Este trabalho apresenta as características básicas de uma máquina elétrica com fluxo axial, ímãs permanentes, rotor duplo e estator com enrolamentos toroidais montado entre os rotores. A máquina foi construída no Laboratório de Máquinas Elétricas, Acionamentos e Energia da Escola de Engenharia da UFRGS. O trabalho contém modelos analíticos para as induções magnéticas dos ímãs permanentes e dos enrolamentos de armadura. A partir dos modelos foram desenvolvidas expressões para o cálculo de forças eletromotrizes e de conjugados, sendo utilizado um software de matemática simbólica para realização dos cálculos. É apresentada uma comparação entre os resultados obtidos através do modelo analítico e os resultados obtidos por simulação numérica. Alguns resultados são comparados também com valores experimentais. As expressões para o cálculo de conjugado desenvolvido pela máquina serão detalhadas em uma etapa posterior. Foi obtida uma razoável coerência entre os dados comparados. / This work presents the basic features of an axial flux, permanent magnet, double rotor and toroidal windings mounted between the rotors. The machine was built in the Laboratory of Electrical Machines, Drives and energy of the School of Engineering of the Federal University of Rio Grande do Sul. The work contains analytical models of permanent magnets and armature windings magnetic inductions. Based in models, expressions of electromotive forces and torques were derived. The calculations were performed with a symbolical mathematical software. It is presented a comparison between results obtained with analytical model and results of the numerical simulation. Some comparisons include experimental results. The expressions of machine torque will be detailed in a next phase. The compared results present an acceptable conformity.

Les travaux de recherche présentés dans cette thèse visent à développer une machine à griffes à base d'aimants permanents pour les applications automobiles avec un concept de réutilisation et de recyclage des aimants permanents. Ces recherches sont menées dans le cadre du projet DEMETER, qui s'inscrit dans le cadre des Marie Sklodowska-Curie Actions dans Horizon 2020 de l'Union européenne. Le projet se concentre sur la récupération des aimants permanents à base de terres rares utilisés dans les applications automobiles en raison des problèmes actuels de fluctuation des prix et des problèmes d’offre et de demande de ces aimants permanents.La machine à griffes est utilisée dans presque toutes les automobiles du monde pour les applications d'alternateur. Avec l'augmentation de la demande en puissance, la machine à griffes est également développée en tant que moteur-générateur utilisé dans les véhicules électriques hybrides. Actuellement, la machine à griffes à base d'aimants permanents est utilisée dans des systèmes d’hybridation légère afin de réaliser des économies d'énergie. La littérature regorge de différentes configurations de machines à griffes pouvant être développées pour obtenir de meilleures performances. Cependant, le montage et le démontage facile des différentes parties de la machine sont également importants pour la réutilisation et le recyclage des aimants. Dans ce travail de recherche, deux concepts ont été développés; premièrement, le concept de réutilisation directe, c’est-à-dire le montage / démontage facile du rotor et des aimants, de manière à pouvoir retirer facilement les aimants pour les réutiliser ou les recycler directement; deuxièmement, le concept de recyclage direct, c'est-à-dire l'utilisation d'aimants recyclés dans la machine pour obtenir les performances souhaitées.Au cours de cette recherche, la conception de base de la machine à griffes a été développée, analysée et optimisée de manière à obtenir le meilleur rapport couple / poids aimant. Cela a permis de réduire le coût des aimants pour presque le même couple. L'optimisation a été effectuée en utilisant une analyse numérique en éléments finis 3D. Le modèle optimisé a été développé de manière à ce que le processus d’assemblage des aimants et des griffes reste le même. Cependant, lors du démontage, les aimants peuvent facilement être retirés sans démonter le rotor complet; et ainsi se servir de ces aimants pour les réutiliser directement dans d'autres applications ou les envoyer au recyclage. Dans le concept de recyclage direct, les aimants utilisés dans la machine sont des aimants recyclés aux performances dégradées. Le type de processus de recyclage est un facteur déterminant de la détérioration des performances de ces aimants recyclés. L'objectif du concept de recyclage direct était d'analyser la machine avec des aimants vierges et recyclés et d'évaluer la consommation d'énergie de la machine selon différents cycles de conduite. On a observé qu'avec l'utilisation d'aimants recyclés dans la machine à griffes, la consommation d'énergie était presque identique à celle de la machine à aimants vierges. On peut donc en conclure que pour les machines à griffes à aimants permanents, l’utilisation d’aimants recyclés est plus durable pour l’environnement car elle peut entraîner une diminution à l’extraction des matériaux de terres rares. Les fluctuations des prix et les problèmes d’offre peuvent également être réduits grâce à l’utilisation accrue des aimants recyclés, même si des politiques et des normes sont appliquées.Le prototype de la machine à aimants