Thesis (PhD (Electric and Electronic Engineering))--University of Stellenbosch, 2009. / Keywords: position sensorless control, torque control, synchronous machines The work in this thesis deals with energy e cient torque control and rotor position estimation in the full speed range, for a family of synchronous machines that should be used more often in the near future. This family consists of the permanent magnet synchronous machine (PMSM), the reluctance synchronous machine (RSM), the interior-PMSM and the PMassisted- RSM. By designing and controlling these synchronous machines correctly, better performance and higher energy e ciency can be expected compared to the performance and e ciency of an industry standard induction machine. However, applications are limited to variable speed drives (VSD) in a certain power range, e.g. below 100kW. With the growing concern and necessity of a better utilization of energy, it is becoming standard to use electronically controlled power converters between the electricity grid and electrical machines. Therefore, there is a very large scope for the implementation of this synchronous machine technology. For traction applications like electrical vehicles, the optimally controlled synchronous machine technology has a very strong position. Very compact and robust synchronous machines with a very high power density can be designed that may out-perform the induction machine by far. However, one major requirement for most applications is position sensorless control, i.e. rotor position estimation in the whole speed range. To achieve energy e cient torque control, maximum torque per Ampere (MTPA) control should be implemented. It is possible to achieve MTPA control at low speed, but above the rated speed of the machine, eld weakening needs to be performed. The question is how to implement MTPA and e ective eld weakening for any value of speed and DC bus voltage and for any machine within this family of synchronous machines. In this thesis a method is explained to achieve this goal using results from nite element (FE) analysis directly. The scheme may be implemented within a very short period of time. The contribution of this thesis is a general understanding of the problems at hand, with an in-depth view into the mathematical representation of synchronous machines, a generic method of energy e cient torque control and a thorough study of rotor position and speed estimation methods.

Thesis (MScEng)--Stellenbosch University, 2011. / ENGLISH ABSTRACT: Several transverse flux and longitudinal flux linear generator topologies exist for freepiston Stirling engine applications. In this thesis the transverse flux permanent magnet linear generators are investigated together with a back-to-back converter which can deliver the electrical energy from the linear generator to the electrical network. The transverse flux permanent magnet linear generator is geometrically optimised with the aim to maximise the power-to-weight ratio while maintaining preset power and efficiency levels. An optimised 3 kW linear generator is built and the measured results correlate to the simulation results. A close-loop current control scheme is introduced to control the current of the rectifier, which is part of the back to back converter. The transverse flux permanent magnet linear generator is connected to the input of the rectifier which has the ability to force a specific current from the generator. The measured results of the rectifier correlate to the results of the simulations that were done. The current control present some complications and it is suggested that another control scheme is used. A close-loop voltage control scheme is introduced for the control of the DC bus voltage. The DC bus is connected between the rectifier and the inverter, which is the other part of the back-to-back converter. A close-loop current control scheme is introduced to control the inverter current that flows from the inverter to the electrical network. The measured results of the inverter and the DC bus correlate to the results of the simulations that were done. The results of the system, including the generator, rectifier and inverter, tested as a unit is presented and discussed. / AFRIKAANSE OPSOMMING: Verskeie tranverse vloed en longitudinale vloed lineˆere generator topologie¨e bestaan vir vrysuier Stirling enjin toepassings. In hierdie tesis word ’n transverse vloed permanente magneet lineˆere generator ondersoek saam met ’n omsetter. Die omsetter dra die elektriese energie van die generator oor aan die elektriese netwerk. Die transverse vloed permanente magneet lineˆere generator word geometries geoptimeer met die doel om die drywing-tot-gewig verhouding te maksimiseer terwyl vasgestelde drywing en effektiwiteit vlakke behou word. ’n Geoptimeerde 3kW lineˆere generator prototipe is vervaardig en die gemete resultate is geverifieer met die simulasie resultate. ’n Geslote lus stroombeheer strategie word voorgestel om die stroom te beheer van die gelykrigter, wat deel is van die omsetter. Die transverse vloed permanente magneet lineˆere generator word aan die gelykrigter, wat die vermo¨e het om ’n spesifieke stroom uit die generator te forseer, se intree verbind. Die gemete resultate van die gelykrigter wat gebou is stem goed ooreen met die van die simulasies wat gedoen is. Die stroombeheer hou komplikasies in wat bespreek word. Dus word die gebruik van ’n alternatiewe stroombeheer voorgestel. ’n Geslote lus spannings beheer strategie¨e word voorgestel om die gs. busspanning te beheer. Die gs. bus is gekonnekteer tussen die gelykrigter en die wisselrigter, wat ook deel uitmaak van die omsetter. ’n Geslote lus stroom beheer word voorgestel om die stroom te beheer wat vanaf die wisselrigter na die elektriese netwerk toe vloei. Die gemete resultate van die wisselrigter en die gs. bus stem goed ooreen met die van die simulasies wat gedoen is. Die resultate van die hele stelsel, wat die generator, gelykrigter en die wisselrigter insluit, wat as ’n eenheid getoets is word weergegee en bespreek.

