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Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines

A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "F: Electrical Engineering".

Deadline for manuscript submissions: 30 April 2025 | Viewed by 11384

Special Issue Editor

Prof. Dr. Damir Žarko

E-Mail Website
Guest Editor
Department of Electric Machines, Drives and Automation, Faculty of Electrical Engineering and Computing, University of Zagreb, Unska 3, 10000 Zagreb, Croatia
Interests: electric machines and drives for power systems, electromobility, aerospace and general industrial applications; design, simulation and optimization of electric machines and power transformers
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Optimization of the design and production process is essential for achieving high performance and energy efficiency in electrical machines. In this context, the design process includes the selection of suitable materials, the optimal design of machine components, and careful consideration of factors such as magnetic losses, thermal management, and electrical insulation. The production process includes the selection of appropriate manufacturing techniques, assembly procedures, and quality control measures. Optimizing these processes can lead to improved performance, reduced energy consumption, and lower production costs. Achieving these goals requires a multidisciplinary approach that includes expertise in electrical engineering, materials science, mechanical engineering, and manufacturing.

This Special Issue aims to present the most recent advances in electromagnetic, thermal, and mechanical design and production processes for the development of high-performance and energy-efficient electrical machines. The specific topics of interest include (but are not limited to) the following:

  • Development of advanced materials for improved electrical machine performance and energy efficiency;
  • Optimization of electromagnetic design for high-performance and energy-efficient electrical machines;
  • Investigation of thermal management strategies for enhancing the efficiency of electrical machines;
  • Development of advanced electrical insulation materials and techniques to improve machine performance and reliability;
  • Investigation of manufacturing processes for efficient and cost-effective production of electrical machines;
  • Development of design optimization algorithms to improve machine performance and reduce energy consumption;
  • Evaluation of the impact of design and production process variations on electrical machine performance and energy efficiency;
  • Investigation of the impact of operating conditions on electrical machine performance and energy efficiency;
  • Investigation of the impact of new technologies, such as artificial intelligence and machine learning, on the design and production process optimization of electrical machines.

Prof. Dr. Damir Žarko
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Energies is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • electrical machines
  • design optimization
  • production process optimization
  • high performance
  • energy efficiency
  • advanced materials
  • electromagnetic design
  • electrical insulation
  • manufacturing processes
  • design optimization algorithms
  • artificial intelligence
  • machine learning

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Published Papers (7 papers)

