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

Deadline for manuscript submissions: closed (31 December 2020) | Viewed by 45607

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Dr. João Filipe Pereira Fernandes

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Guest Editor

Instituto de Engenharia Mecânica (IDMEC), Instituto Superior Técnico (IST), Universidade Lisboa (UL), Lisbon, Portugal
Interests: electrical machines design and optimization; core and coreless superconducting machines; alternative for rare-earth electrical machines; special materials to reduce saturation in the magnetic circuit core; electrical machines for aircraft and automotive applications
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Special Issue Information

Dear Colleagues,

The interest for higher-performance electrical machines is a constant challenge among the research and industrial communities. This challenge has been enhanced with the emergent and even more critical electrification of modern transportation systems, as for example in the aircraft and in automobile industries, thus creating the need for new designs of electrical machines and to spread their current electromagnetic, thermal, and mechanical limits.

The development of new electromagnetic materials and the significant growth of computational resources have been key aspects contributing to overcoming this challenge. The Guest Editor is inviting submissions to a Special Issue of Energies on the subject area of “Electrical Machine Design 2020”. This Special Issue will deal with novel designs and optimization techniques and with the application of new electromagnetic materials for electrical machines. Topics of interest for publication include but are not limited to:

Techniques for electrical machines design and optimizations;
FEM, BEM, and analytical methods;
Multiphysic coupled simulation and optimization;
Electromagnetic, thermal, and mechanical simulations;
Application of new magnetic material and soft magnetic materials;
Novel machine configurations and topologies;
Electrical machines design for aircraft and automotive applications;
Alternative for rare-earth electrical machines.

Prof. Dr. João Filipe Pereira Fernandes
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

techniques for electrical machines design and optimizations
FEM, BEM, and analytical methods
multiphysic coupled simulation and optimization
electromagnetic, thermal, and mechanical simulations
application of new magnetic material and soft magnetic materials
novel machine configurations and topologies
electrical machines design for aircraft and automotive applications
alternative for rare-earth electrical machines

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Published Papers (11 papers)

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Editorial

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13 pages, 4795 KiB

Open AccessEditorial

Recent Developments in Electrical Machine Design for the Electrification of Industrial and Transportation Systems

by João F. P. Fernandes, Pedro P. C. Bhagubai and Paulo J. C. Branco

Energies 2022, 15(17), 6390; https://doi.org/10.3390/en15176390 - 1 Sep 2022

Cited by 8 | Viewed by 2392

Abstract

The electrification of the industrial and transportation systems has been an important path toward mitigating climate change [...] Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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Research

Jump to: Editorial

28 pages, 16263 KiB

Open AccessArticle

Synchronous Reluctance Machines for Automotive Cooling Fan Systems: Numerical and Experimental Study of Different Slot-Pole Combinations and Winding Types

by Florin Pop-Pîgleşan, Adrian-Cornel Pop and Claudia Marțiş

Energies 2021, 14(2), 460; https://doi.org/10.3390/en14020460 - 16 Jan 2021

Cited by 8 | Viewed by 3544

Abstract

In this paper a side-by-side comparison between synchronous reluctance machines (SynRMs) with concentrated and distributed windings is performed. The characteristics, parameters, and the installation space of a permanent magnet synchronous machine (PMSM) with concentrated windings used in a 13 V automotive cooling fan system (CFMs) are used as requirements and specifications. For that, eight SynRMs with different stator and rotor topologies are investigated and optimized by means of FE-based electromagnetic optimization. Knowing the challenges associated with the development of mechanically stable SynRM rotor structures, for two selected cross-sections in view of being prototyped, designs checks are performed to ensure robust operation at up to two times the required operating speed. The simulated results were verified by means of measurements performed using two different types of loading systems, i.e., with the real ventilator and using a DC machine as a load. Based on this, the relative differences between all three motor technologies in terms of important quantities (e.g., torque-speed characteristic, torque ripple, efficiency, power factor and ultimately the size) are highlighted. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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22 pages, 6746 KiB

