Multiphase Electrical Machines (MPEMs) with variable phase-pole configurations have recently gained interest as it offers advantages such as a larger operating range and improved fault tolerance compared to more traditional MPEMs. The current state-of-the-art modeling and control method, Vector Space Decomposition (VSD), has the drawback of introducing discontinuities in the model when transitioning from one phase-pole configuration to another. The newly developed Harmonic Plane Decomposition (HPD) theory, which is an extension of the VSD, solves this issue by unifying all possible phase-pole configurations into one transformation. To enable further research on HPD theory and MPEMs with variable phase-pole configuration, a test bench is desired to obtain experimental results. The Sustainable Power Lab at KTH already possesses a MPEM with varying phase-pole configurations, the Wound Independently- Controlled Stator Coils machine (WICSC machine), but is missing a complete drive that can capitalize on the additional degrees of freedom that the machine offers. The aim of the thesis is to commission the test bench by implementing HPD control on a Digital Signal Processor (DSP) and design the missing hardware required to close the signal chain. The HPD control was implemented on a Xilinx System on a Chip (SoC) programmed using C and hardware description languages. Part of the control was tested but due to issues with the data acquisition, the complete control was not managed to be fully tested and verified. For the missing hardware, three Printed Circuit Boards (PCBs) were designed for the test bench. Two of them were built and tested, and one PCB was designed but not fabricated during the project. / Multifasmaskiner med variabel fas pol konfiguration har på senaste tiden fått mer uppmärksamhet på grund av fördelar som mer operationspunkter och förbättrad feltolerans jämfört mot mer traditionella multifasmaskiner. Den modernaste metoden, Vector Space Decomposition (VSD), för att styra traditionella multifasmaskiner har nackdelen att modellen blir diskontinuerlig när man går från en fas pol konfiguration till en annan. Den nyutvecklade Harmonic Plane Decomposition (HPD) teorin, vilket är en påbyggnad på VSD, löser det problemet genom att samla alla möjliga fas pol konfigurationer till en transform. För att fortsätta forskningen kring HPD och multifasmaskiner med variabel fas pol konfiguration behövs en testbänk för att kunna skaffa experimentella resultat. Elkraftlabbet på KTH har redan investerat i en multifasmaskin med variabel fas pol konfiguration, men saknar en komplett växelriktare som kan utnyttja maskinens alla frihetsgrader. Målet med projektet var att färdigställa testbänken genom att implementera HPD styrningen på en processor och konstruera hårdvara som testbänken saknade. HPD styrningen implementerades på en systemkrets från Xilinx och programmerades med C och hårdvarubeskrivande språk. Delar av styrningen kunde testas men på grund av problem med inläsningen av data så gick det inte att verifiera hela den implementerade styrningen. Till testbänken konstruerades också tre kretskort varav två byggdes, testades och fick sin funktionalitet verifierad. Det andra kretskortet konstruerades men blev inte tillverkat under projektet.

In this report, the effect of external torque injection of a particular phase and frequency was analyzed using an induction motor assembly consisting of a prototype of an induction motor and a flexible mounting arrangement. The eigenfrequencies of the several components that make up the construction of the induction machine assembly are found out both by analytical and FEM methods. The electromagnetics of the Induction machine is simulated utilizing COMSOL Finite Element Analysis (FEA) software. The single direction coupling is set up to synchronize the parameters between the Rotating Machinery, Magnetic (RMM) and Multi Body Dynamics (MBD) models in COMSOL. / I denna rapport analyserades effekten av extern momentinsprutning av särskild fas och frekvens med hjälp av en induktionsmotor som består av en prototyp av induktionsmotor och ett flexibelt monteringsarrangemang. Egenfrekvenserna för de flera komponenterna som utgör konstruktionen av induktions maskin aggregatet upptäcks både med analytiska metoder och metoder. Induktions maskinens elektromagnetik simuleras med COMSOL FEA programvara. En enkelriktad koppling är konfigurerad för att synkronisera parametrarna mellan RMM och MBD modellerna i COMSOL.

