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Cette thèse s’intéresse à l’étude d’une structure de moteur électrique à aimants permanents afin de réduire l’utilisation d’aimants à basse de terres rares et qui puisse être utilisée pour des applications industrielles. Il est montré dans la première partie de ce travail de recherche que la machine synchro-réluctante à aimants permanents est une bonne solution potentielle. Une analyse paramétrique est alors réalisée en utilisant une modélisation par éléments finis pour mettre en évidence les particularités de son comportement électromagnétique. Puis, une modélisation analytique multi-physique innovante du système convertisseur-moteur est détaillée dans le but de calculer les performances de ce dernier en un temps raisonnable. Les modèles multi-physiques présentés dans ces travaux concernent l’onduleur et le moteur. Ils intègrent les aspects électromagnétique, électrique, énergétique, thermique, mécanique et technico-économique. Le modèle multi-physique de la machine électrique est validé par comparaison à des résultats d’essais sur un prototype. Le modèle du système qui a été développé est ensuite utilisé dans une procédure de conception par optimisation de systèmes d’entrainements. Pour cela, une démarche d’optimisation originale est présentée pour le dimensionnement conjoint de deux applications en imposant la contrainte d’utiliser la même tôlerie magnétique. Il s’agit d’une part d’une application à vitesse fixe et d’autre part d’une application de type traction électrique. La méthode d’optimisation employée est à évolution différentielle. Les résultats des optimisations réalisées permettent de déterminer des conceptions optimales ou des compromis optimaux aux sens de Pareto qui répondent aux deux applications visées. Finalement, cette thèse a permis de positionner la machine synchro-réluctante à aimants permanents parmi les structures de machines à fort potentiel industriel. / This thesis focuses on the study of a structure of permanent magnet electric motor which reduces the amount used of permanent magnets composed of rare earths and which can be used in industrial applications. In the first part of the research work, it is shown that the permanent magnet assisted synchronous reluctance machine is a good alternative. A parametric analyse is realised using a finite element modelling in order to highlight the peculiarities of its electromagnetic behaviour. Then, an innovative multi-physic analytical modelling for the system inverter-motor is detailed in order to evaluate its performances in a reasonable computational time. The multi-physic models presented in this work concern the inverter and motor. They integrate the electromagnetic, electric, energetic, thermal, mechanic, and techno-economic aspects. The multi-physical model of the electric machine is validated by means of tests carried out on a prototype. The model of the system which has been developed is used in a design procedure by optimization of drive systems. For this purpose, an original optimization approach is presented for the simultaneous design of two applications by imposing the constraint of using the same magnetic lamination. On one hand it is an application of fixed speed and on the other hand an application of electric traction. The optimization method used is a type of differential evolution optimization. The results of the optimizations realised determine the optimal designs or the optimal compromise with Pareto front which deal with both applications. Finally, this thesis has placed the permanent magnet assisted synchronous reluctance machine among structures of machines with great industrial potential.

Cette thèse s’intéresse à l’étude d’une structure de moteur électrique à aimants permanents afin de réduire l’utilisation d’aimants à basse de terres rares et qui puisse être utilisée pour des applications industrielles. Il est montré dans la première partie de ce travail de recherche que la machine synchro-réluctante à aimants permanents est une bonne solution potentielle. Une analyse paramétrique est alors réalisée en utilisant une modélisation par éléments finis pour mettre en évidence les particularités de son comportement électromagnétique. Puis, une modélisation analytique multi-physique innovante du système convertisseur-moteur est détaillée dans le but de calculer les performances de ce dernier en un temps raisonnable. Les modèles multi-physiques présentés dans ces travaux concernent l’onduleur et le moteur. Ils intègrent les aspects électromagnétique, électrique, énergétique, thermique, mécanique et technico-économique. Le modèle multi-physique de la machine électrique est validé par comparaison à des résultats d’essais sur un prototype. Le modèle du système qui a été développé est ensuite utilisé dans une procédure de conception par optimisation de systèmes d’entrainements. Pour cela, une démarche d’optimisation originale est présentée pour le dimensionnement conjoint de deux applications en imposant la contrainte d’utiliser la même tôlerie magnétique. Il s’agit d’une part d’une application à vitesse fixe et d’autre part d’une application de type traction électrique. La méthode d’optimisation employée est à évolution différentielle. Les résultats des optimisations réalisées permettent de déterminer des conceptions optimales ou des compromis optimaux aux sens de Pareto qui répondent aux deux applications visées. Finalement, cette thèse a permis de positionner la machine synchro-réluctante à aimants permanents parmi les structures de machines à fort potentiel industriel. / This thesis focuses on the study of a structure of permanent magnet electric motor which reduces the amount used of permanent magnets composed of rare earths and which can be used in industrial applications. In the first part of the research work, it is shown that the permanent magnet assisted synchronous reluctance machine is a good alternative. A parametric analyse is realised using a finite element modelling in order to highlight the peculiarities of its electromagnetic behaviour. Then, an innovative multi-physic analytical modelling for the system inverter-motor is detailed in order to evaluate its performances in a reasonable computational time. The multi-physic models presented in this work concern the inverter and motor. They integrate the electromagnetic, electric, energetic, thermal, mechanic, and techno-economic aspects. The multi-physical model of the electric machine is validated by means of tests carried out on a prototype. The model of the system which has been developed is used in a design procedure by optimization of drive systems. For this purpose, an original optimization approach is presented for the simultaneous design of two applications by imposing the constraint of using the same magnetic lamination. On one hand it is an application of fixed speed and on the other hand an application of electric traction. The optimization method used is a type of differential evolution optimization. The results of the optimizations realised determine the optimal designs or the optimal compromise with Pareto front which deal with both applications. Finally, this thesis has placed the permanent magnet assisted synchronous reluctance machine among structures of machines with great industrial potential.