Open AccessArticle

Impact of Current Density and Cooling on the Weight Balance of Electrical Propulsion Drives for Aviation

by Jan Hoffmann, Wolf-Rüdiger Canders and Markus Henke

Energies 2020, 13(22), 6149; https://doi.org/10.3390/en13226149 - 23 Nov 2020

Cited by 6 | Viewed by 3530

Abstract

Through applying an exemplary design study, the dependencies between current density, temperatures, and weight in an electrical drive system for a small range aircraft with conventional electrical fan or propeller drives are evaluated. This study applies a combined numerical (Finite Element Method FEM) and analytical approach to the machine design, calculation of temperatures, and cooling system design (cooler, pumps, piping). A design scenario was defined using start and climb flight in a warm tropical surrounding as the worst load case. The design has to move between two fixed temperature limits: The maximum allowable temperature in the machine insulation and the ambient temperature. The implemented method facilitates a comparatively fast-medium depth design of the drive system. The derived results show, in fact, a minimum of weight at a certain current density, which is one of the key interests for the designers of the electrical machine. The main influences on this minimum are the temperature drops in the machine, the heat transfer to the cooling fluid, the heat transfer to the cooler wall, and the remaining heat rejection to the ambient. Method and results are transferable to other types of airplanes with different ratings. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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22 pages, 7792 KiB

Open AccessArticle

Optimization Methodology of PMSM Cooled by External Convection in Aircraft Propulsion

by Luigi Pio Di Noia, Luigi Piegari and Renato Rizzo

Energies 2020, 13(15), 3975; https://doi.org/10.3390/en13153975 - 2 Aug 2020

Cited by 8 | Viewed by 2539

Abstract

Nowadays, the reduction of aircraft emissions is one of the industrial targets with a horizon time until 2050. The recent progresses in electrical drives give the opportunity to modify the aircraft propulsion based on thermal engine or gas turbine to a hybrid/full electric one. Some problems must be solved: weight, reliability, and the choice of the best configuration for the electric propulsion. One of the most important aspects to solve is the thermal behavior of power converters and electric motors. This paper proposes an optimization procedure for the design of surface permanent magnet motors used for the aircraft propulsion: the aim of the paper is to investigate the possibility of cooling the motor with only the air flow due to the aircraft speed. The optimization procedure has been solved with the integration of analytical model and finite element analysis and using a differential evolution algorithm. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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17 pages, 2934 KiB

Open AccessArticle

Detection of Partial Demagnetization Faults in Five-Phase Permanent Magnet Assisted Synchronous Reluctance Machines

by Carlos Candelo-Zuluaga, Jordi-Roger Riba, Dinesh V. Thangamuthu and Antoni Garcia

Energies 2020, 13(13), 3496; https://doi.org/10.3390/en13133496 - 6 Jul 2020

Cited by 8 | Viewed by 3817

Abstract

This paper analyzes partial demagnetization faults in a five-phase permanent magnet assisted synchronous reluctance motor (fPMa-SynRM) incorporating ferrite permanent magnets (PMs). These faults are relevant because of the application of field weakening, or due to high operating temperatures or short circuit currents, the PMs can become irreversibly demagnetized, thus affecting the performance and safe operation of the machine. This paper proposes fault indicators to detect such fault modes with low demagnetization levels between 5.0% to 16.7% relative demagnetization. Four partial demagnetization fault detection methods are tested, which are based on the analysis of the harmonic content of the electromotive force (EMF) under no load conditions, the harmonic content of the line currents, the harmonic content of the zero-sequence voltage component (ZSVC) and the analysis of the power factor (PF). This work also compares the sensitivity and performance of the proposed detection methods. According to the fault indicators proposed in this paper, the results show that the analysis of the EMF, ZSVC and PF are the most sensitive detection methods. Experimental results are presented to validate finite element analysis (FEA) simulations. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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20 pages, 2022 KiB