Cette thèse présente le dimensionnement d’une machine électrique à rotor disque pour la traction de véhicules hybrides. Un état de l’art complet sur les machines électriques à rotor disque permet de montrer que la machine à flux axial à rotor central est la plus adaptée. Différentes géométries du circuit magnétique sont successivement étudiées et comparées par simulations par éléments finis. Pour maximiser le rendement de la machine, les pertes d’origine électromagnétique sont étudiées. Un modèle analytique des pertes par effet de peau dans les conducteurs de cuivre est proposé et validé par éléments finis. Un second modèle analytique estime les pertes par courant induits dans les aimants permanents pour tous les points de travail de la machine se basant sur uniquement trois simulations par éléments finis permettant ainsi un gain de temps important lors du dimensionnement. Deux méthodes de dimensionnement sont comparées : le dimensionnement manuel par essais/erreurs et l’optimisation multi-objectifs. Cette dernière méthode automatise le dimensionnement et permet une optimisation plus pointue et une forte amélioration des performances. Dans ce cas, la densité de couple a par exemple été augmentée de 29%. La machine à flux axial dimensionnée est comparée avec une machine à flux radial pour véhicules hybrides. Cette comparaison révèle le potentiel de la machine à flux axial avec notamment une densité de couple augmentée de plus de 20%. Enfin, deux prototypes ont été construits et mesurés pour valider les simulations. / This PhD presents the design of a disc rotor electric machine for the traction of hybrid vehicles. A complete state of the art enables the selection of the internal rotor axial flux machine which is the most suited to this application. Different geometries of the magnetic circuit are successively studied and compared with finite elements simulations. To maximize the efficiency of the machine losses generated in the magnetic circuit are studied. An analytic model on the skin effect in the copper conductors is proposed and validated with finite elements simulations. A second analytic model estimates the eddy current losses in the permanent magnets for every operating point of the machine based on only three finite element simulations enabling an important time-saving. Two dimensioning methods are compared: the manual dimensioning based on a tries/errors method and the multi-objectives optimization. This last method automates the dimensioning and enables a more refined optimization and a strong improvement of the performances. For example, the torque density has been improved by 29% in that case. The designed axial flux machine is compared to a state of the art radial flux machine for hybrid vehicle. This comparison shows the potential of the axial flux machine with an improvement of the torque density by more than 20%. Finally two prototypes have been built and measured to validate the simulations.

This diploma thesis deals with proposal of electrical equipment for soaking and drying cores for making castings at foundry in a Great Britain. It brings look at system of technical norms ČSN and it compares it with british system of technical norms British standards. The second part of this thesis contains detailed proposal of this equipment, including specification of control system, specification of power supply cables and control cables and particular technological units. The whole project documentation is enclosed as an inseparable attachment of this diploma thesis.

L’objectif de ce travail est d’élaborer un modèle performant/précis de la machine électrique permettant de proposer une technique de pronostic. Dans cette thèse, nous commençons par un état de l’art sur les véhicules électriques hybrides (VHE), les différents types de machines électriques utilisées dans les VHE ainsi que les différents types de défauts pouvant survenir dans ces machines électriques. Nous identifions également les indicateurs de défauts appropriés aux différents défauts considérés. Ensuite, une synthèse de techniques de pronostic pouvant être appliquées est proposée. Le modèle à éléments finis électromagnétiques, thermiques et vibratoires (FEM) de la machine à aimants permanents est présenté. Le modèle est élaboré en fonctionnement normal et défaillant. Les types de défauts considérés sont : démagnétisation, court-circuit et excentricité. Une comparaison entre les deux approches analytique et FEM (méthode numérique) pour la modélisation de machines électromagnétiques est effectuée. Les indicateurs de défauts analysés pour l’extraction les plus pertinents utilisent les différents signaux mesurées suivants : le couple, la température ainsi que les signaux vibratoires en états sains et défectueux. L’approche de pronostic adoptée qui est le modèle de Markov caché (HMM) est développée. L'aspect technique de la méthode est présenté et le module du pronostic est formulé. La méthode de HMM est utilisée pour détecter et localiser les défauts à petites amplitudes. Une stratégie systématique a été développée. Le vieillissement de l’équipement de la machine, en particulier des éléments sensibles comme la bobine de stator et l’aimant permanent, est une question très importante pour le calcul du RUL (Remaining Useful Life). Une stratégie d’estimation pour le calcul RUL est présentée et discutée. La configuration en boucle fermée est très importante. Elle est adoptée par tous les systèmes de véhicules disponibles. Par conséquent, les mêmes étapes mentionnées précédemment s'appliquent également à une configuration en boucle fermée. Un modèle global où l’entrée du FEM de la machine provient de l’onduleur modélisé est élaboré. / The core of the work is to build an accurate model of the electrical machine where the prognostic technique is applied. In this thesis we started by a literature review on hybrid electric vehicles (HEV), the different types of electrical machine used in HEV’s and the different types of faults that may occur in those electrical machine. We also identify the useful monitoring parameters that are beneficial for those different types of faults. Then, a survey is presented where all the prognostic techniques that can be applied on this application are enumerated. The electromagnetic, thermal and vibration finite element model (FEM) of the permanent magnet machine is presented. The model is built at healthy operation and when a fault is integrated. The considered types of faults are:demagnetization, turn to turn short circuit and eccentricity. A confrontation between analytical and FEM (numerical method) for electromagnetic machine modeling is illustrated. Fault indicators where useful measured parameters forfault identification are recognized and useful features from the measured parameters are extracted; torque, temperature and vibration signal are elaborated for healthy and faulty states. The strategy of the adopted prognostic approach which is Hidden Markov Model (HMM) is explained. The technical aspect of the method is presented and the prognostic model is formulated. HMM is applied to detect and localize small scale fault small scale faults were where a systematic strategy is developed. The aging of the machine’s equipment,specially the sensitive ones that are the stator coil’s and the permanent magnet, is a very important matter for RUL calculation. An estimation strategy for RUL calculation is presented and discussed for those mentioned machine’s components. Closed loop configuration is very important; it is adopted by all available vehicle systems. Hence, the same previously mentioned steps are applied for a closed loop configuration too. A global model where the input of the machine’s FEM comes from the modeled inverter is built.

