DESIGN AND DEVELOPMENT OF A SMALL SCALE 12S -14P...
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DESIGN AND DEVELOPMENT OF A SMALL SCALE 12S -14P OUTER ROTOR HEFSM GADAFI BIN M.ROMALAN UNIVERSITI TUN HUSSEIN ONN MALAYSIA
Transcript of DESIGN AND DEVELOPMENT OF A SMALL SCALE 12S -14P...
DESIGN AND DEVELOPMENT OF A SMALL
SCALE 12S -14P OUTER ROTOR HEFSM
GADAFI BIN M.ROMALAN
UNIVERSITI TUN HUSSEIN ONN MALAYSIA
DESIGN AND DEVELOPMENT OF A SMALL-SCALE 12S-14P OUTER
ROTOR HEFSM
GADAFI BIN M.ROMALAN
A thesis submitted in
fulfilment of the requirement for the award of the
Degree of Master of Electrical Engineering
Faculty of Electrical & Electronic Engineering
Universiti Tun Hussein Onn Malaysia
AUGUST 2016
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To my beloved family.
Thank you for your prayer and support.
I love you all.
DEDICATION
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ACKNOWLEDGEMENT
In the name of ALLAH, the most Gracious and the Most Merciful.
Alhamdulillah, all praises to Allah Almighty for His grace and His blessings given to
me for the successful completion of my master’s studies.
I also wish to express my gratitude to my supervisor, Dr. Erwan Sulaiman for
his guidance, invaluable help, advice, and patience on my project research. Without
his constructive and critical comments, continuous encouragement, and good humour
while facing difficulties, I could not have completed this research. I am also very
grateful to him for guiding me to think critically and independently.
I acknowledge, with many thanks, UTHM and KPM MyBrain15 for awarding
me a scholarship for my master’s programme. I am much honoured to be the recipient
for this award. Receiving this scholarship has given me motivation, confidence, and
willingness to achieve my goals.
Without support from technical staff and my lab fellows of FSM research
group, this research would not have been undertaken. My sincere thanks to all my FSM
group friends, especially Mr. Md Zarafi Ahmad, Mr. Faisal Khan, and Mr. Fairoz
Omar. They helped me many times with their technical knowledge.
It has been a very pleasant and enjoyable experience to work in UTHM with a
group of highly dedicated people, who have always been willing to provide help,
support, and encourage me whenever needed. I would like to thank all my friends
during my stay in UTHM. Life would never have been so joyful without you.
Finally, I would like to give my sincerest gratitude to my parents for their
endless love, support, and for always making compromises to let me try whatever I
consider worth doing.
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ABSTRACT
Simulation, prototype experimental, and mathematical modelling is an essential
process to provide sufficient evidence before a full-scale development or mass
production. Hence, this study focuses on validating a small scale of 12S-14P outer-
rotor hybrid excitation flux switching motor (OR-HEFSM) through simulation,
experimental, and mathematical modelling. The JMAG-Designer software as finite
element solver is used to design and analyse the designed geometry structure.
Throughout simulation process, the rotor design with direct drive structure as
illustrated in Appendix A is chosen based on optimisation process. Thus, the generated
back EMF, torque, and power through simulation at a speed of 1,200 r/min is 6.58 V,
16.4 Nm, and 12.4 kW, correspondingly. The designed model has been fabricated
using actual prototype analysis (APA) approach, which is involves five stages, namely
3-D design, material selection, fabrication, assembly, and experimental test. The
computer-aided software of SolidWorks is used to implement the first stage of APA
while the prototype structure is fabricated using a computer numerical control (CNC)
machine. The prototype has been tested experimentally using a measurement tool such
as Fluke Analyser and oscilloscope. The back EMF showed a good agreement between
simulation and preliminary experimental results with percentage differences
approximately 5.1% at a speed of, 1,200 r/min. In contrast with the prediction results
based on mathematical modelling using sizing equation, the calculated back EMF,
torque, and power is 7.58%, 8.6%, and 8.4% higher than simulation results,
respectively. Even so, the results had proven that the concept of three-phase working
principle for small-scale 12S-14P OR-HEFSM with direct drive structure remained the
same for simulation, experiment, and prediction.
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ABSTRAK
Simulasi, pengujian secara eksperimen dan pemodelan matematik ialah proses penting
untuk memberikan bukti yang mencukupi sebelum pembangunan berskala penuh atau
pengeluaran secara besar-besaran dilakukan. Oleh itu, kajian ini memberikan tumpuan
dalam mengesahkan reka bentuk 12S-14P OR-HEFSM berskala kecil melalui
simulasi, eksperimen dan pemodelan matematik. Perisian JMAG Designer sebagai
penyelesai unsur terbatas telah digunakan untuk mereka bentuk dan menganalisis
struktur geometri yang direka bentuk. Melalui keseluruhan proses simulasi, reka
bentuk rotor dengan struktur pemacu terus seperti yang ditunjukkan dalam lampiran A
telah dipilih berdasarkan proses pengoptimuman. Dengan itu, hasil voltan teraruh,
daya kilas dan kuasa melalui simulasi pada kelajuan 1200 r/min masing-masing ialah
6.58 V, 16.4 Nm dan 12.4 kW. Reka bentuk model telah dihasilkan menggunakan
pendekatan analisis prototaip (APA) yang melibatkan lima peringkat iaitu reka bentuk
3-D, pemilihan bahan, penghasilan, penyusunan dan kerja pengujian. Perisian
berbantukan komputer SolidWorks telah digunakan untuk menerapkan peringkat
pertama APA dan prototaip dihasilkan menggunakan mesin kawalan komputer
berangka (CNC). Prototaip telah diuji secara eksperimen menggunakan alatan
pengukuran seperti Fluke Analyser dan osiloskop. Hasil voltan teraruh adalah sepadan
dengan hasil simulasi dan eksperimen awal dengan beza peratusan kira-kira 5.1% pada
kelajuan 1200 r/min. Berbeza dengan hasil ramalan berdasarkan pemodelan matematik
menggunakan persamaan saiz, hasil pengiraan voltan teraruh, daya kilas dan kuasa
masing-masing ialah 7.58%, 8.6% dan 8.4% lebih tinggi daripada hasil simulasi.
