Double rotor machines, appearing in versatile forms and configurations thanks to the great flexibility of having a pair of rotors, are seen in a number of applications. Double rotor machines show promising prospect in the application of advanced hybrid electric vehicle powertrains due to the requirement of dual electro-mechanical ports in such systems. Integrating these powertrain systems with double rotor machines not only brings design freedom of laying out components, but also reduces number of parts and thus improves compactness. The switched reluctance type double rotor machines, offering unique characteristics of having a simple structure and no permanent magnets, are strong candidates for high performance applications. In this thesis, a family of double rotor switched reluctance machine with segmented rotors is proposed and studied. Compared to double rotor switched reluctance machines with a more conventional structure, the proposed designs exhibit potentials of achieving higher compactness and performance. A prototype double rotor machine of the segmented rotor design is constructed and tested to benchmark an existing double rotor switched reluctance machine. The experiment results show that the proposed design is able to achieve the same output with similar or higher efficiency than the benchmark machine, while occupying only about 60% of overall volume. The double segmented rotor switched reluctance machine demonstrates to be a promising double rotor topology and is worth further research. / Thesis / Master of Applied Science (MASc)

The purpose of this work was to investigate a permanent magnet synchronous machine which will be produced by an industry partner of the Institut für Stromrichtertechnik und Elektrische Antriebe (ISEA) an institute of the Rheinisch Westfälisch Technische Hochschule - Aachen, Germany (RWTH). The machine manufacturer noted certain abnormalities with the frequency spectrum produced by an electric machine that they were developing; this problem was brought to ISEA in order to be investigated. My work continues the work of my supervisor, Dipl.- Ing Matthias Bösing, and seeks to further examine the machine for a much wider range of operating points, determine the relationship between current amplitude, harmonics, control angle and rotor position on radial force components of the machine and therefore stresses on the stator; which are the primary causes of electrical machine noise. Rather than investigate acoustic issues in particular, the study was limited to the study of electromagnetically generated radial force ripple, which is the cause of stator deflection modes and therefore the emission of sound waves. The primary results of this thesis researched the operation of a permanent magnet synchronous machine and described its behavior with regards to force, torque, and force and torque ripple and their spectrums versus numerous parameters, including control angle, secant current and rotor position. Next, the work used provided data, literature and the simulation results for this thesis in order to deconstruct the operation regions of the particular machine and therefore link the causes of particular noise spectral components to the operation of the machine. From this it was possible to identify potential ways to eliminate these areas of noise. Following this, the thesis examined a particular abnormality in the torque and force waveforms produced by the machine and devised actions which could correct this abnormality. After identifying this asymmetry, the work explored how to choose an optimal control strategy for eliminating particular harmonics based on the simulated operating points and a desired command torque. Finally, the research built on the previous work by supplementing the method of current harmonic injection for eliminating radial force harmonics in this machine, with a method of determining an optimal operating point before the injection currents are calculated.

The increase of greenhouse gas emission is commonly accepted to largely contribute to global warming, in part due to the massive use of non-renewable fossil energy sources. It is a reason why recently, beside other industrial sectors, electric mobility has been considered as the next generation for transportation systems. But the electrification of a vehicle introduces new challenges in its design since it involves different domains of expertise than the ones from Internal Combustion Engine (ICE) vehicles. In particular, Noise, Vibration and Harshness (NVH) comfort is significantly affected by powertrain changes, i.e. from ICE to electric machine. High and unpleasant acoustic noise from resonances may occur but can be addressed numerically to support decision making processes early enough in the design stages. The accurate prediction of its radiated acoustic noise then requires a thorough multi-physical understanding, from the system-level (electric machine) to the component-level (stator and rotor cores).First from a system-level point of view, two multi-physical modeling frameworks that use different model simplifications were implemented. By comparing simulated results to experimental measurements at each physical step of the modeling flow (electromagnetic, vibration, acoustic), it was shown that both models are accurate enough for pre-designing phases. It was also shown that considering only the stator core to contribute to the vibro-acoustic behavior of electric machines is a valid assumption.Second from a component-level point of view, the rotor and the stator core were investigated. The rotor influence on the complete machine structural dynamics was assessed. Beside the validated effects of different rotor topologies on the radiated noise, an analytical model was successfully developed to explain the occurrence of a particular vibration mode; whose explanation was still not offered in literature. In parallel, the stator core was studied, essentially because it is composed of hundreds of thin laminations stacked together which introduce difficulties in understanding its structural behavior. The effects of the laminations on the structural behavior of the stator core were studied numerically and experimentally as well. Two modeling guidelines were thus provided depending on the mode shape of interest and the computational resources available. The experimental studies comforted these two modeling approaches, and also permitted to highlight the importance of looking at the damping properties. Therefore it was shown that different lamination stacking techniques could affect significantly this damping.Finally the influence of the stacking technique (gluing, welding) on the structural behavior of the laminated compound motivated the implementation of an alternative solution to the mitigation of resonance phenomenon responsible for large acoustic noise. By using a skewed distribution of welding or glue lines, the technique aims at forcing laminations to vibrate with different phases which generates friction between them. The induced damping increases and then depends on the introduced asymmetry and on the mode shape considered. This innovative technique was validated experimentally and showed up to 7 times higher structural damping and 10 dB reduction in structural transfer function amplitudes. / Doctorat en Sciences de l'ingénieur et technologie / info:eu-repo/semantics/nonPublished