In this master thesis, the magnetic properties of SiFe laminations after cutting and welding are studied. The permeability and the iron loss density are investigated since they are critical characteristics for the performance of electrical machines. The magnetic measurements are conducted on an Epstein frame for sinusoidal variations of the magnetic ux density at frequencies of 50, 100 and 200 Hz, according to IEC 404-2. Mechanical cutting with guillotine and cutting by means of ber and CO2 laser are performed. The inuence of the ber laser settings is also investigated. Especially the assisting gas pressure and the power, speed and frequency of the laser beam are considered. In order to increase the cutting e ect, the specimens include Epstein strips with 1, 2 and 3 additional cutting edges along their length. It is found that mechanical cutting degrades the magnetic properties of the material less than laser cutting. For 1.8% Si laminations, mechanical cutting causes up to 35% higher iron loss density and 63% lower permeability, compared to standard Epstein strips (30 mm wide). The corresponding degradation for laser cut laminations is 65% iron loss density increase and 65% permeability drop. Material of lower thickness but with the same Si-content shows lower magnetic deterioration. Additionally, laser cutting with high-power/high-speed characteristics leads to the best magnetic characteristics among 15 laser settings. High speed settings have positive impact on productivity, since the cutting time decreases. The inuence of welding is investigated by means of Epstein measurements. The test specimens include strips with 1, 3, 5 and 10 welding points. Experiments show an iron loss increase up to 50% with a corresponding 62% reduction in the permeability. A model that incorporates the cutting e ect is developed and implemented in a FEMbased motor design software. Simulations are made for a reference induction motor. The results indicate a 30% increase in the iron losses compared to a model that does not consider the cutting e ect. In case of laser cut core laminations, this increase reaches 50%. The degradation prole considers also the deteriorated magnetizing properties. This leads to increased nominal current up to 1.7% for mechanically cut laminations and 3.4% for laser cut la / I detta examensarbete studeras hur de magnetiska egenskaperna hos SiFe-plat paverkas av skarning och svetsning. Permeabilitet och jarnforlustdensitet undersoks eftersom de ar kritiska variabler for elektriska maskiners prestanda. De magnetiska matningarna genomfordes pa en Epstein ram med en odesfrekvens pa 50, 100 och 200 Hz, enligt IEC 404-2. E ekterna av mekanisk skarning med giljotin samt skarning med ber- och CO2-laser studerades. Inverkan av olika berlaserinstallningar undersoktes ocksa genom att variera gastrycket, skarhastigheten samt frekvensen och e ekten av laserstralen. For att oka skare ekten inkluderades Epsteinremsor med ytterligare 1, 2 och 3 langsgaende skarsnitt. Det visas att mekanisk skarning har en mindre paverkan pa de magnetiska egenskaperna hos materialet an vad laserskarning har. Matningar pa plat med 1.8% Si visar att da prov med tre extra langsgaende giljotinklipp anvands kan permeabiliteten reduceras med upp till 63% och jarnforlusterna kan oka med upp till 35%. Motsvarande resultat for laserskurna platar visar en permeabilitetsreduktion pa upp till 65% och en jarnforlustokning pa upp till 65%. Ur studien av de tva studerade skarprocesserna framkommer aven att tunnare plat paverkas mindre negativt an tjockare plat. Ett antal olika installningar har provats for att utreda hur olika parametrar paverkar e ekterna av laserskarning. Studien indikerar att skarning med hog e ekt och hog hastighet ger den minsta paverkan pa materialets magnetiska egenskaper. Vilket aven har en positiv inverkan pa produktiviteten vid laserskarning. Epsteinprover har aven utforts for att undersoka vilka e ekter som introduceras da SiFe-plat svetsas. Provstyckena bestod av remsor med en, tre, fem och 10 svetspunkter. Experimenten visar en jarnforlustokning med upp till 50% samt en permeabilitetsreduktion upp till 62% da platarna svetsats samman tva och tva. En modell for att studera e ekterna av de forandrade materialegenskaperna vid skarning pa en induktionsmotor utvecklas och implementeras i en FEM-baserad mjukvara. Resultaten tyder pa en jarnforlustokning med 30% da skare ekten orsakad av giljotin beaktas. Vid simulering av laserskuren plat kan denna okning vara sa stor som 50%. Det framkommer aven att laserskarningen kan reducera e ektfaktorn sa mycket som 2.6%.