Multiphysics Simulation by Design for Electrical Machines, Power Electronics and Drives

Dr. Marius Rosu, Dr. Ping Zhou, Dr. Dingsheng Lin, Dr. Dan M. Ionel, Dr. Mircea Popescu, Dr. Frede Blaabjerg, Dr. Vandana Rallabandi, Dr. David Staton

• Publisher: Wiley-IEEE Press
• Year: 2017
• Print ISBN: 9781119103448
• eBook ISBN: 9781119103486
• Edition: 1
• Topic: Scienze fisiche
• Subtopic: Energia

Presents applied theory and advanced simulation techniques for electric machines and drives

This book combines the knowledge of experts from both academia and the software industry to present theories of multiphysics simulation by design for electrical machines, power electronics, and drives. The comprehensive design approach described within supports new applications required by technologies sustaining high drive efficiency. The highlighted framework considers the electric machine at the heart of the entire electric drive. The book also emphasizes the simulation by design concept—a concept that frames the entire highlighted design methodology, which is described and illustrated by various advanced simulation technologies.

Multiphysics Simulation by Design for Electrical Machines, Power Electronics and Drives begins with the basics of electrical machine design and manufacturing tolerances. It also discusses fundamental aspects of the state of the art design process and includes examples from industrial practice. It explains FEM-based analysis techniques for electrical machine design—providing details on how it can be employed in ANSYS Maxwell software. In addition, the book covers advanced magnetic material modeling capabilities employed in numerical computation; thermal analysis; automated optimization for electric machines; and power electronics and drive systems. This valuable resource:

• Delivers the multi-physics know-how based on practical electric machine design methodologies
• Provides an extensive overview of electric machine design optimization and its integration with power electronics and drives
• Incorporates case studies from industrial practice and research and development projects

Multiphysics Simulation by Design for Electrical Machines, Power Electronics and Drives is an incredibly helpful book for design engineers, application and system engineers, and technical professionals. It will also benefit graduate engineering students with a strong interest in electric machines and drives.

CHAPTER 1
Basics of Electrical Machines Design and Manufacturing Tolerances

1.1 Introduction

Recent progress in the area of electric machines, including new materials, manufacturing technologies, and conceptual topologies, require a systematic design approach to ensure improved performance and/or reduced cost for new developments. This chapter discusses fundamental aspects of the state-of-the-art design process and includes examples from industrial practice and case studies in order to introduce basic concepts and methods.

Traditionally, the core of electric machines is manufactured by punching and stacking thin laminations of cold rolled or silicon steel, as illustrated in Figure 1.1 [1]. Even with the rotor laminations nested inside the stator ones, the process results in a relatively large amount of steel being scraped due to the slots and outer stator profile. Depending on the machine type and design topology, in the rotor, permanent magnets (PM) maybe inserted or attached to the core, an electrically conductive cage maybe die-cast from aluminum, for example, or a winding (not applicable for the design shown in Figure 1.1) maybe inserted. The stator typically incorporates a collection of coils made of conductive wires separated by electrical insulation and forming a winding. A multiphase distributed winding, such as the one exemplified in Figure 1.1, maybe manufactured by automatically producing the coils and then inserting them into the core, in a process that has high through output, and results in a relatively high ratio of net conductor per slot area, that is, slot fill factor, but also yields relatively large end coils.

Figure 1.1 Typical steps for the manufacturing of an electric machine, in this case a line-fed permanent magnet (PM) synchronous motor, which includes in the rotor a die-cast aluminum cage.

In order to reduce the scrap of laminated steel, different punching arrangements may be employed. The example shown in Figure 1.2 is particularly advantageous for stator designs with relatively large tooth width and small tooth tips. Modules of core and concentrated coils, each wound around a tooth, can be organized with a single or multiple teeth, formed to shape, and then assembled to produce a stator, such as the three-phase 18-slot design example from Figure 1.2, which is suitable to be used together with a 16-pole PM rotor [2,3].

Figure 1.2 Example of stator modular construction with segmented core and concentrated coils forming a multiphase winding [2,3]. Versions with a single tooth and...

Table of contents

• Cover
• IEEE Press
• Title page
• Copyright
• Acknowledgments
• Preface
• CHAPTER 1 Basics of Electrical Machines Design and Manufacturing Tolerances
• CHAPTER 2 Fem-Based Analysis Techniques for Electrical Machine Design
• CHAPTER 3 Magnetic Material Modeling
• CHAPTER 4 Thermal Problems in Electrical Machines
• CHAPTER 5 Automated Optimization for Electric Machines
• CHAPTER 6 Power Electronics and Drive Systems
• Index
• IEEE Press Series on Power Engineering
• EULA