Thesis (MScEng (Electrical and Electronic Engineering))--University of Stellenbosch, 2009. / ENGLISH ABSTRACT: With the current worldwide energy problems electric vehicles are set to replace conventional combustion engine vehicles. Electric vehicles with gearless in-wheel mounted brushless permanent magnet motors provide a more flexible and efficient means of vehicle propulsion but the electric motors, particularly the non-overlap stator winding type have not been fully researched. This study focuses on the selection and design of suitable in-wheel hub drive machine. Several machine topologies are evaluated and the single-sided axial flux machine is chosen. The average vehicle requirements are determined and design optimisations are carried with the aid of finite element analysis and an optimisation algorithm. A comparison of torque quality between single-layer and double-layer machines is carried out and it is found that double-layer machines have the least torque ripple and single-layer machines with un-equal teeth the best torque per ripple characteristics. A 16 kW, 30-pole 27-slot prototype machine optimised for power density is built, and it is found fitting for the application meeting the design requirements. The prototype machine is extensively tested and good agreement is found between finite element and measured results. The well known axial flux attraction forces are encountered in the prototype machine and they are overcome by suitable bearing selection and mechanical design. It is found that theoretical and measured cogging torques are inconsistent, the reason for this is that practical machines are not absolutely ideal due to material and manufacturing tolerances. Excessive rotor losses are found in the prototype machine and appropriate methods for their reduction are presented. This work does not aim to find the best in-wheel hub drive solution, but instead looks to uncover some of the technical available solutions. / AFRIKAANSE OPSOMMING: Met die huidige wêreldwye energie probleme, is elektriese voertuie bestem om konvensionele binnebrandenjin voertuie te vervang. Elektriese voertuie met ratlose binnewiel-geleë borsellose permanente magneet motors, voorsien „n meer aanpasbare en effektiewe metode van voertuig aandrywing, maar die elektriese motors, veral die oorvleulende stator winding tipe is nog nie ten volle nagevors nie. Hierdie studie fokus op die keuse en ontwerp van „n binnewiel aandryf masjien. Verskeie masjien uitlegte word geëvalueer en „n enkelkant aksiaalvloed masjien is gekies. Die gemiddelde voertuig behoeftes word bepaal en ontwerp optimalisering word uitgevoer met behulp van eindige element analise en „n optimaliserings algoritme. Enkellaag en dubbellaag masjiene se draaimoment kwaliteit word vergelyk. Die bevinding is dat dubbellaag masjiene die laagste draaimoment rimpel toon terwyl die enkellaag masjiene, met oneweredige tande, die beste draaimoment per rimpel karakteristieke toon. „n 16 kW, 30 pool, 27 gleuf prototipe masjien, wat vir drywingsdigtheid ge-optimaliseer is, is gebou en is geskik vir die toepassing en die vereistes. Die prototipe masjien is getoets en goeie vergelykings word getref tussen die eindige element analise en die gemete resultate. Die alom bekende aksiaal vloed aantrekkings kragte word in die prototipe masjien gesien en word oorkom deur die regte rollaer keuse en meganiese ontwerp. Nog „n bevinding is dat die teoretiese en gemete waardes vir die vertandings draaimoment nie ooreenstem nie. Die rede hiervoor is dat die praktiese masjien nie ideaal is in terme van materiaal en vervaardigings toleransies nie. Groot rotor verliese in die prototipe masjien is gevind en goeie metodes vir die minimering daarvan word voorgestel. Hierdie werk is nie „n soektog na die beste binnewiel aandrywings oplossing nie, maar mik eerder om sommige van die tegniese beskikbare oplossings te onthul.

