Electrical Machines Team specialize in linear & rotating electrical machine design, physics- based control and diagnostics and the integration of magnetics, materials and thermal technologies. With deep capabilities in machine controls, signal processing and high speed & high torque testing, the Team provides breakthrough electromechanical conversion solutions in torque density, high speed and extreme environment designs as well as for hybrid electric propulsion, actuation for robotics and reduced OPEX for oil & gas machines.
The breadth of electrical machines across GE's product portfolio is significant and gives scientists and engineers on the Team broad exposure and experience innovating across many different industry sectors. Their contributions are helping to promote everything from clean renewable wind power to the future of hybrid electric flight. And as GE expands its scope of work with new strategic partners outside of GE, the Team' could have impact in other spaces as well such as electric transportation.
Electrical machines and electrical drive trains are inherently multiphysical. Therefore, to completely determine the behavior of such devices, analyses have to be performed in multiple physical domains. Besides system-level aspects such as controlling the electrical machine and running drive cycle analysis, cooling and noise and vibration (NV) behavior also have to be addressed. In all of these disciplines, a detailed knowledge of the behavior of the electrical machine in the electromagnetic domain is key.
Biological computing machines, such as micro and nano-implants that can collect important information inside the human body, are transforming medicine. Yet, networking them for communication has proven challenging. Now, a global team, including ECE graduate student Jiaming Wang, has developed a protocol that enables a molecular network with multiple transmitters.
ECE Professor Philip T Krein and Associate Professor Patrick Lyle Chapman recently received funding from the Office of Naval Research to further investigations dedicated to improving electric machine design. As a result, the University of Illinois, in collaboration with the Georgia Institute of Technology and Purdue University, will become one of the few institutions in the nation preparing new electromechanics design applications for the next generation of engineers.
In addition to developing mathematical models to facilitate machine design, Krein and Chapman have made efforts to assemble a national consortium dedicated to the modern design of electric machines for the past two years. After all, their objective to update machine design has been a key focus of the Grainger Center, which has focused on improving education, technology, and research activities for electric machinery, since it was formed in 1999.
Over the years, Krein and Chapman have sought ways to bring all of the new advances in technology into effect. As a result, they decided to focus their research on 4D design tools, in which time and operating dynamics become the fourth dimension.
Through their ongoing research, Krein and Chapman hope to eventually produce tools that will enable a competent engineer to design electric machines that are light and inexpensive, with improved performance.
"We really want to leverage the advances we have in control electronics," Chapman said. "We hope to take a machine that was designed with a very standard old standby method and compare it to our new design methods that show a very clear cut advantage."
Krein and Chapman invited Georgia Institute of Technology and Purdue University to participate in the research project for a variety of reasons. Georgia Tech is one of the few institutions that still teaches a course on motor design. It is home to Professor Ron Harley, one of the last remaining experts on the design of electric machines. Meanwhile, Purdue has worked with the Office of Naval Research and other organizations interested in updating machine design for many years. Chapman said that the three institutions will each look at different angles of electric machine design.
In the future, Krein and Chapman hope to rebuild their courses to reflect their ongoing research and developments in the field. In fact, the pair is currently designing a textbook for undergraduate education that includes sections of electric machine design. The book, entitled Electromechanics: The Science and Engineering of Electrical Forces and Motion, is scheduled to be available in late 2009.
Key technologies covered include computer-aided design and manufacturing (CAD/CAM), electrical and electronics, fastening and joining, fluid power, manufacturing, engineered materials, mechanical engineering, and motion control.
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