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Research

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21 pages, 10477 KiB  
Article
Development of an Experimental Acoustic Noise Characterization Setup for Electric Motor Drive Applications
by Moien Masoumi, Abeka Selliah and Berker Bilgin
Energies 2024, 17(21), 5371; https://doi.org/10.3390/en17215371 - 29 Oct 2024
Viewed by 472
Abstract
This paper presents the development of an experimental setup for acoustic noise characterization of electric motors. It describes the sound measurement microphones utilized in the setup and discusses the application of octave bands and A-weighting in noise measurement. Various methods for acoustic noise [...] Read more.
This paper presents the development of an experimental setup for acoustic noise characterization of electric motors. It describes the sound measurement microphones utilized in the setup and discusses the application of octave bands and A-weighting in noise measurement. Various methods for acoustic noise measurement and sound power calculation, including those based on sound pressure and sound intensity, are also covered. Given the relatively noisy test environment and restricted access around the test setup, discrete point sound intensity measurement is selected for sound power calculation. Initially, a stationary probe-holding fixture is designed and fabricated for sound intensity measurements. To enhance the fixture’s flexibility and the accuracy of the measurements, a transportable fixture is subsequently designed and fabricated. The necessary hardware and software settings for acoustic noise characterization are then developed. Finally, the setup is used to conduct acoustic noise characterization of an IPM motor, validating the application of the transportable probe-holding fixture. Full article
(This article belongs to the Special Issue Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines)
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23 pages, 11603 KiB  
Article
Electromagnetic Design Optimization Integrated with Mechanical Stress Analysis of PM-Assisted Synchronous Reluctance Machine Topologies Enabled with a Blend of Magnets
by Praveen Kumar, Robin Wilson and Ayman EL-Refaie
Energies 2024, 17(8), 1873; https://doi.org/10.3390/en17081873 - 14 Apr 2024
Cited by 1 | Viewed by 1106
Abstract
Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance [...] Read more.
Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option. Full article
(This article belongs to the Special Issue Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines)
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17 pages, 5849 KiB  
Article
In Search of the Proper Dimensions of the Optimum In-Wheel Permanent Magnet Synchronous Motor Design
by Ali Sinan Cabuk and Ozgur Ustun
Energies 2024, 17(5), 1106; https://doi.org/10.3390/en17051106 - 26 Feb 2024
Viewed by 1308
Abstract
In this paper, a new approach to the optimized design of outer rotor Permanent Magnet Synchronous Motors (PMSMs) for in-wheel light electric vehicle (LEV) applications is presented. The optimized design study is based on various dimensions such as back iron depth, permanent magnet [...] Read more.
In this paper, a new approach to the optimized design of outer rotor Permanent Magnet Synchronous Motors (PMSMs) for in-wheel light electric vehicle (LEV) applications is presented. The optimized design study is based on various dimensions such as back iron depth, permanent magnet depth and air gap length. The novel method is developed to reveal the quality factor of design (QFD), which implies the maximum possible performance results, and determine the best possible design for in-wheel PMSMs for direct-drive LEV applications. Therefore, the thickness of the back iron, permanent magnet and air gap dimensions are altered accordingly to obtain an optimized design. This design study is conducted for an in-wheel PMSM that has rated values of 2.5 kW, 150 V, 900 min−1, and 24-slot/20-pole configuration intended for LEV propulsion. These designs are simulated in order to obtain the maximized combination of efficiency, shaft power, shaft torque and a minimized combination of total weight, iron losses, copper losses, input current and cogging torque. The measure of the optimized parameters is named QFD, which indicates the goodness of the design through the use of radar charts. The values of the essential coefficients of QFD may vary for different applications, e.g., the design of PMSMs used in traction applications has some certain criteria that imply high-performance operation. Additionally, the QFD can guide motor manufacturers as a starting point for a design study. Full article
(This article belongs to the Special Issue Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines)
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13 pages, 13806 KiB  
Article
Electromagnetic Characterization of Silicon–Iron Additively Manufactured Cores for Electric Machines
by Daniele Michieletto, Luigi Alberti, Filippo Zanini and Simone Carmignato
Energies 2024, 17(3), 650; https://doi.org/10.3390/en17030650 - 30 Jan 2024
Cited by 3 | Viewed by 1034
Abstract
This paper deals with the electromagnetic characterization of a laminated toroidal ferromagnetic core made through additive manufacturing, specifically using the laser powder bed fusion process. The continuing demand for increasingly efficient, lightweight, and higher performance electric machines is creating huge challenges in the [...] Read more.
This paper deals with the electromagnetic characterization of a laminated toroidal ferromagnetic core made through additive manufacturing, specifically using the laser powder bed fusion process. The continuing demand for increasingly efficient, lightweight, and higher performance electric machines is creating huge challenges in the design and realization of new electric motor solutions. The constant improvements in additive manufacturing technologies have prompted researchers to investigate the possibility of adopting these production techniques for the manufacture of high-value electric motors. For these reasons, this paper investigates the ferromagnetic characteristics of an additively manufactured core made with FeSi6.5 powder. The BH curve and the specific iron losses of the processed material have been measured so that they can be compared with a commercial lamination, and have the possibility of carrying out more precise finite element simulations. Full article