vierges a été fabriqué et testé pour ses performances. Il a été observé que les résultats expérimentaux correspondent très bien aux résultats des analyses de conception, validant ainsi le processus de conception et la méthodologie. / The research work presented in this thesis aims at developing a permanent magnet based claw-pole machine for automotive application with permanent magnet reuse and recycle concept. The aforesaid research is under the aegis of Project DEMETER which is in the framework of European Union’s Horizon 2020 Marie Sklodowska-Curie actions. The project focuses on the recovery of rare earth permanent magnets utilized in automotive applications due to the prevailing problems of price fluctuations and supply-demand issues of these permanent magnets.The claw-pole machine is employed in almost all of the automobiles in the world for alternator application. With the increase in power demands, the claw-pole machine is also being developed as a motor-generator utilized in the hybrid electric vehicles. At present the permanent magnet based claw-pole machine is being used in mild hybrid electric vehicles for energy savings. The literature is replete with various configurations of claw-pole machines that can be developed to achieve better performances. However, easy assembly and disassembly of various parts of the machine is also important for the reuse and recycle of magnets. In this research work two concepts have been developed; first, the direct reuse concept i.e. easy assembly/disassembly of the rotor and magnets, so as to easily take out the magnets for direct reuse or recycle and; second, the direct recycle concept i.e. utilization of recycled magnets in the machine to achieve the desired performance.In the course of this research the base design of the claw-pole machine was developed, analyzed and optimized so as to attain best torque versus magnet-weight ratio. This helped in the reduction of magnet cost for almost the same torque. The optimization was carried out using 3-D numerical analysis. The optimized model was developed in a way that the assembly process of the magnets and claw-poles remained the same. However, during disassembly the magnets can easily be withdrawn without disassembling the complete rotor; therefore utilizing these magnets for direct reuse in other applications or sent for recycling. In the direct recycle concept, the magnets used in the machine are recycled magnets with deteriorated performance. The type of recycling process is a strong determinant of the deterioration in performance of these recycled magnets. The aim of the direct recycle concept was to analyze the machine with virgin and recycled magnets, and evaluate the energy consumption of the machine under different drive cycles. It was observed that with utilization of recycled magnets in the claw-pole machine, the energy consumption was almost same as that of the machine with virgin magnets. Thus it can be concluded that for the permanent magnet based claw-pole machine, the utilization of recycled magnets is more sustainable for the environment as it can lead to consequential limits on the mining of rare earth materials. The price fluctuations and supply-demand problems can also be reduced with the increase in utilization of recycled magnets, albeit policy and norms are effectuated.The prototype of the machine with virgin magnets have been developed and tested for performance. It has been observed that the experimental results match fairly well with the design analysis results, hence validating the design process and methodology.

Este trabalho apresenta as características básicas de uma máquina elétrica com fluxo axial, ímãs permanentes, rotor duplo e estator com enrolamentos toroidais montado entre os rotores. A máquina foi construída no Laboratório de Máquinas Elétricas, Acionamentos e Energia da Escola de Engenharia da UFRGS. O trabalho contém modelos analíticos para as induções magnéticas dos ímãs permanentes e dos enrolamentos de armadura. A partir dos modelos foram desenvolvidas expressões para o cálculo de forças eletromotrizes e de conjugados, sendo utilizado um software de matemática simbólica para realização dos cálculos. É apresentada uma comparação entre os resultados obtidos através do modelo analítico e os resultados obtidos por simulação numérica. Alguns resultados são comparados também com valores experimentais. As expressões para o cálculo de conjugado desenvolvido pela máquina serão detalhadas em uma etapa posterior. Foi obtida uma razoável coerência entre os dados comparados. / This work presents the basic features of an axial flux, permanent magnet, double rotor and toroidal windings mounted between the rotors. The machine was built in the Laboratory of Electrical Machines, Drives and energy of the School of Engineering of the Federal University of Rio Grande do Sul. The work contains analytical models of permanent magnets and armature windings magnetic inductions. Based in models, expressions of electromotive forces and torques were derived. The calculations were performed with a symbolical mathematical software. It is presented a comparison between results obtained with analytical model and results of the numerical simulation. Some comparisons include experimental results. The expressions of machine torque will be detailed in a next phase. The compared results present an acceptable conformity.