This dissertation presents an investigation of miniaturized magnetic induction and permanent magnet (PM) machines, intended for use in a microengine. Similar to a macroscale turbogenerator, a microengine comprises a small, gas-fueled turbine engine for converting chemical fuel energy into mechanical power and an integrated electrical generator for converting mechanical power to electrical power. The microengine system is proposed as a revolutionary, high power-density source for portable electronics. In this research, miniaturized magnetic induction machines and PM machines were designed, fabricated, and characterized. Both types of machines used axially directed magnetic fields and were nominally 10 mm in diameter and 1.5-2.3 mm in thickness. Innovative microfabrication techniques were developed to demonstrate the feasibility of integrating magnetic machines within a bulk-micromachined, silicon-based microengine system. Two-phase, eight-pole induction machines were constructed within silicon substrates using Cu coils in a laminated, slotted ferromagnetic NiFe or CoFeNi stator core. Silicon etching, wafer bonding, and electrodeposition were used to form all of the magnetic machine components. The induction machines were characterized in motoring mode using tethered rotors and demonstrated motoring torques of up to 2.5 uN-m. Also, three-phase, eight-pole, surface wound PM machines were built using a hybrid microfabrication/assembly approach. The stators were fabricated by electroplating Cu coils on ferromagnetic NiFeMo (Moly Permalloy) substrates. The rotors were formed by assembling a magnetically patterned SmCo PM with a FeCoV (Hiperco 50) back iron. The PM machines were tested as generators with free-spinning rotors, powered by an air-driven spindle, and demonstrated 2.6 W of mechanical-to-electrical power conversion with continuous DC power generation of 1.1 W at 120 krpm rotor speed. The primary contributions of this work are (1) the demonstration of microfabricated magnetic machines integrated within bulk-micromachined silicon and (2) the demonstration of multi-watt power conversion from a microfabricated PM generator. These achievements represent progress in the ongoing development of silicon-based microengines, but in addition, the fabrication technologies and device structures may find application in other microsystems.

Thesis (MScEng (Electrical and Electronic Engineering))--University of Stellenbosch, 2011. / ENGLISH ABSTRACT: In this study a new type of gearless, direct-drive wind generator, which can be connected directly to the grid, is proposed. The working characteristics of this generator are based upon the principles of the permanent magnet induction generator (PMIG). By omitting the need for a gearbox and power electronic converter this generator type has several advantages regarding cost and reliability. Although the PMIG is proposed in previous studies as favourable for wind power generation, the mechanical complexity and difficult construction associated with these types of generators, seems to be the main reason why these generator systems are not used. The design methods presented in this study are intended to alleviate these constructional issues by proposing the split-PMIG (S-PMIG), where the stator winding and the induction cage-rotor windings are electromagnetically separated. The machine is basically split into two permanent magnet (PM) machines, a grid connected synchronous generator (SG) unit and a turbine connected induction generator (IG) unit. These two units are mechanically linked by a common PM-rotor. To evaluate this concept a finite element (FE) design analysis is done independently for both machine components. The emphasis of the design optimisation is the minimisation of the cogging torque, while still having a decent performing, easily constructible generator. This generator should also have low load ripple content. Cogging torque can result in the failure of the turbine to start up, especially at low wind speeds. As