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The 2nd Power and Energy Conversion Symposium (PECS 2014) Melaka, Malaysia 12 May 2014 Initial Design of 12s-10p and 12s-14p with OuterRotor Field-Excitation Flux Switching Machine Syed Muhammad Naufal Syed Othman, Erwan Sulaiman, Mohamed Mubin Aizat Mazlan, Zhafir Aizat Husin Universiti Tun Hussein Onn Malaysia, Locked Bag 101, Batu Pahat, Johor, 86400 Malaysia [email protected], [email protected] Abstract—This paper shows the initial design of Outer-Rotor Field Excitation Flux Switching Machine with 12slot-10 pole and 12slot-14pole as an alternative for a non-permanent magnet flux switching machine. The performance, design specification and a no-load test is presented. All excitation sources such as armature winding and field winding is located at the stator, although the stator at the inner and rotor at the outer part. Furthermore, salient pole is used to modulate and switch polarity of the flux linkage in the armature winding, while the rotor comprise only stack of iron only. Armature Coil (a) (b) Index Terms—35H210, copper, FEC coil, 2D-Finite Element Analysis, ORFEFSM, FEFSM, IPMFSM I. INTRODUCTION Armature Coil In this day, Induction Permanent Magnet Flux Switching machine is one of the most successful candidate for a high torque, speed and power density especially in the sector of transportation such as hybrid electric vehicle. The common use for a high torque and high speed rating is the 3-phase system used worldwide. Flux switching machine(FSM) comprise of Permanent Magnet(PM), Field Excitation(FE) and Hybrid Excitation. Of all the three classification of FSM, field excitation is the best candidate with a decent performance with a low cost of manufactured. Hence, FEFSM motor has a huge advantages in the construction (simple), magnet-less, and variable flux control capabilities which suitable for various performances. Since the permanent magnet is being used widely in research for a better optimization, making the usage of rare earth magnet to increase in demand. FEFSM do perform magnetization but from the magnetic field of the coil differ from the PMFSM, which magnetization performs from the rare earth magnet itself. Filed excitation flux switching machine perform distinct compared to PMFSM and HEFSM, because it us field excitation to generate flux. The basic operation of the motor is based on the principle of switching flux. It describe machine as the stator tooth flux switches the polarity followed with the motion of the salient pole rotor. It can be illustrated in the following Figure 1(a), (b), (c) and (d). Figure 1(a) and (b) shows how the flux of FEC direction unto the rotor while Figure 1(c) and (d) illustrates the FEC fluxes unto the stator and hence completed a one cycle of flux. The transition between Figure 1(a) and (b) causes the stator flux to switch between the stator tooth alternate tooth (c) (d) Figure 1: Principle operation of FEFSM (a) θe=0° and (b) θe=180° flux moves fromstator to rotor (c) θe=0° and (d) θe=180° flux moved from rotor to stator II. DESIGN RESTRICTION, SPECIFICATIONS AND PROCEDURES FOR HYBRID ELECTRIC VEHICLE APPLICATIONS Table 1 shows the design restriction, specification for outer-rotor FEFSM with 12S-10P and 12S-14P. 650V of DC bus voltage and 360A of maximum inverter is the electrical restrictions that are set. As for the limitation of current density, it is set to a maximum 30Arms/mm2 for armature winding and 30A/mm2 for FEC respectively. The main part of the design such as outer diameter, motor stack length, shaft radius and air gap are restrict to 264mm, 70mm, 30mm and 0.8mm. Since it consists of only iron stack sheets, it can be assumed that it is mechanically robust to rotate at high speed. 