Open AccessArticle

Electromagnetic and Calorimetric Validation of a Direct Oil Cooled Tooth Coil Winding PM Machine for Traction Application

by Alessandro Acquaviva, Stefan Skoog, Emma Grunditz and Torbjörn Thiringer

Energies 2020, 13(13), 3339; https://doi.org/10.3390/en13133339 - 30 Jun 2020

Cited by 15 | Viewed by 4398

Abstract

Tooth coil winding machines offer a low cost manufacturing process, high efficiency and high power density, making these attractive for traction applications. Using direct oil cooling in combination with tooth coil windings is an effective way of reaching higher power densities compared to an external cooling jacket. In this paper, the validation of the electromagnetic design for an automotive 600 V, 50 kW tooth coil winding traction machine is presented. The design process is a combination of an analytical sizing process and FEA optimization. It is shown that removing iron in the stator yoke for cooling channels does not affect electromagnetic performance significantly. In a previous publication, the machine is shown to be thermally capable of 25 A/mm

^{2}

(105 Nm) continuously, and 35 A/mm

^{2}

(140 Nm) during a 10 s peak with 6 l/min oil cooling. In this paper, inductance, torque and back EMF are measured and compared with FEA results showing very good agreement with the numerical design. Furthermore, the efficiency of the machine is validated by direct loss measurements, using a custom built calorimetric set-up in six operating points with an agreement within 0.9 units of percent between FEA and measured results. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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15 pages, 3856 KiB

Open AccessArticle

Axial-Flux Permanent-Magnet Dual-Rotor Generator for a Counter-Rotating Wind Turbine

by Filip Kutt, Krzysztof Blecharz and Dariusz Karkosiński

Energies 2020, 13(11), 2833; https://doi.org/10.3390/en13112833 - 2 Jun 2020

Cited by 27 | Viewed by 7457

Abstract

Coaxial counter-rotating propellers have been widely applied in ships and helicopters for improving the propulsion efficiency and offsetting system reactive torques. Lately, the counter-rotating concept has been introduced into the wind turbine design. Distributed wind power generation systems often require a novel approach in generator design. In this paper, prototype development of axial-flux generator with a counter-rotating field and armature is presented. The design process was composed of three main steps: analytical calculation, FEM simulation and prototype experimental measurements. The key aspect in the prototype development was the mechanical construction of two rotating components of the generator. Sturdy construction was achieved using two points of contact between both rotors via the placement of the bearing between the inner and outer rotor. The experimental analysis of the prototype generator has been conducted in the laboratory at the dynamometer test stand equipped with a torque sensor. The general premise for the development of such a machine was an investigation into the possibility of developing a dual rotor wind turbine. The proposed solution had to meet certain criteria such as relatively simple construction of the generator and the direct coupling between the generator and the wind turbines. The simple construction and the lack of any gearbox would allow for such a system to be constructed relatively cheaply, which is a key aspect in further system development. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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18 pages, 5850 KiB

Open AccessArticle

Analysis of Magnetic Field and Torque Features of Improved Permanent Magnet Rotor Deflection Type Three-Degree-of-Freedom Motor

by Zheng Li, Xuze Yu, Zengtao Xue and Hexu Sun

Energies 2020, 13(10), 2533; https://doi.org/10.3390/en13102533 - 16 May 2020

Cited by 4 | Viewed by 2510

Abstract

This paper proposes a novel layered permanent magnet motor (N-LPM), which is based on a three-degree-of-freedom (3-DOF) permanent magnet motor. Compared with the former, the improved N-LPM air gap magnetic density, torque and structure stability have been significantly improved. The proposed N-LPM has three layers of stator along the axis direction, and each layer of stator has three-phase winding. In order to calculate the magnetic field and torque distribution of the N-LPM, an analytical method (AM) is proposed. For performance verification and accurate calculation, finite-element analysis (FEA) is adopted. The two kinds of motors before and after the improvement are compared, and their magnetic field, torque and stability are analyzed. The optimization rate is defined to evaluate the performance of the motor before and after improvement. The results show that the radial flux density, rotation torque, deflection torque and the volume optimization rate of the permanent magnet of the improved motor are 80%, 25%, 50% and 54.72% respectively, and the comprehensive performance is improved significantly. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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24 pages, 11534 KiB

Open AccessArticle

Design, Multi-Objective Optimization, and Prototyping of a 20 kW 8000 rpm Permanent Magnet Synchronous Motor for a Competition Electric Vehicle

by Pedro P. C. Bhagubai, João G. Sarrico, João F. P. Fernandes and P. J. Costa Branco

