Search Results (32)

Electric mountain bikes (eMTBs) demand compact, high-torque motors capable of handling steep terrain and variable load conditions. Surface-mounted permanent magnet synchronous motors (SPMSMs) are widely used in this application due to their simple construction, ease of manufacturing, and cost-effectiveness. However, SPMSMs inherently lack reluctance torque, limiting their torque density and performance at high speeds. While interior PMSMs (IPMSMs) can overcome this limitation via reluctance torque, they require complex rotor machining and may compromise mechanical robustness. This paper proposes a surface-inset PMSM topology as a compromise between both approaches—introducing reluctance torque while maintaining a structurally simple rotor. The proposed motor features inset magnets shaped with a tapered outer profile, allowing them to remain flush with the rotor surface. This geometric configuration eliminates the need for a retaining sleeve during high-speed operation while also enabling saliency-based torque contribution. A baseline SPMSM design is first analyzed through finite element analysis (FEA) to establish reference performance. Comparative simulations show that the proposed design achieves a 20% increase in peak torque and a 33% reduction in current density. Experimental validation confirms these findings, with the fabricated prototype achieving a torque density of 30.1 kNm/m³. The results demonstrate that reluctance-assisted torque enhancement can be achieved without compromising mechanical simplicity or manufacturability. This study provides a practical pathway for improving motor performance in eMTB systems while retaining the production advantages of surface-mounted designs. The surface-inset approach offers a scalable and cost-effective solution that bridges the gap between conventional SPMSMs and more complex IPMSMs in high-demand e-mobility applications. Full article

This paper proposes an improved analytical model for a line-start explosion-proof magnet synchronous motor that considers the effect of magnetic bridge saturation. Under the condition of maintaining the air-gap magnetic field unchanged, and taking into account the topological structures of embedded magnets, squirrel cages, and rotor slot openings, a subdomain model partitioning method is systematically investigated. Considering the saturation effect of the magnetic bridge of the rotor, the equivalent magnetic circuit method was utilized to calculate the permeance of the saturated region. It not only facilitates the establishment of subdomain equations and corresponding subdomain boundary conditions, but also ensures the maximum accuracy of the equivalence by maintaining the topology of the rotor. The motor was partitioned into subdomains, and in conjunction with the boundary conditions, the Poisson equation and Laplace equation are solved to obtain the electromagnetic performance of the motor. The accuracy of the analytical model is verified through finite element analysis. The accuracy of the analytical model is verified through finite element analysis (FEA). Compared to the FEA, the improved model maintains high precision while reducing computational time and exhibiting better generality, making it suitable for the initial design and optimization of industrial motors. Full article

In this paper, an advanced model of a switched reluctance generator (SRG) with mutual coupling, iron losses, and remanent magnetism is presented. The proposed equivalent circuit for each SRG phase is represented by the winding resistance, phase inductance and electromotive forces (EMFs) induced by mutual flux-linkage and remanent magnetism. In the advanced SRG model, the phase inductance and equivalent iron-loss resistance need not be known, as the components of the phase current flowing through them are determined directly from appropriate look-up tables, making the advanced SRG model simpler. Both the magnitude of the mutual flux-linkage and its time derivative are considered in the advanced model. The proposed model only requires knowledge of data that can be obtained using the DC excitation method and does not require knowledge of the SRG material properties. For the first time, the remanent magnetic flux of the SRG is modeled and the induced EMS caused by it is included in the advanced SRG model. Stray losses within the SRG are considered negligible. Connection to an asymmetric bridge converter is assumed. Magnetization angles of individual SRG phases are provided by the terminal voltage controller. The results obtained with the advanced SRG model are compared with experiments carried out in the steady-state of the 8/6 SRG with a rated power of 1.1 kW SRG over a wide range of load, terminal voltage, turn-on angle, and rotor speed in single-pulse mode suitable for high-speed applications. Full article