Este trabalho apresenta as características básicas de uma máquina elétrica com fluxo axial, ímãs permanentes, rotor duplo e estator com enrolamentos toroidais montado entre os rotores. A máquina foi construída no Laboratório de Máquinas Elétricas, Acionamentos e Energia da Escola de Engenharia da UFRGS. O trabalho contém modelos analíticos para as induções magnéticas dos ímãs permanentes e dos enrolamentos de armadura. A partir dos modelos foram desenvolvidas expressões para o cálculo de forças eletromotrizes e de conjugados, sendo utilizado um software de matemática simbólica para realização dos cálculos. É apresentada uma comparação entre os resultados obtidos através do modelo analítico e os resultados obtidos por simulação numérica. Alguns resultados são comparados também com valores experimentais. As expressões para o cálculo de conjugado desenvolvido pela máquina serão detalhadas em uma etapa posterior. Foi obtida uma razoável coerência entre os dados comparados. / This work presents the basic features of an axial flux, permanent magnet, double rotor and toroidal windings mounted between the rotors. The machine was built in the Laboratory of Electrical Machines, Drives and energy of the School of Engineering of the Federal University of Rio Grande do Sul. The work contains analytical models of permanent magnets and armature windings magnetic inductions. Based in models, expressions of electromotive forces and torques were derived. The calculations were performed with a symbolical mathematical software. It is presented a comparison between results obtained with analytical model and results of the numerical simulation. Some comparisons include experimental results. The expressions of machine torque will be detailed in a next phase. The compared results present an acceptable conformity.

O presente trabalho apresenta uma transformação dq não senoidal e sua aplicação em máquinas síncronas com ímã permanente na superfície do rotor (MSIP) e forma de onda de FEM não senoidal. O modelo resultante da aplicação dessa transformação permite o controle direto do torque eletromagnético, permitindo reduzir as ondulações do torque produzido nesse tipo de máquina. A redução dessas ondulações em MSIPs não senoidais possibilita que esse tipo de máquina seja empregado em aplicações onde somente MSIPs senoidais, que possuem custo mais elevado, poderiam ser usadas. Simulações e resultados práticos, obtidos pela implementação do sistema de controle vetorial não senoidal desenvolvido, são apresentados no trabalho. Pelos resultados obtidos, pode-se verificar que o método proposto é eficaz na redução das ondulações do torque eletromagnético em MSIPs não senoidais. / This work presents a non-sinusoidal dq transformation and its application in permanent- magnet synchronous machines (PMSM) with a non-sinusoidal back-EMF waveform. The resulting model of the application of such transformation permits direct control of machine electromagnetic torque, which achieves the reduction of torque ripple. The reduction of torque ripple in non-sinusoidal PMSMs makes possible the use of this kind of PMSM instead of sinusoidal PMSMs, which are more expensive. Simulation and practical results, obtained by the implementation of such non-sinusoidal vectorial control system, are shown in this work. Those results show that the method presented is efficacious in the torque ripple reduction in non-sinusoidal PM synchronous machines.