Walau bagaimanapun, hasil ini mengesahkan konsep prinsip kerja tiga fasa untuk
struktur pemacu terus 12S-14P OR-HEFSM berskala kecil adalah tetap sama untuk
simulasi, pengujian secara eksperimen dan pemodelan matematik.
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CONTENTS
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xii
LIST OF SYMBOLS AND ABBREVATIONS xv
LIST OF PUBLICATIONS xvii
LIST OF AWARDS xviii
CHAPTER 1 INTRODUCTION 1
1.1 Background Introduction 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Scopes 3
1.5 Research Contribution 4
1.6 Thesis Outline 5
CHAPTER 2 LITERATURE REVIEW 7
2.1 Flux Switching Motor 7
2.1.1 Fundamental of Outer-Rotor HEFSM 8
2.1.2 Outer-Rotor HEFSM Design 9
2.2 Fabrication of Motor Design 12
2.2.1 Prototype of Inner-Rotor Design 12
2.2.2 Prototype of Outer-Rotor Design 17
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2.3 Prototype Experimental 19
2.3.1 Measurement System 19
2.3.2 Weightage in Fabrication 21
2.4 Summary 22
CHAPTER 3 DESIGN AND ANALYSIS OF SMALL SCALE
12S-14P OR-HEFSM USING JMAG DESIGNER 23
3.1 Design of Small-Scale 12S-14P OR-HEFSM 23
3.1.1 Part 1: Main Component of Rotor and
Stator Design 24
3.1.2 Part 2: Excitation Element of PM, FEC
and armature coil 35
3.1.3 Part 3: Finite Element Analysis (FEA)
and Material Setup 37
3.1.4 Part 4: Circuit Setup 37
3.1.5 Part 5: Simulation 38
3.2 Simulation Using JMAG Designer Solver 40
3.2.1 No-Load Analysis of 12S-14P
OR-HEFSM 40
3.2.2 Load Analysis of 12S-14P OR-HEFSM 43
3.2 Summary 44
CHAPTER 4 PROTOTYPE DEVELOPMENT OF THE
DESIGNED 12S-14P OR-HEFSM USING APA 45
4.1 Actual Prototype Analysis (APA) 45
4.1.1 Gathering and Stacking Approach 45
4.2 Development of Small Scale 12S-14P
OR-HEFSM Using APA 48
4.2.1 Stage 1 of APA: 3-D Design 48
4.2.2 Stage 2 of APA: Material Selection 54
4.2.3 Stage 3 of APA: Fabrication 57
4.2.4 Stage 4 of APA: Assembly 61
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4.3 Development of Direct Drive Prototype 68
4.4 Summary 70
CHAPTER 5 EXPERIMENTAL ANALYSIS OF A SMALL
SCALE PROTOTYPE 71
5.1 Experimental analysis 71
5.2 Prediction of Motor Performances by
Analytical Sizing Equations 77
5.3 APA Weightage (W factor) 82
5.4 Summary 87
CHAPTER 6 CONCLUSION AND FUTURE WORK 88
6.1 Conclusion 88
6.2 Future Work 89
REFERENCES 90
APPENDIX A: Technical Drawing 99
APPENDIX B: Details of Silicon Steel 35H210
and 35A250 103
APPENDIX C: Details of Cooper Coil 105
APPENDIX C: Details of Permanent Magnet
Neodymium 35AH 106
VITA 107
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LIST OF TABLES
1.1 Restriction and specification 4
3.1 Rotor design analysis 26
3.2 Analysis of rotor design D with different number
of rotor holders 28
3.3 Analysis of rotor holders width 32
3.4 Analysis of rotor holders height 32
3.5 Analysis of chamfer and fillet on 4 rotor holders design 33
3.6 Parameter specifications P1 to P19 35
3.7 Materials for the design of 12S-14P OR-HEFSM 37
3.8 Ia and Ie (Ampere) based on various current density 38
3.9 Condition for simulation decision 39
4.1 Example of gathering terms regarding fabrication process 46
4.2 Example of stacking process based on task 46
4.3 Legend stacking of task for APA 46
4.4 Example of material decision table for stator and rotor 55
4.5 Material list for prototype 12S-14P OR-HEFSM 56
4.6 Example of machine decision table 57
4.7 Number of turn and filling factor of armature
coil and FEC 63
5.1 Differences in percentage of experimental to simulation
back EMF 77
5. 2 Calculated magnetic flux density at various Ja
with constant PM and Je 81
5.3 Division Weightage (DW) for APA 83
5.4 Division Evaluate Mark (DEM) analysis 83
5.5 Weightage stage 1 APA 85
5.6 Weightage stage 2 APA 85
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5.7 Weightage stage 3 APA 86
5.8 Weightage stage 4 APA 86
5.9 Weightage stage 5 APA 86
5.10 Final weightage factor 87
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LIST OF FIGURES
2.2 Fundamental electromagnetic concept 8
2.3 Principle operation of OR-HEFSM 9
2.4 Design of 8S-4P OR-HEFSM 10
2.5 Performance of 8S-4P OR-HEFSM 10
2.6 Initial design of three-phase 12S-14P OR-HEFSM 11
2.7 Torque versus Je of initial design 12S-14P OR-HEFSM 11
2.8 Comparison of 12S-14P OR-HEFSM 11
2.9 Torque versus Je of the improved design 12S-14P
OR-HEFSM 12
2.10 PM brushless prototype design using SMC 13
2.11 PM mini motor using low cost fabrication technic 14
2.12 PMSM design 14
2.13 PM design axial-flux direct drive for scooter 15
2.14 18S-12P SRM design for EV 15
2.15 FSM design based on TSFE 16
2.16 Electromagnetic wave of FSM design based on TSFE 16
2.17 Complete fabrication of 12S-10P WFFSM 17
2.18 Complete fabrication of outer-rotor PMSM 18
2.19 Complete 3-D design of outer-rotor PMFSM 18
2.20 Complete design of outer-rotor PMSM for wind turbine 19