177 The 2nd Power and Energy Conversion Symposium (PECS 2014) Melaka, Malaysia 12 May 2014 TABLE I DESIGN SPECIFICATIONS AND PARAMETERS FOR 12S-10P (12S-10P) Max. DC-bus voltage inverter (V) Max. inverter current (A) Max. current density in armature winding, Ja (Arms/mm2) Max. current density in excitation winding, Je (A/mm2) Number of phase Number of stator poles Number of rotor poles Outer diameter of motor (mm) Motor stack length (mm) Rotor radius (mm) Air gap length (mm) Rotor pole width (mm) Rotor pole depth (mm) FEC width (mm) FEC depth (mm) Armature coil depth (mm) Armature coil width (mm) FEC 1 (mm) 650 360 30 30 3 12 10 264 70 132 0.8 52 10.82 2.7652 53.04 53.04 3.1674 Figure 4 12S-10P FEFSM windings(FEC 1) FEC 2 The machine configuration and windings are illustrated in Fig. 3 and Fig. 4, respectively. From configuration, the FEC are allocated uniformly between each armature coil slot and alternate FEC and armature coil slot around the stator. The directions of FEC are in counter-clockwise polarity and clockwise polarity, while the three phase armature coils are placed in between them. Figure 5 12S-10P FEFSM windings(FEC 2) Rotor Stator Armature Coil TABLE II DESIGN SPECIFICATIONS AND PARAMETERS FOR 12S-14P Shaft (12S-10P) Max. DC-bus voltage inverter (V) Max. inverter current (A) Max. current density in armature winding, Ja (Arms/mm2) Max. current density in excitation winding, Je (A/mm2) Number of phase Number of stator poles Number of rotor poles Outer diameter of motor (mm) Motor stack length (mm) Rotor radius (mm) Air gap length (mm) Rotor pole width (mm) Rotor pole depth (mm) FEC width (mm) FEC depth (mm) Armature coil depth (mm) Armature coil width (mm) Figure 3 Design configuration of 12S-10P outer-rotor FEFSM 178 (mm) 650 360 30 30 3 12 14 264 70 132 0.8 38.92 10.82 2.7652 53.04 53.04 3.1674 The 2nd Power and Energy Conversion Symposium (PECS 2014) Melaka, Malaysia 12 May 2014 As for 12S-14P, the number of FEC and armature winding is same as 12S-10. Figure 6 below show the diagram for 12S-14P. All of the design is come from commercial finiteelement analysis (FEA), the JMAG Designer 12.1 version. In which, it is release by Japan Research Institute(JRI) as a way to perform a 2D-FEA. Rotor Stator Armature Coil Figure 8.Flux linkage of 12S-14P FEFSM phase U, V and W Shaft Coil test is intended to satisfy whether the machine manner at the U flux at the zero rotor position. Since the U flux value is 0 Wb at the condition of 90º and 270º, while it’s at maximum value during 180º it shows that conditions has been fulfilled. B. FEC flux linkage at varies FEC current density, JE Figure 9 and 10 shows the U phase flux linkage when supplying current at various FEC for design 12Slot-10Pole ORFEFSM and 12S-14P ORFEFSM while Figure 11 and 12 show the maximum U phase flux linkage when Je=0 A/mm2 until Je=30A/mm2. Figure 6 Design configuration of 12S-10P outer-rotor FEFSM III. DESIGN RESULTS AND PERFORMANCES BASED ON 2DFINITE ELEMENT ANALYSIS A. Coil Arrangement Test Coil arrangement tests are performed in order to identify each armature coil separately. What is the operating principle of the outer-rotor FEFSM and to set the position of each armature coil phase, where all armature coils are wounded in counter-clockwise direction while FECs are wounded in clockwise and counter-clockwise direction. The flux linkage at each coil is observed and the armature coil phases are defined according to the conventional three-phase system. Fig. 5 demonstrates the flux linkage of all coils at separate phase as three-phase flux linkage defined as U, V, and W, respectively. The flux produced relatively smooth as there is no distortion occurs. Figure 9. U phase Flux linkage at varies FEC current density, JE Figure 7.Flux linkage of 12S-10P FEFSM phase U, V and W 179 The 2nd Power and Energy Conversion Symposium (PECS 2014) Melaka, Malaysia 12 May 2014 Figure 10. U phase Flux linkage at varies FEC current density, JE where it is not. Meanwhile, the gap between the shaft and stator is small; the flux density there should be saturated. From the JE characteristic graph, the flux increases to 5A/mm2 then decrease at 10A/mm2 considered constant until 30A/mm2. This is because the material used for FEC, copper, has reached its limit to produce flux. Besides, inside the motor, there is some flux that flow in opposite direction thus it will cancelled each other. From both graph, it shows that the maximum value is different, 12S-10P shows a higher maximum value 0.0085 Wb when Je=5 A/mm2, while 0.0060 Wb for 12S-14P. Figure 14.Illustration of flux distribution of the three-phase 12S-10P ORFEFSM Figure11. Maximum U phase flux (12S-10P) at varies FEC current density, JE. Figure 15.Illustration of flux distribution of the three-phase 12S-14P ORFEFSM D. Cogging Torque Figure 16 show the cogging torque graph. This graph is plotted when JE equal 30 A/mm2 and JA equal 0 Arms/mm2 which no current being supply to armature coil. One cycle is formed as the rotor being rotate 6°. There are 6 