Electrical machines in electrified heavy-duty vehicles are subjected to dynamic temperature loadings during normal operation due to the different driving conditions. The Electrical Insulation System (EIS) in a stator winding is aged as an effect of these dynamic thermal loads. The thermal loads are usually high constant temperatures and thermal cycling. The high average constant thermal load is well-known in the electrical machine industry but little is known about the effect of temperature cycling. In this project, the ageing of the EIS in stator windings due to temperature cycling is examined. In this project, computational simulations of different simplified models that represent the electrical insulation system are made to analyse the thermo-mechanical stresses that is induced due to thermal cycling. Furthermore, a test object was designed and simulated to replicate the stress levels obtained from the simulations. The test object is to ease the physical testing of electrical insulation system. Testing a complete stator takes time and has the disadvantage of having a high mass, therefore a test object is designed and a test method is provided. The results from the finite element analysis indicate that the mechanical stresses induced will affect the lifetime of the electrical insulation system. A sensitivity study of several thermal cycling parameters was performed, the stator core length, the cycle rate and the temperature cycle amplitude. The results obtained indicate that the stator core length is too short to have a significant effect on the thermo-mechanical stresses induced. The results of the sensitivity study of the temperature cycle rate and the temperature cycle amplitude showed that these parameters increase the thermo-mechanical stresses induced. The results from the simulations of the test object is similar to the results from the simulations of the stator windings, which means that the tests object is valid for testing. The test method that is most appropriate is the power cycling test method, because it replicates the actual application of stator windings. The thermally induced stresses exposing the slot insulation exceeds the yield strength of the material, therefore plastic deformation may occur only after one thermal cycle. The other components in the stator are exposed to stresses below the yield strength. The thermally induced stresses exposing the slot insulation are high enough to low cycle fatigue the electrical insulation system, thus thermo-mechanical fatigue is an ageing factor of the electrical insulation system.

Le réseau électrique de bord des avions devient le principal vecteur de transmission de l'énergie utilisée en dehors de celle réservée à la propulsion. Le réseau électrique remplace progressivement les réseaux hydrauliques et aérauliques qui assurent respectivement les contrôles de vol et le confort dans la cabine des avions actuels. Pour transmettre une puissance électrique plus importante sans augmenter la masse des conducteurs, un nouveau standard a été défini, le réseau de bord des avions plus électriques sera continu et sa tension est fixée à 540V. En conséquence, les convertisseurs statiques seront systématiquement utilisés pour commander les actionneurs électriques. Des contraintes électriques nettement plus importantes seront appliquées aux bobinages des machines en plus de celles qui sont inhérente à l'aéronautique. Pour obtenir la sureté de fonctionnement requise, la surveillance du vieillissement de l'isolation des machines électriques embarquées devient indispensable. Le travail effectué dans cette thèse est centré sur la définition d’un nouvel indicateur de vieillissement de l’isolation des bobinages des machines électriques utilisées en aéronautique. Le nouvel indicateur delta-C est basé sur la corrélation entre l'augmentation de la capacité inter-spires du bobinage et la réduction des performances caractérisée principalement par la réduction du seuil d'apparition des décharges partielles. La partie expérimentale des travaux est importante; le mémoire donne les résultats des campagnes de vieillissement accéléré d'un grand nombre d'échantillons de fil émaillé standard. Ces résultats permettent de définir des seuils critiques des variations du nouvel indicateur delta-C en fonction du profil de mission de l'actionneur. Le nouvel indicateur delta-C est corrélé avec un paramètre facilement mesurable sur une machine électrique en fonctionnement qui est la fréquence de résonance du bobinage. Un outil numérique est développé pour déterminer les fréquences de résonances à surveiller en fonction de la géométrie et de la technologie du bobinage de la machine. Les prédictions des fréquences déterminées par l'outil numérique développé sont vérifiées par des mesures faites sur des bobines vieillies artificiellement. L'étude est étendue à l'influence du câble d'alimentation de la machine. Les limites de fonctionnement du système de surveillance proposé sont définies pour différentes distances entre la machine et le point de connexion des systèmes de mesure. / For modern aircrafts, the onboard electrical grid becomes the main energy transmission system apart from energy reserved for propulsion. Electrical systems are gradually replacing hydraulic and air systems providing respectively flight controls and cabin comfort in current aircrafts. To transmit higher electrical power without increasing the conductors’ masses, a new standard has been set, the grid of more electrical aircrafts will be 540 VDC. As a result, static converters will systematically be used to drive the electrical actuators. Substantially higher electrical constraints will be applied to electrical machine windings, in addition to those inherent in aeronautics. To obtain the required operational safety, the monitoring of the insulation for onboard electrical embedded machines has become indispensable. This thesis work is focused on the definition of a new aging indicator for the electrical insulation of machine used in aeronautics. The new delta-C indicator is based on the correlation between the increase in the turn-to-turn winding capacitance and reduction of performance mainly characterized by the decrease of Partial Discharge Inception Voltage (PDIV). The experimental part of this work is considerable; the thesis gives the results of accelerated aging tests on a large number of enameled wire standard samples. These results make it possible to define critical threshold for the new delta-C indicator depending on the mission profile of the actuator. The new delta-C indicator is correlated with an easily measurable parameter on an operating electrical machine, i.e. the resonance frequencies of the winding. A numerical tool was developed to determine the resonance frequencies to be monitored according to the geometry and the technology of the winding machine. The prediction frequencies determined by the developed numerical tool have been verified by measurements on artificially aged coils. The study has been extended to the influence of the supply cable of the electrical machine. The operating limits of the proposed monitoring system are defined for various distances between the electrical machine and the connection point of the measurement systems.

