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Aviation is one of the fastest growing methods of transportation, with passenger volumes expected to triple in the next twenty-five years. It is also contributing an ever increasing share of global emissions. One of the highly effective ways to reduce emissions in aerospace is through electrification. This is already underway with the development and adoption of More Electric Aircraft. A next step is the development of hybrid propulsion, or all electric aircraft, with electric propulsion systems. In order to achieve this goal, the power density of the electric drive is of critical importance. Axial flux permanent magnet synchronous machines have been identified as one the highest power density machine types suitable for these electric drives. In this thesis, an axial flux permanent magnet machine is developed for an electric aircraft propulsion system. A review of electric machines in aerospace applications is conducted, followed by an overview of the design and simulation of axial flux machines, and a presentation of the machine under study. The primary objective of this thesis is to improve the stator design of the axial flux machine by reducing loss, weight, and volume. Magnetic materials are studied, and using grain oriented silicone steel for the stator teeth is shown to improve torque production of the machine. The wire, coil, and stator geometry are modified to reduce copper loss. A tightly spaced coil, axially centered on the tooth, with high aspect ratio wire and chamfered pole shoe is shown to reduce loss. Finally, a compact stator winding is proposed with coil terminations on the inner diameter of the stator. The proposed winding reduces the volume of the machine, as well as further reducing copper loss due to less wire utilized. These actions significantly improve the efficiency of the machine, while reducing weight and volume. / Thesis / Master of Applied Science (MASc)

The current standard electrical downhole machine is the induction machine which is relatively inefficient. Permanent magnet (PM) machines, having higher efficiencies, higher torque densities and smaller volumes, have widely employed in industrial applications to replace conventional machines, but few have been developed for downhole applications due to the high ambient temperatures in deep wells and the low temperature stability of PM materials over time. Today, with the development of variable speed drives and the applications of high temperature magnet materials, it is increasingly interesting for oil and gas industries to develop PM machines for downhole applications. Recently, some PM machines applications have been presented for downhole applications, which are normally addressed on certain specific downhole case. In this thesis the focus has been put on the performance investigation of different PM machines for general downhole cases, in which the machine outer diameter is limited to be small by well size, while the machine axial length may be relatively long. The machine reliability is the most critical requirement while high torque density and high efficiency are also desirable. The purpose is to understand how the special constraints in downhole condition affect the performances of different machines.  First of all, three basic machine concepts, which are the radial, axial and transverse flux machines, are studied in details by analytical method. Their torque density, efficiency, power factor and power capability are investigated with respect to the machine axial length and pole number. The presented critical performance comparisons of the machines provide an indication of machines best suitable with respect to performance and size for downhole applications. Conventional radial flux permanent magnet (RFPM) machines with the PMs on the rotor can provide high torque density and high efficiency. This type of machine has been suggested for several different downhole applications. Flux-switching PM (FSPM) machines, which have the PMs located on the stator and are therefore more reliable, can theoretically also exhibit high torque density and relatively high efficiency. This thesis has put an emphasis on studying this type of machine. Two FSPM machines have been investigated in detail and compared by analytical method, FEM simulation and prototype measuremens. Their operating principle and important design parameters are also presented. A lumped parameter magnetic circuit model for designing a high-torque FSPM machine is newly introduced and the designed machine is verified by FEM simulations. A prototype machine with an outer diameter of 100 mm and an axial length of 200 mm is built in the laboratory and tested at room temperature. Based on that, the machine performance at an ambient temperature of 150°C is also predicted. The results show that the FSPM machine can provide a high torque density with slight compromise of efficiency and power factor. Choosing a proper machine type is significantly dependent on the application specifications. The presented results in this thesis can be used as a reference for selecting the best machine type for a specific downhole case.