2.21 No-load property measurement system 20
2.22 Load property measurement system 20
2.23 Experiment set up for motor measurement system [43] 21
2.24 Equivalent block diagram motor of measurement
system in Figure 2.23 21
3.1 Flowchart of JMAG geometry editor and design 24
3.2 Design A with initial small scale design 25
3.3 Design B with rectangular shape rotor 25
3.5 Design D with 4 holders 26
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3.6 Design D with three holders 29
3.8 Design D with six holders 30
3.9 Design D with seven holders 30
3.10 Design D with eight holders 31
3.12 Chamfer on four rotor holders design 33
3.14 Small-scale design of 12S-14P OR-HEFSM 34
3.15 Parameter P1 to P19 35
3.16 Excitation element 36
3.17 Flowchart of simulation analysis 39
3.19 Comparison of magnetic flux distribution at
high current 41
3.20 Flux cancelation and losses in small scale design
of 12S-14P OR-HEFSM 41
3.21 Fundamental and harmonic Back EMF of 12S-14P
OR-HEFSM 42
3.22 Cogging torque of small scale design of 12S-14P
OR-HEFSM 42
3.23 Torque versus FEC current density at various
armatures current densities 43
3.24 Power and Torque versus speed characteristic 44
4.1 Actual Prototype Analysis (APA) flowchart 47
4.2 Complete 3-D design flowchart 49
4.3 Rotor design 50
4.4 Stator design 51
4.5 Permanent magnet design 51
4.6 3-D design armature coil and FEC 52
4.7 Winding coil case 53
4.8 Shaft and retaining clip 53
4.9 Motor housing 54
4.10 Holder rotor to shaft 54
4.11 Silicon electric steel 35A250 57
4.12 Wire cutting machine 58
4.13 Wire cutting fabrication (a) Stator, (b) Rotor 59
4.14 Milling machine 59
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4.15 Milling machine fabrication 60
4.16 3-D printer 60
4.17 Separator coil case 60
4.18 Permanent magnet NICUNI grade 35 61
4.19 Assembling process for prototype 62
4.20 Assembly flow of prototype 12S-14P OR-HEFSM 64
4.21 Full stack prototype 65
4.22 Coil case assembly 65
4.23 Finishing windings 66
4.25 Prototype assembly through step 1 to 6 for internal
assembly 66
4.26 Finishing step 7 and 8 for external assembly
generated by SolidWorks 67
4.27 Finishing prototype 67
4.28 Assembly flow for direct drive prototype 12S-14P
OR-HEFSM 68
4.29 Direct drive prototype 12S-14P OR-HEFSM 69
4.30 Rim to direct drive prototype application of 12S-14P OR-
HEFSM 69
4.31 Finishing direct drive prototype 70
5.1 General experimental flowchart of stage 5 of APA 72
5.2 Block diagram motor measurement system 73
5.3 Motor measurement system 74
5.4 Experimental coil test analysis 74
5.5 Back EMF at 600 r/min 75
5.6 Back EMF at 1,200 r/min 75
5.7 Back EMF at 1,800 r/min 75
5.8 Back EMF at 2,400 r/min 75
5.9 Back EMF at 3000 r/min 76
5.11 Calculated back EMF based on Equation 5.4 78
5.12 Effective area for small scale 12S-14P OR-HEFSM 79
5.13 Calculated and simulation torque versus various
armature current density 81
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LIST OF SYMBOLS AND ABBREVATIONS
A Ampere
AC Alternating Current
B Flux Density [T]
f Frequency [Hz], [rad/s]
I Current [A]
J Current Density [A/m2]
L Length [m]
N Number of turns
P Number of Poles
S Slot area [mm2]
r Radius [m]
r/min Revolution Per Minute
T Torque [Nm]
t Time [s]
V Voltage [V]
EMF Electromotive Force
FEA Finite Element Analysis
FEC Field Excitation Coil
FEFSM Field Excitation Flux Switching Machine or Motor
FSM Flux Switching Machine or Motor
HEFSM Hybrid Excitation Flux Switching Machine or Motor
HEV Hybrid Electrical Vehicles
IMs Induction Motors
PM Permanent Magnet
PMFSM Permanent-Magnet Flux Switching Machine or Motor
SRM Switched Reluctance Machine or Motor
Filling Factor
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Kp Filling Factor Effective Area
Kd Leakage Factor
Bg / Bpm Permanent-Magnet Magnetic Flux Density
Rso Stator Outer Radius
Ф Magnetic Flux
trAC Total Radial Active Component
B Magnetic Flux Density
Ae Effective Area
hPR Rotor Pole Height
DW Division Weightage
TP Total Phase
DEM Division Evaluation Mark
Wfactor Weightage Factor
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LIST OF PUBLICATIONS
Journals
(i) “Actual prototype analysis floor plan for general electric machine,” ARPN
Journal of Engineering and Applied Sciences, Vol. 10, No. 16, pp. 7070-7074.
(ii) “OR-HEFSM D-rive developed structure based on actual prototype analysis
(APA) process”, ARPN Journal of Engineering and Applied Sciences, -
(submitted and accepted)
(iii) “Development small scale direct drive 12s-14p OR-HEFSM” Jurnal Teknologi,
IPECS 2015, - (submitted and accepted)
Proceeding
(i) "Structural and assembly design of outer-rotor hybrid excitation flux switching
motor based on finite element analysis approach," Energy Conversion
(CENCON), 2015 IEEE Conference in Johor Bahru, Malaysia, 2015, pp. 305-
309.