High-speed operation is a crucial approach for achieving high power density of drive motors for new energy vehicles. However, mechanical strength of the rotor has become the primary bottleneck in the development of high-speed drive motors. Adopting a multi-bridge structure can effectively enhance the mechanical strength of the V-shaped rotors widely used in interior permanent magnet synchronous motors (IPMSMs). Firstly, based on the equivalent centroid principle, the centrifugal forces generated by the rotor’s pole shoes and permanent magnets are calculated. An improved centrifugal force method is proposed to establish an analytical mechanical model of the multi-bridge V-shaped rotor structure. This method comprehensively considers the force conditions, deformation constraints, and material properties of the magnetic bridges. Additionally, stress concentration is taken into account to ensure the accuracy of the model. The effects of various structural parameters on the maximum mechanical stress and deformation are then analyzed. These parameters include the V-angle, pole shoe angle, and the dimensions of three types of magnetic bridges, namely, the central bridge, air-gap bridge, and middle bridge. Finally, recommendations for selecting structural parameters in the mechanical strength design of multi-bridge V-shaped rotors are summarized. The effectiveness of the proposed rotor structure is verified through finite element method and experiments. Full article

An axial field hybrid excitation synchronous generator (AF-HESG) is proposed for an independent power supply system, and its electromagnetic performance is studied in this paper. The distinguishing feature of the proposed generator is the addition of static magnetic bridges at both ends to place the field windings and the use of a sloping surface to increase the additional air-gap cross-sectional area. The advantage of the structure is that it achieves brushless excitation and improves the flux-regulation range. The structure and magnetic circuit characteristics are introduced in detail. Theoretical analysis of the flux-regulation principle is conducted by studying the relationship between field magnetomotive force, rotor reluctance, and air-gap flux density. Quantitative calculation is performed using a magnetomotive force (MMF)-specific permeance model, and the influence of the main parameters on the air-gap flux density and flux-regulation range is analyzed. Subsequently, magnetic field, no-load, and load characteristics are investigated through three-dimensional finite element analysis. The loss distribution is analyzed, and the temperature of the generator under rated conditions is simulated. Finally, a 30 kW, 1500 r/min prototype is developed and tested. The test results show good flux-regulation capability and stable voltage output performance of the proposed generator. Full article

The analytical and especially the numerical calculations of the magnetic fields of highly saturated electrical machines require a correctly given magnetizing curve. In practice, professional software may use many points of the magnetizing curve (sometimes 50 or more points). There is a high probability that a point will be entered or measured incorrectly. We have therefore set ourselves three objectives. The first is to reduce the number of points given. The second is to ensure that the curve is given analytically (in the form of orthogonal polynomials) and is as smooth as possible. This means that the derivatives of the reluctance are also as smooth as possible. Therefore, the Newton–Raphson iteration procedure in numerical calculations converges rapidly. The third objective was to make the magnetizing curve continue beyond a magnetic field density of 2 T up to about 3 T. Most professional programs simply limit the magnetizing curve to about 2.2 T. This limitation makes it impossible to calculate accurately the magnetic field in the bridges, especially when the slots in the rotor are closed. Local fields can exceed values of 2.2 T. A solution has been found. It uses higher order orthogonal polynomials. It has been shown that 12 given points of the magnetizing curve is enough to give a good approximation of the measured curve. However, one polynomial function is not enough. We need three functions and another exponential function for magnetic field densities above around 2 T up to a value of relative permeability equal to 1. In the numerical calculation of the field, we thus achieve the desired error (residual) vector of the Newton–Raphson iterative procedure in 10 ÷ 15 steps for semi-closed slots and 20 ÷ 30 steps for closed slots. Full article

Permanent magnet-assisted synchronous reluctance motors (PMA-SynRMs) are widely used in various fields due to their significant advantages, including strong torque output, high efficiency, excellent speed regulation, and low cost. The PMA-SynRM with asymmetric-rotor structure has a weaker anti-demagnetization performance than the conventional PMA-SynRM due to its multi-layer and thin permanent magnets construction. According to the finite element (FEM) simulation analysis, the anti-demagnetization performance of the asymmetric-rotor PMA-SynRM can be improved by adding bypass magnetic bridges on the ribs of the flux barriers and by changing the positions of the permanent magnets. The rotor structure of the proposed model is globally optimized by combining the two methods. Anti-demagnetization performance is improved as much as possible under the premise of ensuring the torque performance of the basic model. After multi-objective optimization, there is almost no difference between the optimized model and the basic model in terms of no-load air-gap flux density, no-load Back-electromotive force (EMF), and average torque. The maximum demagnetization rate of the optimized model is reduced by 81.44% compared with the basic model, and the anti-demagnetization performance is significantly improved. At the same time, the torque ripple is also reduced by 44.14%, which is obviously reduced. Compared with the basic model, the optimized model has better stability and reliability. Full article

