The evolution of aircraft has led into a large increase in the demand for electrically integrated subsystems. Part of this demand is the transformation of a centralized hydraulic systems to independently operated electrical subsystems. The result of this overhaul will decrease aircraft weight, increase reliability, reduce aircraft lifetime maintenance and cost, and help to increase the control of power distribution. This thesis proposes the design methodology of a multi-pole permanent magnet (PM) motor with a capability to operate at high temperature. High temperature capability is one of the key requirements to implement electromechanical actuation for aircraft flight control, replace hydraulic actuation system, especially in tactical military aircraft, due to the hot environment and lack of heat sink. Temperature effects on motor materials are reviewed. The need for high power density is considered in the design. The motor design is confirm by ANYSYS RMXprt software. Along with the motor design, a voltage control method is also designed for the motor. Integrated electrical simulation results of the motor and controller to follow highly dynamic flight profiles are provided to show the stroke tracking, input power (including regenerative power), and winding copper loss. Experimentation set-up of EMA and experimental uncertainties are also discussed.

This dissertation is concerned with the design of permanent magnet synchronous motors (PMSM) to operate at super-high speed with high efficiency. The designed and fabricated PMSM was successfully tested to run upto 210,000 rpm The designed PMSM has 2000 W shaft output power at 200,000 rpm and at the cryogenic temperature of 77 K. The test results showed the motor to have an efficiency reaching above 92%. This achieved efficiency indicated a significant improvement compared to commercial motors with similar ratings. This dissertation first discusses the basic concept of electrical machines. After that, the modeling of PMSM for dynamic simulation is provided. Particular design strategies have to be adopted for super-high speed applications since motor losses assume a key role in the motor drive performance limit. The considerations of the PMSM structure for cryogenic applications are also discussed. It is shown that slotless structure with multi-strand Litz-wire is favorable for super-high speeds and cryogenic applications. The design, simulation, and test of a single-sided axial flux pancake PMSM is presented. The advantages and disadvantages of this kind of structure are discussed, and further improvements are suggested and some have been verified by experiments. The methodologies of designing super high-speed motors are provided in details. Based on these methodologies, a super high-speed radial-flux PMSM was designed and fabricated. The designed PMSM meets our expectation and the tested results agree with the design specifications. 2-D and 3-D modeling of the complicated PMSM structure for the electromagnetic numerical simulations of motor performance and parameters such as phase inductors, core losses, rotor eddy current loss, torque, and induced electromotive force (back-EMF) are also presented in detail in this dissertation. Some mechanical issues such as thermal analysis, bearing pre-load, rotor stress analysis, and rotor dynamics analysis are also discussed. Different control schemes are presented and suitable control schemes for super high- speed PMSM are also discussed in detail.

Driven by the gradually increasing electrification of the transportation industry, in particular the aviation sector, the future’s electrified aircraft requires not only an improvement of the flight operation, but also an enhancement of the movement on ground. One very promising concept to improve the taxiing operation is the integration of an electric propulsion system into the aircraft’s undercarriage, also called “Electric Taxiing”. This yields a decrease of the overall fuel consumption, reduction of emissions, and improvement of aircraft maneuverability to help reducing operating times on ground. In this thesis, the performance requirements for an electric taxiing system are investigated by using self-recorded real-life aircraft taxiing drive cycle data. Based upon the system requirements, the powertrain for the electric propulsion system is sized for a commercial midsize aircraft to achieve a similar driving performance to conventional taxiing maneuvers. The sized powertrain, including the determined electric motor characteristics, is evaluated using a developed simulation model which allows testing the proposed electric taxiing system given the attained drive cycles. For the electric machine which is implemented into the wheel of the aircraft’s main landing gear, an axial flux permanent magnet (AFPM) motor with segmented stator windings is selected due to its very compact structure while providing high torque capabilities. The AFPM motor is designed and evaluated by using analytical models and three-dimensional finite element analysis (3D FEA) to fulfill the specified motor characteristics required for the electric propulsion unit. Finally, suggestions for potential improvements and future work are discussed. / Thesis / Master of Applied Science (MASc)