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LIST OF AWARDS
(i) Silver medal at Malaysia Technology Expo (MTE), International Invention &
Innovation, Kuala Lumpur, Malaysia 18 - 20 February 2016.
(ii) Silver medal at Pencipta 2015, Dewan Konvensyen Kuala Lumpur, 4 – 5
December 2015.
(iii) Bronze medal at Seoul International Invention Fair, Korea 26 - 29 November
2015
(iv) Bronze medal at Research & Innovation Festival, UTHM, Malaysia 16 - 17
November, 2015.
(v) Silver medal at Post Graduate Showcase IEEE CENCON 19 – 21 October 2015.
(vi) Silver medal at Poster Competition Hari Transformasi Minda FKEE, UTHM
2015.
(vii) Bronze medal at Malaysia Technology Expo (MTE), International Invention &
Innovation, Kuala Lumpur, Malaysia 12 - 14 February 2015.
CHAPTER 1
INTRODUCTION
1.1 Background Introduction
Development of direct-drive motor for in-wheel electric vehicle (EV) has grown into
an interesting research topic because of their advantages of direct torque control and
elimination of the transmission gear system. At present, the major types of electric
motors under serious consideration for EVs are the DC motor, induction motor (IM),
permanent magnet synchronous motor (PMSM), and switched reluctance motor
(SRM) [1,2]. Based on the extensive review on state-of-the-art electric propulsion
systems, it may be observed that investigations on cage IMs and PMSMs are highly
dominant [3-5].
In fact, from various types of motors, the flux switching motor (FSM) is a
good design to fulfil direct-drive application due to high starting torque, constant
power over a wide speed range, low torque ripple, and high durability. The FSM
operating principle is quite interesting. This is due to the flux switches from stator pole
to rotor tooth and vice versa that made researchers to develop a novel FSM design for
various applications ranging from domestic appliances to heavy applications such as
electric traction [6, 7].
The outer-rotor hybrid excitation flux switching motor (OR-HEFSM) [8, 9]
is one of the FSMs created and studied to fulfil future expectations of electric vehicles
(EV) with more practical application. In this research, the development of small scale
12S-14P OR-HEFSM is guided by a full-scale 12S-14P OR-HEFSM design, which
has been published and submitted for patent [10]. Moreover, the full-scale design has
successfully achieved the target values and has overcome various problems in interior
permanent magnet synchronous machine (IPMSM) used in EV. The full-scale 12S-
2
14P OR-HEFSM design generated torque and power of 335.08 Nm and 160.2 kW,
respectively [11].
Theoretically, the design capability has been proven through finite element
analysis (FEA) using computer-aided software, JMAG designer. Basically, the
analysis is based on numerical input and operating principle without any compromise
towards error factor from manufacturing such as mechanical deformation. Therefore,
development and fabrication process are required to evaluate the motor performance
through prototype units [12]. However, because of cost and tool constraints, the design
dimension and volume have been rescaled by ratio 1:8.
To interpret the outer-rotor design into prototype unit, the design needs a few
approaches to complete the whole process such as actual prototype analysis (APA) and
FEA-based simulation. The APA is created to set a standard procedure to develop and
fabricate the design via five stages – design, material selection, fabrication, assembly,
and test. All stages of APA come with a specific objective to initiate the process guided
by closed loop flow chart to reach high standards in fabrication. Through the last stage
of APA, the experimental test has been conducted to finalise all aims in the
development and fabrication process [13].
1.2 Problem Statement
In recent research of electric motor drives for EV propulsion, in-wheel direct drive is
becoming more popular in diminishing transmission gearing system, and available
cabin space can be occupied by more batteries. Thus, this application does not only
provide optimal torque directly to the wheel, but also contributes for light vehicle and
wider driving range per charge. In considering for higher torque and power densities
for the in-wheel drive motors, outer-rotor machine configuration is among the good
designs compared with conventional inner-rotor [11].
In a recent review of motor design especially FSM, most researchers focused
on designing the motor using computer-aided software, but which lack of experimental
prototype validation because of cost and measurement tool restriction. As an example,
a 12S-14P OR-HEFSM has been successfully design for in-wheel direct drive
application. The performances achieved in terms of torque, speed, and power are much
higher than conventional IPMSM [10]. The design has successfully countered
IPMSM’s drawbacks with robust rotor structure, less PM usage, and less total weight.
3
However, the proposed motor is yet to be validated experimentally. Thus, in this
research, a complete process involving design and fabrication of a small-scale 12S-
14P OR-HEFSM shall be carried out from the initial stage to the end of experimental
validation before it goes for full scale or mass production.
1.3 Objectives
The objectives of this research are as follows:
(i) To optimise and analyse a small-scale design of 12S-14P OR-HEFSM rotor for
direct drive structure.
(ii) To develop and fabricate a small-scale design of 12S-14P OR-HEFSM using
actual prototype analysis (APA).
(iii) To validate a small-scale design of 12S-14P OR-HEFSM by analytical
modelling and experimentation.
1.4 Scopes
The research focuses on optimising and analysing a small-scale prototype of three-
phase 12S-14P OR-HEFSM, which will be evaluated by analytical modelling and
experimentation. In achieving the research objectives, the followings scopes have been
selected:
(i) Guided by a full-scale design of 12S-14P ORHEFSM [11], the design restriction
and specification for a designated small-scale design of 12S-14P OR-HEFSM
by a ratio of 1:8 are listed in Table 1.1. The FEA process is aided by JMAG
Designer 14 software to design and analyse the load and no load conditions.
(ii) In developing the small-scale prototype of 12S-14P OR-HEFSM, the APA
approach is used. The approach uses a conversion import file format .DWG from
JMAG-Designer to .SLDPRT for SolidWorks V.2014. The 2-D projection from
JMAG-Geometry will be ‘boss extruded’ into SolidWorks to generate the 3-D
projection.
