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This thesis deals with the integral motor of tomorrow, and particularly with a variable speed, sensorless permanent magnet synchronous motor with an integrated converter. The rated power is 15 kW at 1500 r/min. The outer dimensions are approximately the same as for the equivalent standard induction motor. Control strategies for pumps and fans, i.e. suitable loads for variable speed motors, are briefly described. The huge energy savings that can be made by reducing the speed instead of throttling/choking the flow are pointed out. Compared to installing an induction motor with a separate converter, a PM integral motor will probably pay-off in less than a year. A totally analytical expression for calculating the airgap flux density of permanent magnet motors with buried magnets is derived. The analytical expression includes axial leakage, and iron saturation of the most narrow part of the magnetic circuit of the machine. A computer program for optimization of PM motors with buried magnets has been developed. It was used to design the manufactured prototype PM integral motor, and the parameters are investigated with analytical and/or FEM calculations. The optimization program is also used to suggest nearoptimum pole numbers for desired powers (4-37 kW) and speeds (750- 3000 r/min) of inverter-fed PM motors. Results show that compact buried PM motors should have relatively large airgaps and high NdFeB-magnet masses to improve the efficiency. Ferrite magnets are unsuitable. Measurements on the manufactured PM motor, the novel concept of stator integrated filter coils, and the complete PM integral motor are presented. Special attention was given to temperature and overall efficiency measurements. The rotor cage losses were investigated by time-stepping FEM. Four short circuit fault conditions were also examined in order to evaluate the risks of demagnetization of the buried magnets.

<p>This thesis deals with the integral motor of tomorrow, and particularly with a variable speed, sensorless permanent magnet synchronous motor with an integrated converter. The rated power is 15 kW at 1500 r/min. The outer dimensions are approximately the same as for the equivalent standard induction motor.</p><p>Control strategies for pumps and fans, i.e. suitable loads for variable speed motors, are briefly described. The huge energy savings that can be made by reducing the speed instead of throttling/choking the flow are pointed out. Compared to installing an induction motor with a separate converter, a PM integral motor will probably pay-off in less than a year.</p><p>A <i>totally analytical</i> expression for calculating the airgap flux density of permanent magnet motors with buried magnets is derived. The analytical expression includes axial leakage, and iron saturation of the most narrow part of the magnetic circuit of the machine.</p><p>A computer program for optimization of PM motors with buried magnets has been developed. It was used to design the manufactured prototype PM integral motor, and the parameters are investigated with analytical and/or FEM calculations. The optimization program is also used to suggest nearoptimum pole numbers for desired powers (4-37 kW) and speeds (750- 3000 r/min) of inverter-fed PM motors. Results show that compact buried PM motors should have relatively large airgaps and high NdFeB-magnet masses to improve the efficiency. Ferrite magnets are unsuitable.</p><p>Measurements on the manufactured PM motor, the novel concept of stator integrated filter coils, and the complete PM integral motor are presented. Special attention was given to temperature and overall efficiency measurements.</p><p>The rotor cage losses were investigated by time-stepping FEM. Four short circuit fault conditions were also examined in order to evaluate the risks of demagnetization of the buried magnets. </p>

To develop more competitive solutions, one of the trends in the development of drive systems for electric and hybrid electric vehicles (EVs/HEVs) is to integrate the power electronic converter and the electric motor. This thesis aims to investigate the performance and the operation of modular converters in integrated motor drive systems for EVs/HEVs. In the first part, the concept of integrated modular motor drive systems for EVs/HEVs is introduced. Three suitable modular converter topologies, namely, the stacked polyphase bridges (SPB) converter, the parallel-connected polyphase bridges (PPB) converter and the modular high frequency (MHF) converter, are evaluated and compared with conventional electric drives in terms of power losses, energy storage requirements, and semiconductor costs. In the second part of the thesis, the harmonic content of the dc-link current of the SPB converter is analyzed. By adopting an interleaving modulation the size of the dc-link capacitor can be reduced without increasing the switching frequency, which is beneficial for achieving a compact integrated system. This method allows for around 80% reduction of the dc-link capacitance for vehicle drives, resulting in a significant size reduction of the power converter and improved integration. Finally, a communication-based distributed control system for the SPB converter is presented. The communication delay arising from the serial communication is inevitable, thus a timing analysis is also presented. It has been found that stability is maintained even when the baud rate of the SPI communication is lower than 1 Mbps, indicating that other communication protocols with lower bandwidths can also be adopted for this topology. The analytical investigations provided in this thesis are validated by experiments on a four-submodule laboratory prototype. Experimental results verify the correctness of the theoretical analysis, as well as the dynamic performance of the distributed control system. / <p>QC 20161121</p>

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