With the unstable cost and supply of rare earth materials used in permanent magnet electric machines, many alternative machine types are being studied which are suitable for different applications. The focus of this thesis is the design of a novel 6/14 switched reluctance machine which can be fitted in a residential heating, ventilation, and air-conditioning (HVAC) application based on measured performance characteristics of an existing surface mount permanent-magnet synchronous (SMPS) machine. Residential electric motor applications are reviewed and in particular - furnace blower motor appliances. The fundamentals of switched reluctance machines are discussed, including the mechanism, operation, and control strategy. A SMPS motor which is commercially available for retrofitting into residential HVAC systems is analyzed to find its performance characteristics through disassembly, inspection, and dynamometer bench testing. The design of a novel 6/14 SRM optimization process is outlined to investigate the effect of changing the geometry values within the motor on the performance characteristics, while keeping within the size constraints of the original motor. A novel 6/14 SRM design is presented which is capable of achieving the target goals in the desired operating conditions. Further suitability testing is performed in terms of thermal analysis of the motor in the peak and continuous operating condition and mechanical stress analysis of the rotor under various rotational speeds. The full CAD assembly of the motor is designed including components from the original SMPS motor to allow for fitting in the same HVAC application. / Thesis / Master of Applied Science (MASc) / With the unstable cost and supply of rare earth materials used in permanent magnet electric motors, many alternative machine types are being studied which are suitable for different applications. The focus of this thesis is the design of a novel 6/14 switched reluctance machine which can be fitted in a residential heating, ventilation, and air-conditioning (HVAC) application based on measured performance characteristics of an existing surface mount permanent-magnet synchronous (SMPS) machine. Switched reluctance machines have a number of benefits over permanent magnet machines including that they do not have permanent magnets, are less sensitive to high heat scenarios, have lower manufacturing costs, are more robust, and are generally capable of higher operating speeds. Residential electric motor applications are reviewed and in particular - furnace blower motor appliances. The fundamentals of switched reluctance machines are discussed, including the mechanism, operation, and control strategy. A SMPS motor which is commercially available for retrofitting into residential furnace systems is analyzed to find its performance characteristics through disassembly, inspection, and dynamometer bench testing. The design of a novel 6/14 SRM optimization process is outlined to investigate the effect of changing the geometry values within the motor on the performance characteristics, while keeping within the size constraints of the original motor. A novel 6/14 SRM design is presented which is capable of achieving the target goals in the desired operating conditions. Further suitability testing is performed in terms of thermal analysis of the motor in the peak and continuous operating condition and mechanical stress analysis of the rotor under various rotational speeds. The full 3D CAD assembly model of the motor is designed including components from the original SMPS motor to allow for fitting in the same HVAC application.

Enhancing the dependability and power density of a SPMSMs is crucial for its extensive utilization in the automotive and aerospace sectors. One major concern regarding these machines is the significant thermo-mechanical loads experienced by the overall rotating assembly due to high rotational speeds and a wide operational temperature range from $50^\circ C$ to $150^\circ C$. This poses a considerable challenge in maintaining structural integrity among the components. Redesigning components to reduce assembly complexity and weight necessitates careful consideration of boundary conditions and contact modeling to prevent catastrophic failures like magnet fly-by conditions. To reduce model complexity, a simplified approach involves integrating the hub and shaft; both machined from AISI 4340. Additionally, the application of a carbon fiber sleeve is investigated through 3-dimensional composite modeling to enhance structural integrity. The primary objective of this thesis is to scientifically justify the design and validation of an integrated rotor hub and shaft using efficient FEM and integration strategies, with the aim of maximizing the durability of a $150kW$ radial flux SPMSMs spinning at $20,000 rpm$. The integrated topology optimization is evaluated using a multiphysics platform alongside studies on motor assembly eigenfrequency. By employing the integrated approach and utilizing AISI 4340 for both the shaft and rotor hub, a weight reduction of $1.84kg$ is achieved, eliminating the need for standard components such as balancing end clamp plates, locknuts, and washers. Furthermore, introducing a carbon fiber sleeve enhances structural integrity, thereby reducing adhesive stress. The design and optimization of the rotating components ensure that the maximum von Mises stress is $50\%$ lower than the material's yield strength. Reduced masses lead to lower centrifugal forces, thereby diminishing radial stress and promoting component and assembly stiffness. / Thesis / Master of Applied Science (MASc) / This thesis aims to increase the reliability and power density of a surface-mounted permanent magnet synchronous machine (SPMSMs), a commonly used traction motor in the automotive and aerospace industries. One of these machines' main challenges is designing their components to withstand the high mechanical loads caused by their fast rotational speeds. The studies performed in this thesis use a computer modeling technique called Finite Element Modeling (FEM) to strategize and design an integrated rotor hub/shaft by maximizing the durability of a 150kW radial flux SPMSMs rotating at 20,000 rpm. Upon evaluating the integrated design using a variety of physics-based simulations, the design was found to save 1.84kg in weight, reducing centrifugal forces and improving the overall stiffness of the motor assembly. This research could lead to more efficient and durable electric SPMSMs for various applications.