(iii) Using the motor measurement system, the finishing prototype will be evaluated
by Power Flux and Futex Sensit for back EMF and cogging torque, respectively.
The investigated data will be compared with simulation and analytical modelling
data to prove the concept of three-phase motor characteristics.
4
(iv) In determining whether the APA approach is acceptable for general electric
motor fabrication, the collected data of simulation analysis and five stages of
APA will be evaluated using subjective evaluation method [14]. The evaluation
uses numeric score as weightage factor based on data feedback from motor
performance and fabrication qualities.
Table 1.1: Restriction and specification
1.5 Research Contribution
Research contribution throughout this research study are described as follows:
(i) The rotor optimisation and analysis of a small-scale design of 12S-14P OR-
HEFSM contributed to the idea on how the rotor design should be developed to
suit with direct drive structure. Simultaneously, presenting the analysis of a
small-scale 12S-14P OR-HEFSM in terms of back EMF, torque, speed, and
power. (Structural and assembly design of outer-rotor hybrid excitation flux
switching motor based on finite element analysis approach published in Energy
Conversion (CENCON), 2015 IEEE Conference)
(ii) The APA approach contributes to the systematic flowchart to develop and
fabricate the electric motor. Moreover, the APA weightage factor could be used
to determine the successfulness of the fabricated prototype. (Actual prototype
analysis floor plan for general electric machine, published in ARPN Journal of
Engineering and Applied Sciences)
RESTRICTION
AND
SPECIFICATION
DESCRIPTION OR-HEFSM
Electric
Max. DC-bus voltage inverter (V) 400
Max. DC-bus voltage inverter (V) 400
Max. inverter current (Arms) 50
Max. current density in armature
coil, Ja (Arms/mm2) 30
Max. current density in FEC, Je
(A/mm2) 30
Motor
Motor radius (mm) 66
Motor stack length (mm) 35
Shaft/Inner motor radius (mm) 30
Air gap length (mm) 0.4
PM weight (g) 17
Total weight (kg) 10
5
(iii) The mathematical modelling for OR-HEFSM using analytical sizing equation
contributes to the motor performances prediction in terms of power and torque.
(iv) The three-phase fabricated small-scale 12S-14P OR-HEFSM working principle
has been proven experimentally.
1.6 Thesis Outline
This thesis deals with the design studies on OR-HEFSM for HEV applications. The
thesis is divided into five chapters. A summary of each chapter is as follows:
(i) Chapter 1: Introduction
This chapter introduces the research background of design and development of
a small-scale 12S-14P OR-HEFSM. The contents focus on problems, objectives,
scopes, and contributions of the research.
(ii) Chapter 2: Literature review
The review on developing and fabricating the 12S-14P ORHEFSM was divided
into three sections. The first section is the introduction of flux switching motor
(FSM) while focusing on hybrid excitation FSM. It is followed by the review of
fabrication process, which is already established and used by other researchers.
The review covers both motor concepts, from inner to outer rotor fabrication. At
the end of the chapter is the review of measurement systems and weightage for
experimental purpose.
(iii) Chapter 3: Design and analysis of small-scale 12S-14P OR-HEFSM using
JMAG-Designer
This chapter presents the process before the prototype’s development. The
process involves the rotor optimisation and simulation process for small-scale
12S-14P OR-HEFSM using JMAG-Designer. Although the performances of a
small-scale design is quite different from a full-scale analysis, the results proved
that the concept of three-phase working principle concept for both designs
remained the same.
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(iv) Chapter 4: Prototype development of the designed 12S-14P OR-HEFSM using
APA
This chapter clarifies the complete process and results based on the second
research objective. It is divided into three sections namely development of APA
approach, development of small-scale prototype, and development of direct
drive prototype. The development of small scale and direct drive prototype has
been developed by four stages of APA from 3-D design, material selection,
fabrication, and assembly.
(v) Chapter 5: Experimental analysis of a small-scale prototype
This chapter elaborates the experimental analysis of a small-scale prototype of
12-14P OR-HEFSM with respect to simulation configuration. The tool and
calculation process have been explained based on analysis. The analysis is
divided into three sections namely experimental analysis for no load condition,
prediction motor performances based on analytical sizing equation, and
weightage analysis.
(vi) Chapter 6: Conclusion and future work
The final chapter discusses and concludes the process and results of the research.
This chapter also suggests future works to eliminate the drawbacks in small-
scale prototype development.
CHAPTER 2
LITERATURE REVIEW
2.1 Flux Switching Motor
The flux switching motor (FSM) incorporates the features of a conventional DC motor
and switch reluctance motor (SRM). Similar with conventional motor, the rotor and
stator combinations of FSM play a role to drive their operating principle as well as
coming out with various designs probability. In 1950, the first FSM was introduced.
Structurally it had a large value of permanent magnet usage with less slot area [15].
To overcome the large value of permanent magnet usage and to improve the FSM
structure topologies, researchers have tried to figure out the best combination of FSM
in terms of the stator-rotor structure and excitation component.
The general classification of FSMs is demonstrated in Figure 2.1, where the
permanent magnet (PM) and field excitation (FE) FSMs consist of PM and DC field
excitation coil, respectively as their excitation element. The hybrid excitation (HE)
FSM consists of the combination of both PM and FE for their flux excitation.
Flux Switching
Motor (FSM)
Permanent
Magnet (PM)
FSM
Field
Excitation (FE)
FSM
Hybrid
Excitation
(HE) FSM
Figure 2.1: Classification of flux switching motor (FSM)
8
2.1.1 Fundamental of Outer-Rotor HEFSM
The terminology of hybrid can be defined as a combination of two excitation sources,
namely field excitation coil (FEC) and permanent magnet (PM) to excite and switch
the generated flux from stator pole to rotor tooth, while armature coil as the main flux
to interact with excitation source. The operating principle of OR-HEFSM slightly
contrasts by modification for the inner rotor position and outer stator position. Even
the design seems complex, as it presents a great mechanical advantage such as robust
rotor structure that makes it suitable for high-speed applications. In addition, the FEC
could be used to control flux with variable flux capabilities [16].