Torque ripple and radial electromagnetic (EM) vibration can lead to motor vibration and noise, which are crucial to the motor’s NVH (Noise, Vibration, and Harshness) performance. Researchers focus on two main aspects: motor body design and control strategy, employing various methods to optimize the motor and reduce torque ripple and radial EM vibration. Rotor notching and segmented rotor skewing are frequently used techniques. However, determining the optimal notch and skew strategy has been an ongoing challenge for researchers. In this paper, an 8-pole, 36-slot ISG motor is optimized using a combination of Q-axis and magnetic bridge notching (QMC notch) as well as segmented rotor skewing to reduce torque ripple and radial EM vibration. Three skewing strategies—step skew (SS), V-shape skew (VS), and zigzag skew (ZS)—along with four segmentation cases are thoroughly considered. The results show that the QMC notch significantly reduces torque ripple, while skewing designs greatly diminish radial EM vibrations. However, at 14 $f_e$, the EM vibration frequency is close to the motor’s third-order natural frequency, leading to mixed results in vibration reduction using skewing techniques. After a comprehensive analysis of all skewing strategies, four-segment VS and ZS are recommended as the optimal approaches. Full article

High-speed interior permanent magnet (IPM) motors require highly reliable rotors. Some measures must be adopted to improve rotor safety, but its electromagnetic performance is seriously affected. It is a challenge to achieve excellent electromagnetic characteristics while satisfying mechanical strength. This paper presents an electromagnetic optimization design of high-speed IPM motors considering rotor stress. Firstly, the permanent magnet (PM) is segmented by adding stiffeners to improve stress distribution. The effects of the bridge and stiffener thickness on the rotor stress and electromagnetic performance are analyzed. Secondly, an electromagnetic optimization model is built based on a three-segment PM rotor structure, aiming for maximum efficiency and minimum rotor core losses. Then, the initial design and optimized scheme are compared, the results show that the efficiency, safety and temperature performance of the motor are improved. Finally, a 140 kW, 18,000 rpm prototype is manufactured and tested. The above analysis provides a valuable reference for the design and widespread application of high-speed IPM motors. Full article

Studies on the central and bilateral bridges of interior permanent magnet (IPM) motors often focus on individual mechanical strength or electromagnetic performance, lacking comparative studies on the electromagnetic performance of motors with different central and bilateral bridges under the same mechanical strength. This paper designs three rotors with different central and bilateral bridges and compares the electromagnetic performance of the three motors. First, to ensure the safe operation of the three rotors at high speeds, the mechanical stress of each rotor has been analyzed using the finite-element method (FEM). Subsequently, the major electromagnetic performances of the three motors are analyzed and compared, including the air-gap flux density, back electromotive force (back-EMF), inductance, salience, torque, power, loss, efficiency, and demagnetization. The results indicate that the rotor without central bridges has the largest leakage flux and the lowest torque but exhibits minimal torque ripple. The rotor with narrower bilateral bridges has the highest torque and maximum torque ripple. The torque performance of the rotor with wider bilateral bridges lies between the two aforementioned motors, and it possesses the highest efficiency. In the end, by adjusting the dimensions of the permanent magnets, the torque of all three models increases, but the motor with narrower bilateral bridges still has the largest torque. These findings provide valuable references for rotor design. Full article

The continuous strengthening of environmental regulations is expected to have a significant impact on the vessel operations of shipping companies. Each country must reduce greenhouse gas emissions from ships operating in domestic coastal areas to meet its Nationally Determined Contributions (NDC). For new vessels, we are assessing potential emission reductions through various technologies, recognizing that transitioning to alternative fuels is inevitable to achieve our ultimate goal of zero emissions. However, the introduction of alternative fuels for ships involves numerous challenges, including the overall replacement of propulsion systems, etc. Additionally, to ensure that existing ships can comply with the gradually increasing environmental regulations, the immediate adoption of bridge technologies that can be applied is essential. Rotor sails are recognized as a technology that can be installed on both new ships and vessels in operation, offering carbon emission reductions through thrust assistance. Rotor sails have traditionally been mainly employed on ocean routes with consistent wind patterns. In this paper, we conducted a review of the feasibility of operating rotor sails in coastal areas where wind direction frequently changes and wind intensity is not constant. Particularly, a concept of a rotor sail with magnetic bearings for the rotor sail system, utilizing the principle of magnetic levitation, is suggested. The reduction in frictional forces during rotor sail operation contributes to increased maintainability and advantages in terms of noise and vibration. Specifically, in this study, a structural design for minimizing weight for optimal performance has been carried out. Full article