This thesis focuses on utilizing the persistent voltage vector injections by finite control set model predictive control (FCSMPC) to enable simultaneous estimations of both position and parameters in order to realize robust sensorless interior permanent magnet synchronous machine (IPMSM) drives valid at the entire operating region including no-load standstill without any additional signal injection and switchover. The system (here, IPMSM) needs to meet certain observability conditions to identify the parameters and position. Moreover, each combination of the parameters and/or position involves different observability requirements which cannot be accomplished at every operating point. In particular, meeting the observability for parameters and position at no-load standstill is more challenging. This is overcome by generating persistent excitation in the system with high-frequency signal injection. The FCSMPC scheme inherently features the persistent excitation with voltage vector injection and hence no additional signal injection is required. Moreover, the persistent excitation always exists for FCSMPC except at the standstill where the control applies the null vectors when the reference currents are zero. However, introducing a small negative d axis current at the standstill would be sufficient to overcome this situation.The parameter estimations are investigated at first in this thesis. The observability is analyzed for the combinations of two, three and four parameters and experimentally validated by online identification based on recursive least square (RLS) based adaptive observer. The worst case operating points concerning observability are identified and experimentally proved that the online identification of all the parameter combinations could be accomplished with persistent excitation by FCMPC. Moreover, the effect of estimation error in one parameter on the other known as parameter coupling is reduced with the proposed decoupling technique. The persistent voltage vector injections by FCSMPC help to meet the observability conditions for estimating the position, especially at low speeds. However, the arbitrary nature of the switching ripples and absence of PWM modulator void the possibility of applying the standard demodulation based techniques for FCSMPC. Consequently, a nonlinear optimization based observer is proposed to estimate both the position and speed, and experimentally validated from standstill to maximum speed. Furthermore, a compensator is also proposed that prevents converging to saddle and symmetrical ( ambiguity) solutions. The robustness analysis of the proposed nonlinear optimization based observer shows that estimating the position without co-estimating the speed is more robust and the main influencing parameters on the accuracy of the position estimation are d and q inductances. Subsequently, the proposed nonlinear optimization based observer is extended to simultaneously estimate the position, d and q inductances. The experimental results show the substantial improvements in response time, and reduction in both steady and transient state position errors. In summary, this thesis presents the significance of persistent voltage vector injections in estimating both parameter and position, and also shows that nonlinear optimization based technique is an ideal candidate for robust sensorless FCSMPC. / Thesis / Doctor of Philosophy (PhD)

Exploring the integration of multi-speed gearboxes in electric vehicle (EV) drivetrains, this research presents a comprehensive analysis through detailed gearbox modelling, empirical traction machine testing, and analytical drive unit loss evaluations. The study utilizes two distinct automotive-grade electric machines – an axial-flux permanent magnet synchronous machine and an interior permanent magnet machine, the latter coupled with a single-speed gearbox – to demonstrate how multi-speed gearboxes can enhance drivetrain efficiency and performance for a subcompact EV. Extensive dynamometer testing, incorporating a variety of electrical and thermal conditions, characterizes both traction machines. Findings reveal that despite the incremental churning losses from additional gear pairs, two-speed gearboxes facilitate a more efficient operation of the electric machine, inverter, and gearbox, particularly when optimized through strategic gear ratio selection. Dynamometer testing under no-load conditions and at different temperatures underscores the impact of gearbox churning and bearing drag losses and the potential for their reduction. Detailed examinations of load-dependent and independent losses within the drive unit elucidate the interactions among drivetrain components across various gear ratios. Optimized two-speed gearboxes are shown to reduce vehicle energy consumption by up to 9% and increase driving range compared to conventional single-speed configurations, supported by strategic gear ratio selections and optimizations aimed at achieving vehicle performance targets, such as acceleration, gradeability, and top speed. This research contributes to advancing the field of electric vehicle technology by illustrating the complex trade-offs and potential enhancements achievable with multi-speed drivetrains, setting a precedent for future studies to refine gearbox performance and explore novel technologies to optimize powertrain performance across diverse operational landscapes. / Thesis / Doctor of Philosophy (PhD)

