PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

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PMSM Design and Loss Analysis Liping Zheng 07/23/2003

Transcript of PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

Page 1: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

PMSM Design and Loss Analysis

Liping Zheng

07/23/2003

Page 2: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

PMSM Configuration

Litz-wire:

1.78 mm x 2.27 mm

50 strands @ AWG 30

Gap : 0.5 mm

Stator Di: 25.5 mm

Do: 38 mm

Length: 25.4 mm

Shaft diameter: 16 mm

No major shaft stress problem if we select high stress shaft material.

Page 3: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

Progress

Got the Litz-wire with rectangular profile.

Total 22 lb.

Found the permanent magnets (PM) manufacturer to fabricate the special shape PM with 0.001 in (0.025 mm) tolerance.

According to new PM profile, adjust the winding configuration and perform all simulations.

Filter inductor preliminary design.

Page 4: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

5

5

2.5

2.5

Ø 16

All Dimensions are in mm

Shaft Cross-section

Shaft Cross Section

Courtesy of Dipjyoti Acharya

(mm)

Page 5: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

Airgap Flux Density

Low harmonics of the normal flux density.

Tangent flux density is a little large due to large airgap.

Page 6: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

0.0000 0.0001 0.0002 0.0003 0.0004-0.12

-0.10

-0.08

-0.06

-0.04

-0.02

0.00T

orq

ue (

N.m

)

Time (s)

Simulated Torque

Winding pitch is modified from 12/15 to 10/15.

Simulated back EMF=12 V

Use Generator mode to simulate Torque.

Load current = 60.8 A

1.5% ripple

Page 7: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

Inductor Design

W

T

WAu

ggc

g

c

g

g

A

nlR

nAWK

lBRABnI

l

nA

R

nL

Rni

0maxmaxmax

20

2

Constraints:

Page 8: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

DC Filter Inductor

Negligible core loss, proximity loss.

Copper loss dominated.

Flux density chosen simply to avoid saturation.

Airgap is employed.

Page 9: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

AC Filter Inductor

Core loss, copper loss, proximity loss are all significant.

Flux density is chosen to reduce core loss.

A high-frequency core must be employed.

An air gap is employed.

Page 10: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

P Core Structure-p66/56

d1=66.29 mm

d2=54.51 mm

d3=28.19 mm

h1=57.3

h2=43.28

Ferrite type: MnZn (manganese and zinc)

Material :3C81,3C91

Page 11: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

Use P66/56 core

Copper loss

1.2W

Page 12: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

Loss of FiltersCopper Loss (3 turns):

1.2W

Core loss (3C91):

50mW/cm3 @ 10KHz (from manufacturer’s data).

Estimated 10mW /cm3 @ 3.3KHz.

Estimated 20mW /cm3 considering harmonics.

The volume is 124 cm3 2.48W

Total loss of the filters (3 inductors):

3x (1.2+2.48)=11W.

Page 13: PMSM Design and Loss Analysis Liping Zheng 07/23/2003.

PMSM LossCopper loss 16.9 W

Shaft eddy loss 0 ?

Iron loss 10.4 W

Bearing loss 10 W

Filters loss 11 W

Windage loss 12.8 W

Total loss 61.1W

%97)1.612000(2000 m

%95c%1.92 mc

Motor Efficiency:

Control Efficiency:

Total Efficiency:

Future work