this is a directly grid connected generator, torque ripple transferred to the common PM-rotor can destabilise the generator. Based upon the FE designs a preliminary S-PMIG system is constructed and practically evaluated. Due to the modular nature of the design it is possible to implement the synchronous generator part of the S-PMIG in conjunction with a grid-connected solid state converter (SSC). This allows for a useful comparison with the S-PMIG system. Promising results are obtained from initial tests of the S-PMIG directly connected to the grid. It is shown that the operation of this generator is stable under a wide range of wind load conditions. However, some important machine design issues are identified from these practical results, which could prove vital in the implementation of future S-PMIG designs. / AFRIKAANSE OPSOMMING: In hierdie studie word 'n nuwe ratkaslose direk-aangedrewe wind generator voorgestel, wat direk aan die krag netwerk gekoppel kan word. Hierdie generator is gebaseer op die beginsels waarop permanente magneet induksie generators (PMIG’s) werk. Deur die ratkas en drywings-elektroniese omsetter uit te laat, het hierdie generator verskeie voordele rakende koste en betroubaarheid. Alhoewel vorige studies hierdie generator voorstel as 'n belowende opsie vir gebruik in wind-energie-stelsels, lyk dit of die meganiese kompleksiteit en moeilike konstruksie die hoof rede is hoekom hierdie generator stelsels tans nie gebruik word nie. Die ontwerpsmetodes wat in hierdie studie voorgestel word poog om die genoemde konstruksie probleme op te los deur die gesplete-PMIG (S-PMIG), waar die stator wikkelings en die induksie masjien kou-rotor wikkelings elektromagneties ontkoppel is, voor te stel. Hierdie masjien is basies verdeel in twee permanente magneet (PM) masjiene, 'n netwerk gekoppelde sinchroongenerator (SG) eenheid en 'n turbine gekoppelde induksie generator (IG) eenheid. Hierdie twee eenhede word gekoppel deur 'n gemeenskaplike PM-rotor. Om hierdie konsep te evalueer word eindige element analise onafhanklik vir beide masjiene gedoen. Die fokus van die ontwerp optimering is die minimalisering van die vertandingsdraaimoment, terwyl die generator steeds goed presteer en maklik is om te vervaardig. Vertandingsdraaimoment kan tot die gevolg hê dat die turbine versuim om te begin draai, veral by lae windsnelhede. Dit is ook belangrik dat die generator 'n lae rimpel inhoud onder las bevat. Omrede hierdie generator direk aan die netwerk gekoppel is, kan draaimoment pulsasies, oorgedra aan die gemeenskaplike PM-rotor, die masjien destabiliseer. Gebaseer op die eindige element ontwerpe, is 'n voorlopige gesplete-PMIG gebou en prakties geëvalueer. As gevolg van die modulêre struktuur van die ontwerp, is dit moontlik om die SG gedeelte van die gesplete- PMIG saam met 'n drywings-elektroniese omsetter te implementeer. Dit laat toe vir 'n nuttige vergelyk tussen die twee stelsels. Belowende eerste toets resultate is verkry van die gesplete-PMIG direk gekoppel aan die netwerk. Daar word gewys dat hierdie generator stabiel oor 'n wye operasionele gebied kan funksioneer. Verskeie belangrike masjien ontwerpsfaktore word ook uitgelig met die praktiese evaluering van die gesplete-PMIG. Hierdie faktore kan uiters belangrik wees in die ontwerp en implementering van toekomstige gesplete-PMIG stelsels. / Sponsored by the Centre for Renewable and Sustainable Energy Studies