This diploma thesis deals with methods used to determine the temperature field distribution within an electric machine. The first part is focused on methods of temperature measurement, generation and transfer of the thermal energy within the electric machine, asynchronous motor in particular. The thesis describes classical methods of temperature measurement and it also deals with ANSYS Workbench finite element method for thermal analysis of the motor. The final part of the thesis is focused on a comparation of all discussed methods with respect to results of thermal test for real asynchronous motor and concludes the most proper method.

The Master's thesis deals with the mechanical design of electric machine rotor. Within the first two chapters of the practical part of the thesis two simplified computational models of the rotor (level 1 models) are compiled. Specifically, the model of flexible rotor mounted on rigid supports and model of rigid rotor mounted on flexible supports. The essence of these computational models lies in solvability using simple equations. Using these models can save time when constructing a pre-design of the rotor geometry. The following chapter is devoted to comparing different approaches to computational modeling of rotor using FEM. A predetermined preliminary design of a high-speed massive rotor is investigated. Computational models of different levels at stress-strain analysis and modal analysis are presented. It also includes a suggestion on how to proceed effectively in a given analysis.

More efficiency heavy-duty vehicles are developed with higher range, updated electronic and mechanical parts. The fuel efficiency and pollution of carbon dioxide need to be lower to achieve new EU regulations. The global population increases with an increased number of heavy-duty vehicles. This, in turn, increases the emission. By taking the electrical and mechanical parts to the next step, the global emission problems can be massively reduced. Electrical machines are the next step towards a cleaner future. The main goal of this study to investigate the electrical machine’s insulation system. Thermo-mechanical stresses due to thermal cycling affect the electrical machines and its sub-components. By using a FEM application with simplified models of the electrical machine, results are obtained and discussed. Specifically, if 2D-models are sufficient enough to represent a 3D-model. How good different 2D-models can represent the 3D-model is compared and discussed in this study. A physical experimental analysis is done to verify and calibrate the FE-models. Which one of the less frequent higher amplitude or more frequent, lower amplitude thermal cycling affects the insulation system most is determined. The simulations could be done with either, coupled-temperature displacement analysis or sequentially coupled analysis. Coupled-temperature displacement is the fastest method to use in the simulation models. A 3D-model is the best way to describe an object and is therefore implemented. Two additional 2D-models are developed for faster computation and to investigate if the models can represent the three-dimensional geometry. All the models have specific boundary conditions to make the models more simplified. Sensitivity studies have been done to determine which parameter affects the induced thermo-mechanical stresses the most. A physical experimental setup is also implemented to validate and calibrate the simulation model. The result of the 3D-model is most accurate when simulating a three-dimensional object. Simulation results have shown that epoxy, one of the main components in the insulation system, is most critical in terms of reaching breakdown first, followed by paper insulation and copper coating. This is a typical result of all three simulation models. Whereas it is concluded that some 2D-models can present the 3D-model, others can’t. The dependent factor is the different cross-section of the electrical machine. The physical experiment shows similar results between simulation in terms of strain at a lower temperature, and the deviation gets larger as the temperature increases. The 3D-model is the model that has the best representation of a real electrical machine as it accounts for all the normal and