The growing demand of electrified light duty trucks, including sports utility vehicles (SUV) require high performance motors to surpass form their internal combustion engine counterparts. The Axial Flux Permanent Magnet (AFPM) Motor is expected to be one of the leading technologies to meet the demands of these industries due to its efficenct and high torque and power density. Designing a robust thermal management system for this motor is key to utilizing these performance benefits. To meet these demanding conditions, additive manufacturing is expected to play a critical role in enhancing performance. Additively manufactured hollow coil is a cooling strategy to extract heat directly from the hottest part of the motor, the stator. The following research assesses the viability of the design in a prototype motor. ANSYS CFX is used to characterize the pressure drop and flowrate, and a test setup is used to validate the results. The challenges associated with integrating the solution into a motor is highlighted as well as design issues during design development. Finally, the integration of a parallel hybrid SUV using an AFPM motor is documented and the challenges with integration into a vehicle is explained. / Thesis / Master in Advanced Studies (MAS)

Switched reluctance machines (SRMs) are well known for their simple and robust structure, facilitating their increasing application in many sectors, for example vacuum cleaners, where domestic machines operate at high-speed, 50,000 RPM being typical. Conventional SRMs (CSRMs) use a decoupled concentrated phase winding so that torque is predominantly only generated due to the self-inductance, which limits utilization of the machine electrical circuits. In this thesis, the toroidal winding SRM (TSRM) is introduced, which operates based on the variation of mutual inductance between different phases. The toroidal winding introduces additional winding space, and the winding is practically easy to implement, both features that lead to a relatively higher copper filling factor. The toroidal winding also benefits the machine thermal performance, as the winding is directly exposed on the machine periphery and thus accessible to cooling. All these make TSRMs interesting and meaningful for further study. Following a comprehensive comparison of CSRM and TSRM characteristics, a general torque equation is presented that is applicable to both CSRM and TSRM. Two 12-switch converters are proposed to drive three-phase TSRMs. Moreover, sinusoidal current excitation with a commercial three-phase half-bridge converter has been suggested as an alternative converter solution for TSRMs. Accordingly, a three-phase six-stator-pole, four-rotor-pole CSRM is designed and optimized with a speed of up to 50,000 rpm in this thesis. A TSRM is resized to achieve the same envelope dimension as a benchmark CSRM. Thus, a comparative study between high-speed CSRM and TSRMs has been carried out. They have both been prototyped and tested. The findings suggest that the TSRM is superior, considering machine mass and wire temperature management. The TSRM has a better torque output at lower speeds because copper losses are dominant. However, the CSRM has more advantages at higher speeds due to lower iron losses and lower DC voltage requirements. / Thesis / Doctor of Philosophy (PhD)

A novel belt alternator starter (BAS) is proposed to replace the starter and alternator in a hybrid electric vehicle. The BAS designed utilizes an 18 rotor, 12 stator pole switched reluctance machine (SRM) configuration, with concentrated bar windings wound in parallel. Through iteration of various machine geometry parameters, the SRM can meet the torque and speeds demands over standardized drive cycles described by the US Environmental Protection Agency. / With the depletion of oil wells and changing global climate, a large emphasis is placed on the research, development and adoption of electric vehicles (EVs) to replace vehicles driven by internal combustion engines (ICEs). However the global supply chain is still not ready for such a large demand in EVs; therefore hybrid electric vehicles (HEVs) aim to ease the transition between ICEs and EVs. The research outlined in this thesis investigates the design of a 18 stator, 12 rotor pole (18/12) configuration switched reluctance machine (SRM) utilizing novel technologies for use as a belt alternator starter (BAS) motor in an HEV. Background research on current trends and technologies for electric motors and vehicles is performed before evaluating initial geometry for the motor core to be designed. Initial geometry is brought into JMAG to develop an electromagnetic model and begin the geometry optimization. The 18/12 design process highlights how changes to motor parameters from a geometry and winding standpoint will affect motor performance. After the motor core geometry yields suitable performance, a mechanical design is proposed encompassing the rotary assembly, cooling as well as solutions for mounting. / Thesis / Master of Applied Science (MASc) / Hybrid electric vehicles are becoming more prevalent as stricter restrictions are placed on fuel economy and emissions targets. Full electric vehicles on the other hand have not yet become the standard form of transportation due to the limits on range and infrastructure. Because of this, automotive manufacturers are researching and developing new methods in which they can meet these restrictions and limitations. Switched reluctance motors aim to be a solution to meet these demands while forging a new path by alleviating the demand on rare earth metals for the motor core. In this thesis, a design is proposed to fill an existing role in vehicle electrification best suited for a belted alternator starter.