Figure 2.2 illustrates the fundamental electromagnetic concept or right hand
screw rule in terms of magnetic field (B) behaviour as the current (I) flows with respect
to the current direction. In contrast, the operating principle of OR-HEFSM is illustrated
in Figure 2.3 [17, 18]. The single piece of rotor is shown in the upper part, while the
stator consisting of PM, FEC, and armature coils are located in the lower part. The PM
and FEC are placed between two stator poles to generate excitation fluxes that create
the term “hybrid excitation flux”.
Figures 2.3 (a) and (b) demonstrate the flux generated by PM and FEC flow
from the stator into the rotor and vice versa to produce a complete one flux cycle. The
combined flux generated by PM and FEC establishes more excitation fluxes to
generate high torque for motor. Moreover, when the rotor moves to the right as shown
in Figures 2.3 (c) and (d), the rotor pole goes to the next stator tooth, switching the
magnitude and polarities of the flux linkage. The flux shifts clockwise and counter
clockwise in direction with each armature current reversal. This condition establishes
less excitation flux and generates less torque [19].
Figure 2.2: Fundamental electromagnetic concept
Current (I)
Current (I)
Magnetic field (B)
Magnetic field (B)
9
Figure 2.3: Principle operation of OR-HEFSM (a) θe = 0º (b) θe = 180º more
excitation, (c) θe = 0º (b) θe = 180º less excitation
2.1.2 Outer-Rotor HEFSM Design
Several researches have been conducted with various probable designs involving the
OR-HEFSM operating principle as illustrated in Figures 2.4 and 2.5. Figure 2.4 (a)
shows the combination of single-phase 8S-4P OR-HEFSM, which produced a great
result for the initial design [20], while Figure 2.4 (b) shows the design improvement
[21] using optimisation process that successfully achieved much higher performances
than the initial design. The torque and power performance of both initial and optimised
designs are illustrated in Figure 2.5. It is obvious that the torque and power increased
approximately 22.1% and 59.5%, respectively.
PM PM
Armature
coil Armature
coil
Armature
coil
Armature
coil
FEC FEC
N S N S
Stator Stator
Rotor Rotor
PM
Armature
coil Armature
coil
Armature
coil
Armature
coil
FEC FEC
N S N S
Stator Stator
Rotor Rotor
(a) (b)
(c) (d)
PM flux flow
PM flux flow
FEC flux flow
FEC flux flow FEC flux flow
FEC flux flow
PM flux flow
PM flux flow
10
(a) (b)
Figure 2.4: Design of 8S-4P OR-HEFSM (a) Initial design, (b) Improved [21]
(a) (b)
Figure 2.5: Performance of 8S-4P OR-HEFSM (a) Torque, (b) Power [21]
In 2014, the initial three0phase 12S-14P OR-HEFSM was proposed, as
illustrated in Figure 2.6. The proposed motor produced a great performance in terms
of torque and power, as illustrated in Figure 2.7. Meanwhile, Figure 2.8 illustrates the
structural comparison of the final design for the initial and optimised design of the
proposed motor. It is obvious that the stator and rotor structures of the final design
have improved the flux flow capability and magnetic flux density. Deterministic
optimisation approach is used to improve the torque and power performances of the
initial design. The torque characteristic at various Je and Ja of the final design is
depicted in Figure 2.9. The torque performance had increased 26.6% more than the
initial design and surpassed the performance of IPMSM with the same motor
dimension [22].
11
Figure 2.6: Initial design of three-phase 12S-14P OR-HEFSM [22]
Figure 2.7: Torque versus Je of initial design 12S-14P OR-HEFSM [22]
(a) (b)
Figure 2.8: Comparison of 12S-14P OR-HEFSM (a) Initial, (b) Improved [22]
Improved
point
Initial
point
12
Figure 2.9: Torque versus Je of the improved design 12S-14P OR-HEFSM [22]
2.2 Fabrication of Motor Design
The term fabrication has been defined as an act or process to construct something new
or already in the market based on sketching. Electric motors are one of the great things
fabricated by Moritz Jacobi in 1834. Designers have used a few elements such as
copper wire winding isolated by shellac, square shaft iron, and magnet [23-27]. The
basic structure for electric motor design is still used in modern times with a few
improvements in design, concept, size, material, power source, and many more to
achieve various targets in industrial civilisation.
There are two types of popular structure in motor design: inner-rotor and outer-
rotor motors. However, research on motor design to date has been focusing mainly on
general electromagnetic analysis and optimisation of the inner-rotor type, with hardly
any attention given to the outer-rotor motor [28-30]. This happened because the market
needed an inner-rotor design and the design is easy to be fabricated even with a
complex design.
2.2.1 Prototype of Inner-Rotor Design
In an inner-rotor type motor, the rotor is inside the stator while the excitation part is
either on the stator or on both stator and rotor. The design structure is quite simple in
terms of mechanical assembly because the rotor rotates inside the stator with the shaft
position always in the middle of the stator and rotor setup. From a market prospective,
13
this design concept is the cheapest at the moment due to its simple design structure
and ease of fabrication.
There are few inner rotor types such as interior permanent magnet synchronous
motor (IPMSM), switch reluctant motor (SRM), and flux switching motor (FSM). The
design in Figure 2.10 shows a PM brushless stator core made by the precision
machining from a cylindrical piece of soft magnetic composite (SMC). The rotor
consists of four arc-shaped with surface mounted by magnet segments with a solid
mild steel back-iron. The prototype machine has an unusually large air gap of 6.5 mm
compared with its 2.5 mm magnet thickness [31].