Thesis (MScEng)--Stellenbosch University, 2013. / ENGLISH ABSTRACT: The slip synchronous permanent magnet generator (SSG) is a direct-driven direct-grid connected generator developed to alleviate the need for expensive gearboxes and solid-state power converters on wind turbine generators. This study identifies certain key areas where the current wind turbine generator (WTG) system does not comply with the grid code for wind energy facilities (WEF) as specified by the National Energy Regulator of South Africa. The current WTG system does not have a reactive power compensation device. The main focus in this study is the development of an on-load tap changer (OLTC) transformer to control the terminal voltage of the generator. By controlling the terminal voltage of the generator the excitation-mode of the SSG can be changed allowing for control over the reactive power output of the SSG. An OLTC transformer utilising a solid-state assisted mechanical diverter circuit is built and tested to determine the viability of using an OLTC as a reactive power control device. Practical test results show that the OLTC can successfully control the terminal voltage of the SSG without interrupting the load current. The required accuracy regarding power factor control capability was not met due to the large change in reactive power output per tap change operation. A method of using small shunt capacitor banks to provide additional reactive power in between consecutive tap changes is evaluated in simulation. Simulation results show that the addition of these small shunt capacitor banks dramatically improves the reactive power control accuracy. Additionally the grid code specifies that a WEF must have the ability to curtail the active power output during frequency disturbances. The effects of frequency disturbances on the SSG output is simulated and it was found that the SSG will comply with the minimum connection requirements as specified in the grid code. A method of using an IGBT switched DC load to limit the active power output of the WEF is developed and simulated. From the simulation results it was found that the proposed active power curtailment device will meet the minimum power curtailment response time requirements as specified in the grid code. / AFRIKAANSE OPSOMMING: Die glip sinchroon permanente magneet generator (SSG) is ʼn direkte dryf, direkte netwerk gekoppelde wind generator wat ontwikkel is om behoefte aan duur ratkaste en drywing elektroniese omsetters te verlig. Hierdie studie identifiseer sekere sleutel areas waar die huidige wind generator opstelling nie aan die netwerk kode spesifikasie soos uiteengesit deur die Nasionale Energie Reguleerder van Suid-Afrika voldoen nie. Die wind turbine generator stelsel beskik nie oor ʼn reaktiewe drywing beheer meganisme nie. Die belangrikste fokus in hierdie studie is die ontwikkeling van ʼn transformator tap wisselaar wat gebruik sal word om die generator se terminale spanning te beheer. Deur die terminaal spanning te beheer kan die opwekking modus van die generator verander word om dan die uittree reaktiewe drywing te beheer. ʼn Tap wisselaar wat gebruik maak van ʼn drywingelektronies gesteunde meganiese skakelaar is ontwikkel en getoets om die lewensvatbaarheid van die tegniek te ondersoek. Praktiese toets resultate toon dat die tap wisselaar suksesvol beheer oor die generator se terminaal spanning kon uitvoer, sonder om die las-stroom te onderbreuk. Ongelukkig is die vereiste akkuraatheid ten opsigte van die reaktiewe drywing beheer nie gehaal nie. Die rede hiervoor is dat die verandering in uittree reaktiewe drywing baie groot is vir opeenvolgende tap verstellings. ʼn Metode waar twee klein kapasitor banke geskakel word om reaktiewe drywing te lewer, tussen opeenvolgende tap veranderinge, is deur middel van simulasie ondersoek. Die simulasie resultate toon aan dat die toevoeging van die kapasitors ʼn drastiese verbetering in die beheerbaarheid van die uittree reaktiewe drywing het. Verder spesifiseer die netwerk kode ook dat ʼn wind plaas oor die vermoë moet beskik om die aktiewe drywing te verminder tydens ʼn netwerk frekwensie versteuring. Die effek wat ʼn frekwensie versteuring op die SSG het, is deur middel van simulasie ondersoek en daar is gevind dat die SSG aan die netwerk verbinding spesifikasie sal voldoen. ʼn Metode waarby ʼn IGBT geskakelde GS las gebruik word om die aktiewe drywing van die wind generator te beperk is ondersoek en gesimuleer. Vanaf die simulasie resultate is daar gevind dat die drywing beperkings toestel aan die minimum drywing en reaksie tyd spesifikasies soos vereis sal voldoen.