Over the last years, environmental concerns have grown regarding the pressure manufacturing activities exerts on natural resources. Many materials have been classified by the EU as scarce, rare earth elements found in magnets are amongst critical materials with high supply risk. Furthermore, this has led to increasing material costs and disruptions in the supply chain. Efforts towards increased electrification are reliant on these and other critical materials. Electric machines that power a battery electric vehicle (BEV), are vulnerable to this price variations as magnets represent high material costs. Circular business strategies present the opportunity to decouple value generation from resource use, providing a cost effective way to support net zero targets. Legislation is toughening up, increasing original equipment manufacturer (OEM) extended responsibility, which might lead to mandatory product returns that require end of life (EOL) treatment. Therefore, OEMs need a systematic way to explore EOL design strategy combinations, that can quantify the impact of a circular business model, which considers product returns and remanufacturing activities. Thus preparing to meet greener demands from customers, government and society in general. This thesis work focuses on quantifying economic and environmental factors, of circular design strategies, through simulations tools to support EOL decisions at component level. Scania’s electric machine (EM) has been used as a case study for the simulation, collecting expert input from 6 different groups. Anylogic Professional software (8.8.1 version) has been used to set up a model that represents a closed loop supply chain. An optimization experiment has been conducted, to find the cost minimum design strategies for the EM’s parts. It shows redesigning part 1 and one entire module for easy reuse minimizes overall costs. This generates economic and environmental benefits in the form of savings compared to business as usual (linear) scenario; cost savings amount to 17.7%, CO2 equivalent emissions savings to 38.7% (cradle-to-gate), and virgin material saved (from extraction) to 14.7%. The results of this work are intended to provide data supporting circular initiatives, for Scania and potentially other OEMs, for better decision making.

O objetivo do trabalho é apresentar o funcionamento de um gerador a relutância chaveado monofásico. Para isso, foi desenvolvido um modelo computacional em ambiente Matlab Simulink, fazendo-se a comunicação entre diferentes partes do sistema. O comportamento da dinâmica de geração é apresentado para diferentes pontos do sistema, e testes experimentais realizados em um pequeno protótipo confirmam as características funcionais desta máquina. Ensaios realizados comprovam sua funcionalidade e simplicidade de operação, tendo estabilidade de geração para ampla faixa de velocidade de funcionamento, caracterizando uma máquina promissora, robusta e eficiente para aplicações especiais. / This work presents a single-phase switched reluctance machine operating as a generator. For that purpose, a computational model was developed in Matlab Simulink environment, wherein all the system components, such as voltage source, drive and machine model, and load were integrated. The current and voltage behavior for several points of operations are presented. Furthermore, experimental tests were also carried out in a simple prototype to validate its functionality and simplicity of operation, providing a stable power generation over a wide range of speed. The results showed that the single-phase switched reluctance generator can be robust, efficient, and promising for especial applications.

O objetivo do trabalho é apresentar o funcionamento de um gerador a relutância chaveado monofásico. Para isso, foi desenvolvido um modelo computacional em ambiente Matlab Simulink, fazendo-se a comunicação entre diferentes partes do sistema. O comportamento da dinâmica de geração é apresentado para diferentes pontos do sistema, e testes experimentais realizados em um pequeno protótipo confirmam as características funcionais desta máquina. Ensaios realizados comprovam sua funcionalidade e simplicidade de operação, tendo estabilidade de geração para ampla faixa de velocidade de funcionamento, caracterizando uma máquina promissora, robusta e eficiente para aplicações especiais. / This work presents a single-phase switched reluctance machine operating as a generator. For that purpose, a computational model was developed in Matlab Simulink environment, wherein all the system components, such as voltage source, drive and machine model, and load were integrated. The current and voltage behavior for several points of operations are presented. Furthermore, experimental tests were also carried out in a simple prototype to validate its functionality and simplicity of operation, providing a stable power generation over a wide range of speed. The results showed that the single-phase switched reluctance generator can be robust, efficient, and promising for especial applications.