Figure 2.10: PM brushless prototype design using SMC [31]
Some motors were developed by undocumented method where most of the
design developed by local manufacture. In one case of developing PM mini motor, the
design used low-cost batch fabrication techniques. This technique adapts lithography
and electroplating techniques, similar with those used in inductive head fabrication
[32]. However, this technique is to create the stator and rotor material layer by defining
the best way for producing electric steel in terms of seed layer, resistivity, magnetic,
and strength. The mini-motor in Figure 2.11 shows the horseshoe-shaped
electromagnets which surrounds a rotor. The stator diameter is 17 mm, rotor radius
2.976 mm, core width 0.7 mm, and coil width 60 mm, and there are 120 turns per core,
which generates 900 r/min and 0.6 µNm.
14
Figure 2.11: PM mini motor using low cost fabrication technic [32]
Although the 3-D dimension has been developed, the complete process in
fabrication is still vague due to secondary manufacturers’ usage such as in fabrication
process for PM synchronous motor (PMSM) [33]. The PMSM design as depicted in
Figure 2.12 shows the design process as initiated by taking the dimensions of an
existing stator lamination of an induction motor. This was done to reduce tool cost and
required time when developing the motor.
(a) (b)
Figure 2.12: PMSM design (a) Stator, (b) Rotor [33]
The main aim in fabrication is to validate the simulation data, but
simultaneously, the process must follow the detail of design application especially for
complex design. The PM motor illustrated in Figure 2.13 is concerning the application
of axial-flux PM motors in EV drive with a 16-pole axial-flux PM motor prototype
used in the propulsion system of an electric scooter devoted to city mobility. The axial-
flux PM motor prototype has 45 Nm peak torque, 6.8 kg active material weight, and is
coupled directly to the scooter rear wheel [34]. Figure 2.14 shows the SRM, designed
15
for EV with 18 stator poles, 12 rotor poles, and three-phase windings with 50 kW of
power [35].
Figure 2.13: PM design axial-flux direct drive for scooter [34]
(a) (b)
Figure 2.14: 18S-12P SRM design for EV (a) Stator, (b) Rotor [35]
A flux switching motor (FSM) is still new in electric motor family. However,
the drive still uses the basic concept of inner or outer-rotor such as in Figure 2.15,
which shows the FSM is based on time stepping finite element (TSFE) [36]. The
design uses an inner-rotor concept, which incorporates the features of a conventional
DC machine and SRM. In addition, FSM features high-speed, high-output torque, low-
cost power converter, and relatively simpler control strategy. This fabricated machine
generates an average torque of 1.25 Nm over time as depicted in Figure 2.16.
16
(a) (b)
Figure 2.15: FSM design based on TSFE (a) Stator, (b) Rotor [36]
Figure 2.16: Electromagnetic wave of FSM design based on TSFE [36]
As for 12S-10P wound field flux switching motor (WFFSM) [37], the motor
fabrication has been developed with dimension specification of stator and rotor
structure using outsource manufacture. Even so, maximum torque and power obtained
are 154.5 Nm and 74.1 kW, respectively. The stator core assembly shown in Figure
2.17 (a) is made of 200 pieces of 35H210 electromagnetic steels to build 70 mm stator
stack length. Meanwhile, Figure 2.17 (b) presents the three-phase armature windings
and FEC accommodated in the 24 stator slots. A full assembly, including the rotor
core, is illustrated in Figure 2.17 (c) and the prototype surrounded by the housing with
a water cooling jacket is shown in Figure 2.17 (d).
17
(a) (b)
(c) (d)
Figure 2.17: Complete fabrication of 12S-10P WFFSM (a) Stator, (b) FEC winding,
(c) Full assembly stator and rotor, (d) Prototype with water cooling jacket [37]
2.2.2 Prototype of Outer-Rotor Design
The design is quite similar to other motors with all excitation part still on the
stator or both on stator and rotor while the rotor rotates around the stator. Figure 2.18
illustrates an example of PM gear with an outer-rotor PMSM. The design consists of
2.5 mm thick magnets at the stator and a yoke section to magnetically decouple the
armature flux from the magnetic gear. The yoke section is covered with 9 mm thick
magnets on the outside, which are secured against centrifugal forces with a 3 mm thick
titanium sleeve [38]. Another 12-pole PMFSM using analytical sizing equations are
derived to determine the parameters of the motor and fabricated by the University of
Sheffield [39]. Figure 2.19 shows the design appearance of a 12-pole PMFSM, which
is similar with Figure 2.18, but slightly different in terms of stator and rotor design.
18
Figure 2.18: Complete fabrication of outer-rotor PMSM [38]
Figure 2.19: Complete 3-D design of outer-rotor PMFSM [39]
As stated for the inner-rotor concept, the fabrication always leads by the aim of
the design. Most designers develop and fabricate the motor for certain application. In
this case, Figure 2.20 shows the outer-rotor PMSM for a generator application [40].
The generator for small wind turbines is suitable with the outer-rotor concept. This
kind of design makes the construction of the turbine more convenient because of the
simple installation of wind rotor directly on the generator’s surface. Meanwhile, the
blades can be put straight forward into the nests of outer-rotor frame.
19
Figure 2.20: Complete design of outer-rotor PMSM for wind turbine [40]
Although the torque and power results shows close agreement between
experimental and predicted results, it still has not satisfied the FEA performance. A
few demerits include materials for fabrication and the method of fabrication itself,
perhaps making the experimental prototype slightly come off from the FEA result. It
is noteworthy that a proper consideration in material and fabrication process is needed
for further experimentation.
Most of the prototypes that have been presented produced efficiencies above
90%, but there are also publications where the efficiency is rather low, mainly caused
by various unfavourable aspects in the physical assembly of the prototype and the
remaining loss was claimed to be mechanical loss [40-42].