QC 20111214

Neste trabalho é estudado um motor trifásico de ímã permanente no rotor, com fluxo não senoidal, através da análise do campo magnético. Essa máquina foi projetada utilizando-se a estrutura ferromagnética do estator de um motor de indução monofásico de 24 ranhuras o qual recebeu um novo enrolamento trifásico, e foi construído o rotor que é constituído de ímãs permanentes em sua superfície. Ela é aplicada em compressores herméticos de refrigeração, possibilitando o controle de velocidade e a melhoria da eficiência, quando comparada às demais máquinas utilizadas para a mesma aplicação. O estudo é realizado através da análise dos resultados obtidos utilizando-se um programa computacional baseado no método dos elementos finitos, aplicado em grandezas como: tensão induzida, densidade de fluxo magnético, torque eletromagnético e perdas. São apresentados resultados numéricos comparativos para a máquina existente (protótipo) com as seguintes alterações: diminuição do tamanho do entreferro, troca dos ímãs de ferrita pelos de NdFeB (Bonded) e, juntamente com essas mudanças, o recálculo do número de espiras e do diâmetro do enrolamento do estator. / In this work is studied a three-phase permanent-magnet motor, with nonsinusoidal flux, through the analysis of magnetic field. This machine was designed to use the same stator of a 24 slots single-phase induction motor that received a new three-phase winding. The rotor consists of permanent-magnet on its surface. The main application of this machine is in hermetic compressor household refrigeration systems. It has speed control and better efficiency than other machines used for the same application. The study is made through the analysis of numerical results, obtained by a software joint in the finite element method. The results consist in electromagnetic quantity like, back-emf, magnetic flux density, electromagnetic torque and losses. Comparisons between the prototype with these changes are presented: fall in the size of airgap, exchange of ferrite magnets for NdFeB (Bonded) magnets and, together with these changes, the number of turns in each winding and the wire diameter are recalculated.

Neste trabalho é estudado um motor trifásico de ímã permanente no rotor, com fluxo não senoidal, através da análise do campo magnético. Essa máquina foi projetada utilizando-se a estrutura ferromagnética do estator de um motor de indução monofásico de 24 ranhuras o qual recebeu um novo enrolamento trifásico, e foi construído o rotor que é constituído de ímãs permanentes em sua superfície. Ela é aplicada em compressores herméticos de refrigeração, possibilitando o controle de velocidade e a melhoria da eficiência, quando comparada às demais máquinas utilizadas para a mesma aplicação. O estudo é realizado através da análise dos resultados obtidos utilizando-se um programa computacional baseado no método dos elementos finitos, aplicado em grandezas como: tensão induzida, densidade de fluxo magnético, torque eletromagnético e perdas. São apresentados resultados numéricos comparativos para a máquina existente (protótipo) com as seguintes alterações: diminuição do tamanho do entreferro, troca dos ímãs de ferrita pelos de NdFeB (Bonded) e, juntamente com essas mudanças, o recálculo do número de espiras e do diâmetro do enrolamento do estator. / In this work is studied a three-phase permanent-magnet motor, with nonsinusoidal flux, through the analysis of magnetic field. This machine was designed to use the same stator of a 24 slots single-phase induction motor that received a new three-phase winding. The rotor consists of permanent-magnet on its surface. The main application of this machine is in hermetic compressor household refrigeration systems. It has speed control and better efficiency than other machines used for the same application. The study is made through the analysis of numerical results, obtained by a software joint in the finite element method. The results consist in electromagnetic quantity like, back-emf, magnetic flux density, electromagnetic torque and losses. Comparisons between the prototype with these changes are presented: fall in the size of airgap, exchange of ferrite magnets for NdFeB (Bonded) magnets and, together with these changes, the number of turns in each winding and the wire diameter are recalculated.