Traffic congestion in large urban and metropolitan areas is a substantial problem plaguing these areas. Not only are commuters losing valuable time, but greenhouse gas emissions are substantially worse because of congestion. Considerable research and development into next generation electrified aircraft is ongoing to introduce air mobility as a viable new means of transporting people and goods across long commutes. This development extends into commercial aviation as a whole as a means of reducing the industry’s carbon footprint with new aircraft designs that employ electrified propulsion systems. Many electrified aircraft projects are currently underway, ranging from small commuter aircraft all the way to large twin-aisle aircraft, and part of the development scope for alot of these projects is creating highly robust and power dense electric machines that replace the current state-of-the-art. The axial flux permanent magnet synchronous machine is an exciting candidate for aircraft propulsion due to its exceptional torque density and compact axial nature. In this thesis, the mechanical design for three generations of axial flux permanent magnet synchronous machines is discussed. These machines serve as development phase prototypes for machines that are ultimately intended for propulsion applications in commercial aviation, particularly for eVTOL aircraft. The motivation for electrification in the commercial aviation industry is discussed, followed by an overview of the development landscape for electrified propulsion systems in commercial aviation, focusing primarily on electric machines that are currently state-of-the-art or are set to be in the near future, as well as what is required for future electric machines in terms of power output and power density. The axial flux architecture is then presented, including a high-level comparison to the radial-flux architecture, an overview of the various axial flux machine designs and topologies, and a discussion of the inherent mechanical design challenges associated with the axial flux architecture. The yokeless and segmented armature axial flux permanent magnet synchronous machine design was selected for the machines developed as part of the research for this thesis, and the discussion of the mechanical design of these machines is broken up into the two core sub assemblies: stator assembly and rotating assembly. High-level design methodologies are introduced for both sub-assemblies, which is further broken down into different approaches pertaining to each generation. The first and second generation designs are presented at a high level, followed by deep-dives into the complete mechanical design for the third generation stator, the bearing selection, arrangement, and analysis for the third generation rotating assembly, and adhesive characterization trials used to guide adhesive selection for rotor magnetics retention in the second and third generation machines. The current status of the machines and any outcomes from testing that has been conducted thus far, particularly with respect to performance, is presented at the end. / Thesis / Master of Applied Science (MASc)

Recently, permanent magnet assisted (PMa)-synchronous reluctance motors (SynRM) have been considered as a possible alternative motor drive for high performance applications. In order to have an efficient motor drive, performing of three steps in design of the overall drive is not avoidable. These steps are design optimization of the motor, identification of the motor parameter and implementation of an advanced control system to ensure optimum operation. Therefore, this dissertation first deals with the design optimization of the Permanent Magnet Assisted Synchronous Reluctance Motor (PMa-SynRM). Various key points in the rotor design of a low cost PMa-SynRM are introduced and their effects are studied. Finite element approach has been utilized to show the effects of these parameters on the developed average electromagnetic torque and the total d-q inductances. As it can be inferred from the name of the motor, there are some permanent magnets mounted in the rotor core. One of the features considered in the design of this motor is the magnetization of the permanent magnets mounted in the rotor core using the stator windings to reduce the manufacturing cost. At the next step, identification of the motor parameters is discussed. Variation of motor parameters due to temperature and airgap flux has been reported in the literatures. Use of off-line models for estimating the motor parameters is known as a computationally intensive method, especially when the models include the effect of cross saturation. Therefore in practical applications, on-line parameter estimation is favored to achieve a high performance control system. In this dissertation, a simple practical method for parameter estimation of the PMa-SynRM is introduced. Last part of the dissertation presents one advanced control strategy which utilized the introduced parameter estimator. A practical Maximum Torque Per Ampere (MTPA) control scheme along with a simple parameter estimator for PMa-SynRM is introduced. This method is capable of maintaining the MTPA condition and stays robust against the variations of motor parameters. Effectiveness of the motor design procedure and the control strategy is validated by presenting simulation and experimental results of a 1.5 kW prototype PMa-SynRM, designed and manufactured through the introduced design method.