L'optimisation topologique est une méthode de conception qui permet de définir de manière autonome la topologie, les formes et les dimensions d'un dispositif en vue de répondre de manière optimale à des critères de design. Initialement réservée au dimensionnement de pièces mécaniques, elle s'oriente aujourd’hui vers la conception de dispositifs plus complexes comme ceux rencontrés dans le domaine de l'électromécanique. C'est dans ce cadre que se situe notre travail. Un outil d'optimisation topologique étant formé de l'association d'un algorithme d'optimisation et d'un formalisme de distribution de matière, nous avons dans une première étape comparé différents couplages d'algorithmes métaheuristiques et de formalismes de distribution de matière en vue de choisir le couple qui semble le mieux adapté au problème traité. Cette comparaison nous a conduits à choisir comme outil d'optimisation l'association d'un algorithme génétique et d'une distribution de matière par cellules de Voronoï. Nous avons ensuite examiné comment améliorer les capacités d'exploration et d'exploitation de cet outil. Nous avons, à cet effet, étudié les aspects liés à la gestion de la taille de la population et à l'adaptation des mécanismes de reproduction au caractère graphique du problème. A l'issue de cette deuxième étape, nous avons finalisé un outil d'optimisation que nous avons testé sur des cas d'étude dont la complexité se rapproche de celle rencontrée au niveau industriel. Nous avons ainsi montré le potentiel de notre outil d'optimisation au niveau de la conception dans le cadre de l'électromécanique. / Topology optimization is a method of conception which is able to define the topology, the form and the dimensions of a device with the aim of responding optimally to given design criteria. Initially reserved to the sizing of mechanics parts, this method is directed today towards the conception of more complexes devices as those encountered in applied electromagnetic. It is in this context that our work was performed. A topology optimization tool is made of the combination of an optimization algorithm and a material distribution formalism. In a first step, we compared different couplings of metaheuristic algorithms and material distribution formalisms. This comparison led us to choose as optimization tool for the problem under study, the combination of a genetic algorithm and a distribution of material by Voronoi cells. In a second step, we discussed how to improve the exploration and exploitation capabilities of this tool. We have, for this purpose, studied aspects related to the management of the size of the population and to the adaptation of the mechanisms of reproduction to the graphical nature of the problem. After this second step, we builded our optimization tool that we tested on study cases whose complexity is similar to that encountered at industrial showing its potential of to design electromechanical devices.

Modern electric machine drives, particularly three phase permanent magnet machine drive systems represent an indispensable part of high power density products. Such products include; hybrid electric vehicles, large propulsion systems, and automation products. Reliability and cost of these products are directly related to the reliability and cost of these systems. The compatibility of the electric machine and its drive system for optimal cost and operation has been a large challenge in industrial applications. The main objective of this dissertation is to find a design and control scheme for the best compromise between the reliability and optimality of the electric machine-drive system. The effort presented here is motivated by the need to find new techniques to connect the design and control of electric machines and drive systems. A highly accurate and computationally efficient modeling process was developed to monitor the magnetic, thermal, and electrical aspects of the electric machine in its operational environments. The modeling process was also utilized in the design process in form finite element based optimization process. It was also used in hardware in the loop finite element based optimization process. The modeling process was later employed in the design of a very accurate and highly efficient physics-based customized observers that are required for the fault diagnosis as well the sensorless rotor position estimation. Two test setups with different ratings and topologies were numerically and experimentally tested to verify the effectiveness of the proposed techniques. The modeling process was also employed in the real-time demagnetization control of the machine. Various real-time scenarios were successfully verified. It was shown that this process gives the potential to optimally redefine the assumptions in sizing the permanent magnets of the machine and DC bus voltage of the drive for the worst operating conditions. The mathematical development and stability criteria of the physics-based modeling of the machine, design optimization, and the physics-based fault diagnosis and the physics-based sensorless technique are described in detail. To investigate the performance of the developed design test-bed, software and hardware setups were constructed first. Several topologies of the permanent magnet machine were optimized inside the optimization test-bed. To investigate the performance of the developed sensorless control, a test-bed including a 0.25 (kW) surface mounted permanent magnet synchronous machine example was created. The verification of the proposed technique in a range from medium to very low speed, effectively show the intelligent design capability of the proposed system. Additionally, to investigate the performance of the developed fault diagnosis system, a test-bed including a 0.8 (kW) surface mounted permanent magnet synchronous machine example with trapezoidal back electromotive force was created. The results verify the use of the proposed technique under dynamic eccentricity, DC bus voltage variations, and harmonic loading condition make the system an ideal case for propulsion systems.

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