Energies 2020, 13(10), 2465; https://doi.org/10.3390/en13102465 - 14 May 2020

Cited by 14 | Viewed by 4180

Abstract

A high-performance 20 kW, 20 Nm, 8000 rpm, spoke-type interior permanent magnet motor to be integrated into a FormulaStudent electric car’s powertrain has been designed to meet demanding performance requirements for its driving cycle. This paper describes key steps in the design optimization, analysis, fabrication, and testing of this machine. Design optimization used the non-dominated sorting genetic algorithm II (NSGA-II) coupled with a hybrid analytical/finite element model to reduce the computational time, achieving a torque and efficiency of 20 Nm and 98.6%, respectively. A prototype has been constructed. The final motor design has been tested, where experimental nominal torque and efficiency have reached 18.2 Nm and 90%, respectively. Design challenges regarding the manufacturing are presented, justified, and discussed in detail. Test results were conducted to evaluate reliability and motor temperatures with and without water refrigeration at nominal current. Despite those adjustments in the optimized design, one shows that the impact on the car’s lap time was low, going from 77.3 s for the ideal optimized motor to 78.9 s for the prototyped motor. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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22 pages, 40943 KiB

Open AccessArticle

Design and Analysis of a Novel Magnetic Coupler of an In-Wheel Wireless Power Transfer System for Electric Vehicles

by Young Jin Hwang and Jae Young Jang

Energies 2020, 13(2), 332; https://doi.org/10.3390/en13020332 - 9 Jan 2020

Cited by 23 | Viewed by 6267

Abstract

Electric vehicle (EVs), which use an electric motor, are expected to replace internal combustion engine vehicles. However, to date EVs are not highly attractive to consumers due to their unsatisfactory battery charging characteristics and high cost. In particular, the existing conductive charging method makes it more difficult to spread EVs due to the inconvenience of charging and the risk of electric shock. The wireless power transfer (WPT) system can eliminate all of the charging troubles of EVs. However, the WPT systems in existing EVs have large air gaps between the transmitter coil and the receiver coil, posing a hurdle that prevents success. The large air gap cause issues such as a loose coupling, low efficiency, and troublesome electromagnetic compatibility (EMC). An in-wheel WPT system can serve as a solution to address the issues arising due to the large air gap. In this paper, we propose a magnetic coupler structure of an in-wheel WPT system for EV applications. A design of two coils is introduced, in which the transmitter coil and receiver coil are designed based on a design method. Moreover, the pad structure according to the ferromagnetic core geometry is designed and discussed. The aim of this research is to find a suitable configuration of the magnetic coupler for an in-wheel WPT system. The values of the coupling coefficients according the magnetic coupler structure are determined. This paper is expected to provide a good reference for further research, including work on the manufacturing of a prototype. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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26 pages, 3451 KiB

Open AccessArticle

Multi-Level Modeling Methodology for Optimal Design of Electric Machines Based on Multi-Disciplinary Design Optimization

by Zehua Dai, Li Wang, Lexuan Meng, Shanshui Yang and Ling Mao

Energies 2019, 12(21), 4173; https://doi.org/10.3390/en12214173 - 1 Nov 2019

Cited by 8 | Viewed by 2826

Abstract

The transportation sector is undergoing electrification to gain advantages such as lighter weight, improved reliability, and enhanced efficiency. As contributors to the safety of embedded critical functions in electrified systems, better sizing of electric machines in vehicles is required to reduce the cost, volume, and weight. Although the designs of machines are widely investigated, existing studies are mostly complicated and application-specific. To satisfy the multi-level design requirements of power systems, this study aims to develop an efficient modeling method of electric machines with a background of aircraft applications. A variable-speed variable-frequency (VSVF) electrically excited synchronous generator is selected as a case study to illustrate the modular multi-physics modeling process, in which weight and power loss are the major optimization goals. In addition, multi-disciplinary design optimization (MDO) methods are introduced to facilitate the optimal variable selection and simplified model establishment, which can be used for the system-level overall design. Several cases with industrial data are analyzed to demonstrate the effectiveness and superior performance of the modeling method. The results show that the proposed practices provide designers with accurate, fast, and systematic means to develop models for the efficient design of aircraft power systems. Full article

(This article belongs to the Special Issue Electrical Machine Design 2020)

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