The permanent magnet brushless DC motor (BLDCM) is typically controlled using the six-step commutation method, and the flux-weakening method is employed to enable the motor to operate at speeds higher than the base speed. Currently, it is considered that the weak magnetic angle range is 0-pi/3, while the range for deep weakening is pi/3-pi/2. In field-weakening control, a forward shift of the commutation point results in a circulating current flowing in the three-phase bridge of the inverter and the stator winding of the motor. This paper analyses the principle of the circulating current formed by the inverter. Through magnetic potential analysis and Simulink simulation, it is concluded that flux-weakening control generates a circulating current in the inverter and motor stator windings. The inverter’s circulating current affects the motor’s magnetic potential, causing it to shift towards the rotating direction of the motor rotor. When the forward shift angle of the inverter commutation point is within the range of 0-pi/6 electrical angle, the phase shift of the inverter circulating current remains below pi/6. This configuration weakens the magnetic field and provides the driving effect. However, when the forward shift angle falls within the range of pi/6-pi/3, the phase shift of the inverter circulating current exceeds pi/6, resulting in magnetic weakening and braking. During the braking effect, a reverse torque is generated, leading to a decrease in motor torque and efficiency. Therefore, the range of the weak magnetic angle should be between 0-pi/6. Full article

Motor rotor magnetic bridges operate under multiple physical field loads, such as electromagnetic force, temperature, and centrifugal force. These loads can cause fatigue and aging failure of the bridges, especially when the rotor is operating continuously at high speeds and high temperatures. Therefore, the failure analysis and accelerated test cycle development of magnetic bridges is a major aspect of their reliability evaluation. This paper studies rotor multi-physics load transfer characteristics and establishes a rotor magnetic bridge failure physical model. A simulation analysis is conducted from the electromagnetic field, thermal field, structural field, and thermomechanical coupling field to determine the risk point load responses and failure-dominant loads. In addition, the accuracy of the simulation model is verified by actual bench tests. Considering the influence on the rotor bridge’s life under the coupling of multiple failure modes, the fatigue failure model under alternating loads and the fatigue aging coupling failure model are established, respectively. Through a damage analysis, the whole life cycle damage targets for both failure modes are determined, and the test condition levels are screened based on the load frequency distribution and damage distribution. The multi-objective optimization method is used to calculate the number of test cycles and finally develop accelerated test cycle conditions that can reproduce multiple failure modes. This research can provide support for rotor bridge reliability design and verification, as well as product quality development. Full article

This paper presents the design of a switched reluctance motor (SRM) for a direct-drive propulsion application for a light sport aircraft. The SRM is designed to replace a 70 kW permanent magnet synchronous motor used in aerospace application with similar dimensional constraints. As a means of achieving high torque density and efficiency, a multi-objective design framework is used to optimize the geometry parameters of the motor. In order to further reduce the weight, rotor cutouts are implemented. The conduction angles for the asymmetric bridge converter are selected by employing a multi-objective genetic algorithm to map the torque speed characteristics of the motor. The core losses are evaluated with the modified Bertotti method to calculate the motor efficiency and determine the steady-state and transient thermal performance at the base speed. The designed coil winding is wound on a spindle winder, and the coil fitting, fill factor, and the coil retention are validated experimentally. Full article

For decades, sensorless position estimation methods gained lots of interest from the research community, especially in the field of electric drives and active magnetic bearings (AMBs). In particular, the direct flux control (DFC) technique promises unique advantages over other sensorless techniques, such as a higher bandwidth, but on the other hand, it requires the coils to be connected in a star topology. Until now, star-point connections are rarely found on active magnetic bearings. In consequence, there is no known publication about the application of the DFC to an AMB to this date. In order to apply the DFC to an AMB, a star-point driving approach for AMBs must be developed beforehand. A star-connected driving approach, capable of driving a four-phase AMB, is proposed and validated against traditional H-bridges in a simulation. Further, the strategy is tested in a physical application and generalised for 4$\ast n$ phases. In terms of current dynamics, the simulation results can be compared to the well-known full H-bridge driving. The experiments on the physical application show that the actual current in the coils follows a reference with satisfactory accuracy. Moreover, the inductance measurements of the coils show a strong dependency on the rotor’s position, which is crucial for sensorless operation. A star-point connection delivers a satisfying response behaviour in an AMB application, which makes sensorless techniques that require a star point, such as the DFC, applicable to active magnetic bearings. Full article