cycles formed as another 6 cycles are exactly the same as previous. It shows that the rotor is in synchronizing rotation. From both design, the amplitude of each cycle for 12S-10P is higher (6Nm) compared to 12S-14P (4Nm). A high cogging torque can create a disturbance if it do not exceed 10 per cent of the total torque it produce. Figure12. Maximum U phase flux (12S-14P) at varies FEC current density, JE. C. Flux Distribution Flux distribution test is about the flux distribution around the motor. It can classify into many types of color in order to determine its density. The highest value of the parameter is the one that being set during the plot. From the Figure 13, the highest set value is 2.4000T while the maximum value during the operation of the motor is 2.2959T. The condition during this test perform is at Je=30 A/mm2, and Ja=30 A/mm2, where the armature and FEC current supply is at maximum. Figure 15 show a different value of flux density compared to Figure 14, this is because the maximum value is 2.3042 T. From here, we can determine where the flux is saturated and 180 The 2nd Power and Energy Conversion Symposium (PECS 2014) Melaka, Malaysia 12 May 2014 ACKNOWLEDGMENT This research was supported by Geran Insentif Pelajar Siswazah(GIPS, vot 1368) under Research, Innovation, Commercialization and Consultancy management(ORICC) University Tun Hussein Onn Malaysia(UTHM), Batu Pahat and Ministry of Higher Education Malaysia(MOHE). REFERENCES [1] E. Sulaiman, T. Kosaka, Y. Tsujimori and N. Matsui, “Design Of 12-Slot 10-Pole Permanent Magnet Flux-Switching Machine with Hybrid Excitation for Hybrid Electric Vehicle,” Proc. The 5th IET International Conference on Power Electronics, Machine and Drives (PEMD 2010), April 2010. [2] E. Sulaiman, “Less Rare-Earth and High Power Density Flux Switching Motor for HEV Drives,” pp. 15-23, June 2011. [3] M.Z Ahmad, E. Sulaiman, and Z.A Haron, “Design Improvement of a New Outer-Rotor Hybrid Excitation Flux Switching Motor for In-Wheel Drive EV,” Proc. IEEE 7th International Power Engineering and Optimization Conference (PEOCO2013), Langkawi, Malaysia, 3-4 June, 2013, pp. 298303. [4] E. Sulaiman, T. Kosaka, and N. Matsui, “Design optimization and performance of a novel 6-Slot 5-Pole PMFSM with hybrid excitation for Hybrid Electric Vehicle”, IEEJ Trans. on Industry Appl., vol. 132, No. 2, Sec. D, pp. 211-218, 2012.G. Eason, B. Noble, and I. N. Sneddon, “On certain integrals of Lipschitz-Hankel type involving products of Bessel functions,” Phil. Trans. Roy. Soc. London, vol. A247, pp. 529–551, April 1955. [5] E. Sulaiman, T. Kosaka, and N. Matsui, “FEA-based Designand Parameter Optimization Studyof6-slot5-polePMFSM with Field Excitation for Hybrid Electric Vehicle,” IEEE International Conference on Power and Energy (PECon 2010) pp. 206-201, Dec 2010.J. Clerk Maxwell, A Treatise on Electricity and Magnetism, 3rd ed., vol. 2. Oxford: Clarendon, 1892, pp.68–73. [6] S. E. Rauch and L.J. Johnson, ‘Design principles of flux-switch alternators’, Tans. AIEE, vol. 74 pt. III, pp. 1261-1268, 1955. [7] WeizhongFei, Patrick Chi KwongLuk, JianXinShen, Yu Wang, and Mengjia Jin, “A Novel Permanent-Magnet Flux Switching Machine With an Outer-Rotor Configuration for In-Wheel Light Traction Applications,” IEEE Transactions On Industry Applications, Vol. 48, no. 5, pp. 1496-1505, September/October 2012. [8] M.A. Rahman: “IPM Motor Drives For Hybrid Electric Vehicles”, InternationalAegean Conference on Electrical Machines and Power Electronics, Sept. 2007. Figure 16.Cogging Torque of 12S-10P FEFSM Figure 17.Cogging Torque of 12S-14P FEFSM CONCLUSION As for the conclusion design studies and performance analysis of an outer-rotor 12S-10P, 12S14P FEFSM are presented. The design of the proposed motor is quite complicated because of the opposite configuration which exposes in more core loss than inner-rotor. Besides, it is better way of design when compared with inner-rotor FEFSM. There is no usage of permanent magnet and thus, it can be expected as very low cost machine. In addition for future research the final design of outer-rotor FEFSM will have a robust rotor structure with high mechanical strength suitable for high speed motor applications. Therefore, it is reasonable to say that the proposed machine will be good candidate as a non-permanent magnet machine for HEV drives and achieve target performance. 181