L'objectif principal de nos travaux consiste à développer des méthodes d’optimisation des performances de la MSRV sur le plan de la conception et de la commande. La première partie est consacrée à la commande de la MSRV avec prise en compte de la saturation, de l'effet croisé et des pertes-fer. Deux stratégies de commande permettant d’améliorer les performances de la machine en régime permanent sont présentées: commande à rendement optimal et commande à couple maximum par ampère. La deuxième partie de ce travail porte sur la commande de la MSRV en vue de réduire les ondulations de couple. L’optimisation des courants statoriques a été obtenue selon deux critères : un couple électromagnétique constant et des pertes par effet Joule minimales. Une formule originale a été présentée dans le cas où le courant homopolaire est pris en compte. Des schémas de commande neuronale en couple et en vitesse sont ensuite proposés. L’apprentissage, réalisé en ligne, fait que cette proposition est tout à fait adaptée aux applications en temps réel. La troisième partie traite de la conception au moyen de la méthode de calcul numérique par élément finis. Grâce au logiciel JMAG, les barrières du flux au rotor de la MSRV ont été optimisées permettant d’augmenter le couple moyen, le facteur de puissance et le rendement de la machine. Enfin, toutes les approches neuromimétiques ont été validées par de tests expérimentaux. De plus, des comparaisons avec les méthodes de commande classique démontrent la validité des méthodes proposées. / The main objective of our work is to develop the methods for performance optimization of the SynRM in terms of the design and control. The first part is devoted to control of the SynRM taking into account the saturation, cross coupling and iron losses. Two strategies control to improve the performances of the machine in steady-state are presented: optimal efficiency control and maximum torque per ampere control. The second part of this work focuses on the control of the non-sinusoidal SynRM to reduce torque ripple. Optimal stator currents were obtained with the objectives: a constant electromagnetic torque and minimum ohmic losses. An original formula was presented in the case where the homopolar current is considered. The torque and speed control based on artificial neural networks are then proposed to obtain optimal currents online in real time. The third part deals with the design optimization of SynRM by finite element method. With JMAG software, the barriers of the rotor SynRM were optimized to maximize the average torque, power factor and efficiency of the machine. Finally, all the approaches based on neural networks have been validated by experimental tests. Moreover, the comparisons with conventional methods demonstrate the validity of the proposed methods.

This thesis deals with the analysis of magnetic losses in electrical machines and the possibilities of their measurement. Magnetically soft and hard materials are very prone to changing magnetic properties. They can be changed simply by changing the temperature of the material or different stresses induced in the material, resulting in different results. These changes are important to keep in mind when an electric machine is being designed. The original parameters of the affected materials can be restored by annealing or grinding. These methods release the induced stresses within the material. Due to these effects, it is also important to know how to measure magnetic parameters. Each way has its own specifics and has a certain error of the measurement. When the machines for higher efficiency, rpm or higher temperatures are designed, it is advisable to know how their magnetic properties changed. This thesis deals with the properties of different materials, their measurements and finally simulation of the chosen electric machine with the application of the measured results.