This thesis presents scaling methods for sizing a prototype micro prismatic revolute (PR) manipulator actuated by permanent magnet (PM) direct current (d.c.) gearmotors. Dimensional analysis was the principle tool used in this investigation, and addressed the problems of scaling a trajectory planner, control law, and gearmotors that exhibit internal nonlinear friction. Similitude methods were used to develop a scaleable two degree-of-freedom trajectory planner from a third order polynomial. Scaling laws were developed from Buckingham's Pi theorem to facilitate the selection process of gearmotors. Nondimensional, nonlinear, differential equations were developed to describe viscous, Coulomb and static friction in comparative PM d.c. motors. From the insights gained through dimensional analysis, a scaleable controller based on the computed torque method was developed and implemented with a cubic trajectory planner. Model and prototype PR manipulator systems were simulated using a hybrid Matlab/Simulink simulation scheme. Experimental systems were constructed with dissimilar model and prototype motors. Control was provided by an AT class PC equipped with 12-bit A/D, D/A cards operating at a sample rate of 100 Hz. The control algorithm was written in Borland 3.1 C for DOS. Results from the experimental testing showed excellent agreement between the test and simulated data and verified the viability of the scaling laws. The techniques presented in this thesis are expected to be applicable to any application that involves scaling PM d.c. micro gearmotors that have significant internal friction terms. These simple, practical tools should be especially beneficial to designers of micro robotic systems. / Master of Science

The permanent magnet motors have become essential parts of modern motor drives recently because need for high efficiency and accurate dynamic performance arose in the industry. Some of the advantages they possess over other types of electric motors include higher torque density, higher efficiency due to absence of losses caused by field excitation, almost unity power factor, and almost maintenance free construction. With increasing need for specialized PM motors for different purposes and areas, much effort has also gone to design methodologies. In this thesis a design model is developed for surface PM motors. This model is used with an available optimization algorithm for the optimized design of a PM motor. Special attention is paid to measurement of parameters of a sample PM motor. As a result of this study, an effective analytical model with a proven accuracy by measurement results is developed and applied in a design process of a surface PM motor. Parametric and performance results of analytical model and tests have been presented comparatively. A prototype motor has been realized and tested.

In recent years, due to growing environmental awareness regarding global warming, green cars, such as hybrid electric vehicles, have gained a lot of importance. With the decreasing cost of rare earth magnets, brushless permanent magnet motors, such as the Interior Permanent Magnet Motor, have found usage as part of the traction drive system in these types of vehicles. As a design issue, building a motor with a performance curve that suits both city and highway driving has been treated in this thesis as a multi-objective problem; matching specific points of the torque-speed curve to the desired performance output. Conventionally, this has been treated as separate problems or as a combination of several individual problems, but doing so gives little information about the trade-offs involved. As a means of identifying the compromising solutions, we have developed a stochastic optimizer for tackling electromagnetic device optimization and have also demonstrated a new innovative way of studying how different design parameters affect performance.

Thesis (MScEng (Electrical and Electronic Engineering))--University of Stellenbosch, 2011. / Due to finite oil resources and its political and economical impact, a renewed interest in energy independence has compelled industry and government to pursue electric vehicle designs. The current worldwide research that is being conducted on drivetrain topologies for EVs, focus mainly on direct in-wheel drive, direct differential drive and fixed-gear differential drive topologies. Furthermore, the control strategy for these type of motor drives require a, so called, field-weakening operation in order to achieve acceptable performance characteristics for the vehicle. This thesis evaluates the use of a manual gearbox drivetrain topology and a radial flux air-cored permanent magnet (RFAPM) synchronous machine, without flux-weakening operation, as a traction drive application for EVs. For the purpose of this research study, a 2006 model Opel Corsa Lite is converted to a battery electric vehicle, and the Corsa is renamed to the E-Corsa. The Corsa is converted so that all the original functionality, boot space and space inside the vehicle are retained. The original 5-speed manual gearbox is used as drivetrain for the vehicle and a 40 kW, 70 Nm RFAPM traction drive is developed for the manual gearbox. A power electronic converter is designed for RFAPM traction drive and a Lithium ion (Li-ion) battery pack is used as energy source for the traction drive. The battery pack is mounted partially in the front and partially in the back of the vehicle to maintain an even weight distribution in the vehicle.