The demand for ultra-high-speed machines (UHSM) is rapidly growing in high-tech industries due to their attractive features. A-mechanically-based-antenna (AMEBA) system is another emerging application of UHSM. It enables portable wireless communication in the radio frequency (RF)-denied environment, which was not possible until recently. The AMEBA system requires a high-power (HP) UHSM for its effective communication performance. However, at the expected rotational speed range of 0.5 to 1 million rpm, the power level of UHSM is limited, and no research effort has succeeded to improve the power level of UHSM. The design of HP-UHSM is highly iterative, and it presents several critical challenges, unlike low-power UHSM, such as critical-bending-resonance (CBR), strong mutual influence among Multiphysics performances, exponential air-friction loss, and material limitation. When the magnetic loading of the UHSM rotor is increased to improve the power level, the rotor experiences serious mechanical vibration due to the excessive centrifugal forces and CBR. This vibration limits the operation of HP-UHSM and leads to structural breakdown. Furthermore, the design process becomes more critical when it considers the multidisciplinary design constraints and application requirements. This dissertation proposed a new Multiphysics design method to develop HP-UHSM for critical applications. First, the critical design constraints which prevent increasing the output power of UHSM are investigated. Then, a Multiphysics optimization model is developed by coupling several multidisciplinary analysis modules. This proposed optimization model enables (i) defining multidisciplinary design constraints, (ii) consideration of Multiphysics mutual influence, and (iii) a trade-off analysis between the efficiency and design-safety-margin. The proposed design model adopts the multiphase winding system to effectively increase the electrical loading in the slotless stator. Finally, a 2000 W 500,000 rpm HP-UHSM is optimized for an AMEBA system using the proposed design method. The optimized 2 kW 500,000 rpm machine prototype and its dynamo setup are built in the laboratory. Extensive finite element simulations and experimental testing results are presented to validate the effectiveness of the proposed design method. The results show that the proposed HP-USHM has 94.5% efficiency, 47 kW/L power density, 30% global design safety margin at the maximum speed and no CBR frequency below 11 kHz.

This thesis studies the brushless permanent magnet synchronous (BLPM) machine design for electric vehicle (EV) and hybrid electric vehicle (HEV) application. Different rotor topologies design, winding design, and multiphase designs are investigated and discussed. The Nissan Leaf interior permanent magnet (IPM) traction machine has been widely analyzed and there is much public domain data available for the machine. Hence, this machine is chosen as a representative benchmark design. First, the Nissan Leaf machine is analyzed via finite element analysis (FEA) and the results confirmed via published experimental test data. The procedure is then applied to all the following machine designs and results compared. Then the Nissan Leaf machine rotor is redesigned to satisfy the performance specification with sinusoidal phase current in the full range for the same performance specification and permanent magnet material. Afterword, a comparative study assessing the design and performance attributes of the Nissan Leaf IPM machine, when compared to a surface permanent magnet (SPM) machine designed within the main Nissan Leaf machine dimensional constraints. The study illustrates and concludes that both the IPM and SPM topologies have very similar capabilities with only subtle differences between the design options. The results highlight interesting manufacturing options and materials usage. The grain boundary diffusion processed (GBDP) magnets are proposed to reduce the rare earth material content in the permanent magnet machines, especially subject to high load and high temperature operating scenarios by preventing or reducing the onset of demagnetization. The design and analysis procedure of BLPM machine with GBDP magnets are put forward. In the end, the Nissan Leaf IPM machine is taken as an example to verify the analysis procedure. and the results illustrates that IPM machines with GBDP magnets can realize torque and maintain efficiency at high loads while being less prone to demagnetization. A new multi-phase synchronous reluctance machine (SRM) with good torque performance and conventional voltage source inverter is introduced for traction machine applications. Although the torque density is low compared with BLPM machine, the SRM machine gets rid of permanent magnets and achieve low torque ripple compared with switched reluctance machine when the asymmetric inverter is replaced with conventional voltage source inverter. The concentrated windings are designed and studied with both IPM and SPM rotor according to the Nissan Leaf machine requirements of performance and dimension to investigate how the concentrated windings affect the machine performance and manufacturability and cost. 9-, 12-, 15- slot concentrated windings’ stator share the same slot area with the Nissan Leaf machine distributed winding and the performance are evaluated and compared. Multi-phase concentrated windings machines with IPM and SPM rotor are designed and analyzed based on the Nissan Leaf machine specification and dimension constraints. The performance of 23-phase, 5-phase, 9-phase machine at low speed and top speed are studied and the advantages and disadvantages are compared in terms of torque quality, efficiency, and power electronic requirements. / Thesis / Doctor of Philosophy (PhD)