shear stress components in all directions, but also because it has better boundary conditions compared to the 2D-models. The 2D-model in XY-plane has shown similar results to the 3D-model. One of the main insulation system components, epoxy, is exposed to the highest stresses compared to its yield and ultimate strength, followed by the paper insulation and copper coating. The sensitivity study has concluded that the axial length of the stator does not affect the stress amplitudes. The most critical parameter that affects the thermo-mechanical stresses is the temperature amplitude, the materials CTE and the thickness of the jointed layer. All maximum stress amplitudes of all the components are located at the free end. / Mer effektiva tunga fordon utvecklas med högre räckvidd, uppdaterade elektroniska och mekaniska delar. Bränsleeffektiviteten och föroreningen av koldioxid måste vara lägre för att uppnå nya EU-förordningar. Antalet tunga fordon ökar i takt med att den globala befolkningen ökar, detta leder i sin tur till ökad utsläpp av bland annat koldioxid. Genom att ta de elektriska och mekaniska delarna till nästa steg kan de globala utsläppsproblemen minskas massivt. Elektriska maskiner för framdrivning är nästa steg mot en renare framtid. Studiens huvudmål för att undersöka den elektriska maskinens isoleringssystem. Termomekaniska påfrestningar på grund av termisk cykling påverkar de elektriska maskinerna och dess delkomponenter. Genom att använda en FEM-applikation med förenklade modeller av den elektriska maskinen erhålls och diskuteras resultat. Specifikt om 2D-modeller är tillräckliga för att representera en 3D-modell. Hur tillräckligt de olika 2D-modeller kan representera 3D-modellen jämförs och diskuteras i denna studie. Ett fysiskt experiment utförs för att validera och kalibrera FEA-modellerna. Vilken av de mindre frekventa cykler med högre amplitud eller mer frekventa cyckler med lägre amplitud påverkar isoleringssystemet mest har undersökts. Simuleringarna kan göras med antingen, temperatur kopplad förskjutnings analys eller sekventiellt kopplad analys. Temperatur kopplad kopplad förskjutning är den snabbaste metoden att använda i simuleringsmodellerna. En 3D-modell är det bästa sättet att beskriva ett objekt och har därför implementerats. Ytterligare två, 2Dmodeller är framtagna i FEM-miljö för snabbare beräkning och för att undersöka om 2D-modellerna kan representera den tredimensionella geometrin. Samtliga tre modeller har specifika randvillkor för att förenkla modellerna. Känslighetsstudier görs för att bestämma vilken parameter som påverkar de inducerade termomekaniska spänningarna mest. Ett fysiskt experiment har utförsts för att validera och kalibrera simuleringsmodellerna. Resultatet visar att 3D-modellen representerar ett tre dimensonellt objekt bäst. Simuleringsresultat har visat att epoxy, som är en av huvudkomponenterna i isoleringssystemet, är mest kritisk när det gäller att först nå brott- och sträckgräns, följt av pappersisolering och koppar beläggningen. Detta är ett typiskt resultat av alla tre simuleringsmodeller. Slutsatsen visar att vissa 2D-modeller kan presentera 3D-modellen, andra kan inte. Den beroende faktorn beror på ur vilket tvärsnitt man tittar på den elektriska maskinen. Det fysiska experimentet visar liknande resultat jämfört med simuleringen när det gäller belastning vid en lägre temperatur, och avvikelsen blir större när temperaturen ökar. 3D-modellen, är den modell som har den bästa representationen av en riktig elektrisk maskin eftersom den inkluderar normal- och skjuvspänningskomponenter i alla riktningar. Anledningen är att den har bättre randvillkor jämfört med 2Dmodellerna. 2D-modellen i XY-planet har visat liknande resultat som 3D-modellen. En av huvudkomponenterna i isoleringssystemet, epoxy, utsätts för de högsta spänningarna jämfört med dess sträck- och den brottgräns, följt av pappersisolering och koppar beläggning. Känslighetsstudien har kommit fram till att statorns axiella längd inte påverkar spänningsamplituderna. Den mest kritiska parametern som påverkar de termomekaniska spänningarna är temperatur amplituden, materialens CTE och tjockleken på det skarvade skiktet. Alla maximala spänningsamplituder för samtliga tre komponenter är belägna i den fria änden.