2.3 Prototype Experimental
2.3.1 Measurement System
The motor measurement system consideration should abide by motor and
measurement classifications. This consideration is mostly based on the motor
capability measurement system to provide accurate and constant measurement as well
as to avoid unexpected event. In fact, only the high-end motor measurement system is
able to provide high-end results, which are quite expensive to begin with.
One of the prototype PM brushless design by Gene S. [41] utilised high
bandwidth current with voltage transducers (Hameg HZ56 current probe, Yokogawa
differential probe Model 700925) and a digital oscilloscope (Tektronix TDS 340A) to
20
analyse and record the measurements. Indeed, the outcomes are precise in certain parts,
but are still unable to measure a complete performance of PM brushless.
Meanwhile, Figures 2.21 and 2.22 show the brushless DC motor created by
Koji Ikeda [42], which has been analysed using different measurement systems. The
employed no-load load property systems in both figures are able to provide a complete
result of the motor’s characteristics. The combination of both no-load and load analysis
measurement systems will increase the measurement accuracy for certain applications.
Figure 2.21: No-load property measurement system [42]
Figure 2.22: Load property measurement system [42]
However, if the test is only to prove motor performance on certain data such as
speed and the motor function capability, the high quality measurement device is
unnecessary. The researcher, Weizhong Fei [43] also used a simple type of
measurement system to prove the PMFSM motor capability. The design being
examined such as in Figure 2.23 has an integrated power inverter, basic measurement
device, and motor brake as a dynamo for load analysis [43]. The equivalent block
21
diagram for this type of measurement system has been illustrated in Figure 2.24 in
terms of measurement device and connection.
Figure 2.23: Experiment set up for motor measurement system [43]
Figure 2.24: Equivalent block diagram motor of measurement system in Figure 2.23
2.3.2 Weightage in Fabrication
The weightage has been derived from a perspective view of a preliminary investigation
to predict the final effect of fabrication either in objective or subjective point.
Basically, in subtract or multiple variable into a weightage ratio, the mathematical
modelling such as fuzzy systems is needed to obtain precise weightage calculation. In
contrast, the weightage is derived subjectively or by interpolative decision making
[44]. This method is used in weightage transformation from variable such as dimension
deformation into a ratio.
Different product topology and application lead to new variables in a weightage
calculation. So, a few considerations are needed to conclude the variables into a
Prime moverFEFSM
Controller
Armature Power
supply
FE Power
supplyOscilloscope
Prototype
Dynamo
22
qualitative or quantity ratio, which are used to calculate the weightage. By computing
the weightage based on preliminary result the final performance of model can be
predicted [45]. This technique is also useful to evaluate some model performances that
cannot be measured such as flux distribution.
In motor design, a common weightage is usually used in winding calculation
with respect to allocated winding space, known as filling factor. The ratio ranges
between zero to one by considering one of them as a high filling factor in motor design.
The factor is used to predict the outcome number for the turn of windings by
multiplying the factor with the winding equation [46]. Simultaneously, the filling
factor becomes one of the variables in fabrication weightage. The input and output of
filling factor can be evaluated as winding variables in defining the full fabrication
weightage [47].
2.4 Summary
In this chapter, a review on development and fabrication of 12S-14P ORHEFSM was
divided into three sections. The first section is the introduction of flux switching motor
(FSM) while focusing on hybrid excitation FSM. The second sections reviews the
fabrication process, which is already established and used by other researchers. The
review covered both motor concepts, namely inner to outer-rotor fabrication. Finally,
the third section reviews the measurement systems and weightage for experimental
purpose.
CHAPTER 3
DESIGN AND ANALYSIS OF SMALL SCALE 12S-14P OR-HEFSM USING
JMAG DESIGNER
3.1 Design of Small-Scale 12S-14P OR-HEFSM
Finite element analysis (FEA) based on JMAG Designer version 14.1 is used to design
a small-scale 12S-14P OR-HEFSM before the analysis and fabrication process. The
software can give the user substantially greater insight into design performance while
providing versatility to support users from conceptual design to comprehensive
analysis.
Figure 3.1 illustrates the general flowchart of simulation analysis using JMAG
designer. The design implementation is divided into two parts, namely geometry editor
and designer. Geometry editor is used to design each part of the motor separately, such
as rotor, stator, armature coil, and FEC while the condition setting and simulation are
executed using JMAG-Designer. The overall sequence in the flowchart is divided into
five compulsory factor for motor design namely, the main component of stator and
rotor, the excitation element of PM, FEC and armature coil, the FEA and material setup
based on available market, the circuit setup for input current and simulation setting.
24
START
Sketch of
Rotor
Sketch of
Stator
Sketch of
Armature coil
Sketch of
FEC
Set
materials
Set the
conditions
Set the
circuits
Set the mesh &
study
properties
Run and
Simulate
END
Sketch of
Permanent
Magnet
GEOMETRY
EDITOR
DESIGNER
No-Load analysis:
a. Coil test
b. Flux strengthening /
weakening
c. Flux distribution
d. Flux lines
e. Electromotive force
(EMF)
f. Cogging torque
Load analysis:
a. Torque versus Je/Ja
b. Torque versus speed
c. Power versus speed
d. Iron loss, copper loss,
eddy current lost
e. Efficiency
f. Mechanical strength
Success
Simulation
data
YES
NO
Success
YES
NO
1
1
Figure 3.1: Flowchart of JMAG geometry editor and design
3.1.1 Part 1: Main Component of Rotor and Stator Design
The main component has been divided into rotor and stator which are basic
components in motor design. Guided by full-scale design [11], the stator design remain
the same while the rotor has been altered to suit with direct drive structure. Four design
has been considered for rotor which is usually used by motor designer to develop the
rotor into direct drive structure [48-51]. In justifying which design is suitable, three
90
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