(This article belongs to the Special Issue Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines)
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16 pages, 5462 KiB  
Article
Investigation of the Electrochemical and Thermal Characteristics of NCM811-21700 Cylindrical Lithium-Ion Battery: A Numerical Study and Model Validation
by Jie Liu, Santosh Chavan and Sung-Chul Kim
Energies 2023, 16(17), 6407; https://doi.org/10.3390/en16176407 - 4 Sep 2023
Cited by 4 | Viewed by 2588
Abstract
Recently, there has been growing recognition of the significance of energy and environmental challenges. Utilization of lithium-ion batteries in electric vehicles has shown considerable potential and benefits for tackling these issues. The effective management of battery temperature has become a crucial factor in [...] Read more.
Recently, there has been growing recognition of the significance of energy and environmental challenges. Utilization of lithium-ion batteries in electric vehicles has shown considerable potential and benefits for tackling these issues. The effective management of battery temperature has become a crucial factor in the advancement and widespread adoption of lithium-ion batteries in electric vehicles. In this study, a thermo-coupled pseudo-two-dimensional (P2D) electrochemical model is employed to simulate the heat generation of the NCM811-21700 cylindrical battery cell at various discharge rates at an ambient temperature of 25 °C, and is validated by experimental data. The validation results demonstrate that the thermo-coupled P2D model can effectively predict the battery voltage curve during the discharge process with less than 4% errors. Although there is a slightly larger error in the temperature prediction during the battery 2C and 3C discharge processes, the maximum error approaches 10%, which is still generally within an acceptable range. In addition, the battery’s electrochemical and thermal characteristics during discharge are presented. The suggested thermo-coupled electrochemical model can be used for applications in the thermal management system of the NCM811-21700 battery. Full article
(This article belongs to the Special Issue Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines)
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12 pages, 1322 KiB  
Review
Influence of Electric Motor Manufacturing Tolerances on End-of-Line Testing: A Review
by Nusrat Rezwana Shahreen Popsi, Animesh Anik, Rajeev Verma, Caniggia Viana, K. Lakshmi Varaha Iyer and Narayan C. Kar
Energies 2024, 17(8), 1913; https://doi.org/10.3390/en17081913 - 17 Apr 2024
Cited by 2 | Viewed by 1699
Abstract
Electric vehicles (EVs) are propelled by electric traction drive systems (ETDSs), which consist of various components including an electric motor, power electronic converter, and gear box. During manufacturing, end-of-line testing is the ultimate step for ensuring the quality and performance of electric motors [...] Read more.
Electric vehicles (EVs) are propelled by electric traction drive systems (ETDSs), which consist of various components including an electric motor, power electronic converter, and gear box. During manufacturing, end-of-line testing is the ultimate step for ensuring the quality and performance of electric motors in electric vehicle (EV) traction drive systems (ETDSs). The outcome of end-of-line testing of electric motors is significantly influenced by the tolerances of their structural parameters, such as stator inner and outer diameters, magnet dimensions, air gaps, and other geometric parameters. The existing literature provides insights into parametric sensitivity, offering guidance for enhancing the reliability of end-of-line testing. In this manuscript, the importance of end-of-line testing and the role of manufacturing tolerances of e-motor structural parameters in the manufacturing process of ETDSs are discussed. The impact of tolerances of e-motor structural parameters on the test results, such as torque, efficiency, back EMF, and e-NV (noise and vibration), is investigated. Finally, key challenges and research gaps in this area are identified, and recommendations for future research to mitigate the drawbacks of end-of-line testing are provided. Full article
(This article belongs to the Special Issue Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines)
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19 pages, 6644 KiB  
Review
Cogging Torque Reduction Techniques in Axial Flux Permanent Magnet Machines: A Review
by Franjo Pranjić and Peter Virtič
Energies 2024, 17(5), 1089; https://doi.org/10.3390/en17051089 - 24 Feb 2024
Cited by 2 | Viewed by 2134
Abstract
Axial flux permanent magnet machines have garnered significant attention in recent years due to their numerous advantages in various applications, including electric vehicles, wind turbines, and robotics. However, one of the critical challenges associated with these machines is the presence of cogging torque, [...] Read more.
Axial flux permanent magnet machines have garnered significant attention in recent years due to their numerous advantages in various applications, including electric vehicles, wind turbines, and robotics. However, one of the critical challenges associated with these machines is the presence of cogging torque, which can hinder their efficiency and performance. This review article provides a comprehensive overview of the state-of-the-art techniques employed for cogging torque reduction in Axial Flux Permanent Magnet Machines. Different techniques are described, encompassing geometric optimization, magnet placement, and skewing methods. Firstly, the significance of Axial Flux Permanent Magnet Machines is described, as well as the issue of the cogging torque. In the methods section, a review of the strategies for the reduction of cogging torque is described from various articles, and finally, in the discussion section, a list of actions is presented for cogging torque reduction for different topologies. The novelty of the study is that it combines strategies for cogging torque reduction in a single article. Full article
(This article belongs to the Special Issue Design and Production Process Optimization for High Performance and Energy Efficiency in Electrical Machines)
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