This thesis presents two transient models for a prototype integrated charger for use in a plug-in hybrid-electrical vehicle application. The models can be useful in order to develop control algorithms for the system or to recommend improvements to the machine design. A flux map based method, obtaining input data from simulations using the finite element method (FEM) is used to model the grid synchronization process. The grid side voltage can then be predicted by incorporating spatial flux linkage harmonics. The model is implemented in Matlab/Simulink and compared to stand alone FEM simulations with good agreement. The charging process is modeled using an inductance based model also requiring FEM simulations as input data. Since the flux linkages in the grid and inverter side windings are dependent on each other, the presented transient model is linearized around a specific operating point. This model is also implemented in a Matlab/Simulink environment. Sensorless control of a PMSynRel drive is also studied in this thesis. Focus is put on operating limits due to magnetic saturation when operating at low speeds. The rotating and pulsating voltage vector injection methods for sensorless control are studied in detail. A technique to map the feasible sensorless control region is proposed which utilizes the resulting position error signal rather than data of differential inductances. This technique is implemented experimentally and compared to corresponding FEM simulations with good agreement. The impact of spatial inductance harmonics on the quality of the position estimates is also studied. A method to predict the maximum position estimation error due to the inductance harmonics is proposed based on simplified analytical models. A technique is presented and experimentally verified which can compensate for this effect by injecting a modified rotating voltage carrier. Lastly, the impact of saturation in the rotor structure on the initial magnet polarity detection is investigated. The experimental results, in good agreement with the corresponding FEM simulations, indicate that the impact of saturation in the magnet bridges of rotor is the dominant phenomenon at lower peak current magnitudes. / QC 20110928

QC 20111214

The importance of accurately controlling the speed and torque of Synchronous Machines (SMs) in industry, transportation, aerospace, to name a few, can not be overstated. The driving unit to control the machines are called Variable Speed Drives (VSDs) and they can be designed in many different ways. In this project, a speed sensorless drive using high-frequency square-wave voltage injection is implemented in a open-source Python software called Motulator, developed by Prof. Marko Hinkkanen at Aalto University. The drive is first tested on an already existing linear model of a Permament Magnet Synchronous Machine (PMSM). An equivalent model is built in Matlab/Simulink to benchmark the performance of the implementation in Python. The results suggest that the performance Motulator implementation is satisfactory when compared to the Simulink implementation. Next, a non-linear Synchronous Reluctance Machine (SynRM) is implemented, using data from Finite Element (FEM) simulations of the non-linear flux-current relation. By using the injection scheme (with some tweaks), the speed of the motor is accurately controlled, but a steady-state position error is observed at all operating points. The error is produced due to the cross-saturation effect and a compensation strategy is implemented in an attempt to remove this error. however without full success. / Det är av avgörande betydelse att kunna kontrollera varvtal och vridmomentet hos synkrona elektriska maskiner (SM) inom transport, flyg och rymd, för att nämna några tillämpningar. Drivsystem för att styra de elektriska maskinerna kallas för varvtalsreglerade drivsystem och kan konstrueras på många olika sätt. I det här projektet implementeras ett varvtalsreglerat drivsystem, utan sensor för mätning av varvtalet. Varvtalsestimeringen bygger på att en fyrkantsvåg med hög frekvens injiceras varur det är möjligt att estimera hastigheten. Implementering görs i Python i en open-source programvara kallad Motulator, utvecklad av professor Marko Hinkkanen från Aaltouniversitetet. Regleringen testas först på en redan existerande linjär modell av en permanentmagnetiserad motor. Som jämförelse utvecklas även en motsvarande implementering av regleralgoritm och motor i Matlab/Simulink. Resultaten visar att Motulatorimplementeringen fungerar väl och att simuleringarna stämmer väl överens med Matlab/Simulink-modellen. I nästa steg implementeras en icke-linjär modell av en synkron reluktansmaskin. Det icke-linjära förhållande mellan flöde och ström modelleras med hjälp av data från finita elementsimuleringar (FEM). Simuleringar i Motulator visar att varvtalet i denna motormodell kan kontrolleras för alla olika laster och varvtal. Däremot noteras ett stationärt rotorpositionsfel vid vissa driftpunkter. Felet beror på mättningen av statorinduktansen och en algoritm implementerats för att kompensera effekten av mättningen och därmed eliminera felet. Det visar sig dock att kompenseringsalgoritmen endast fungerar vid vissa driftpunkter.

Energy efficiency in electric machines is both environmentally and economically important. Water pumps with an integrated Variable Frequency Drive (VFD) and a Permanent Magnet Synchronous Machine (PMSM) have challenged the status quo of the Induction Machine (IM) for water pumps. The Synchronous Reluctance Machine (SynRM) is also a viable alternative that does not use permanent magnets. This degree project focuses on the control of SynRM, with particular attention on sensorless control methods. Simulation models for a SynRM and a Surface Permanent Magnet Synchronous Machine (SPMSM), together with their control systems, were developed in MATLAB Simulink. Two sensorless control methods were implemented and examined: the Luenberger state observer and the Model Reference Adaptive System (MRAS). The control system was adapted to use sensorless control methods. The investigated sensorless control methods allowed the application of the speed-torque test profile for two method and motor type combinations, without causing instability. The Luenberger observer was stable with the SPMSM and the MRAS with the SynRM. Parameter sensitivity with respect to the variation of inductance and stator resistance values used by the sensorless methods was also tested. The Luenberger observer kept the control system stable with up to a ±5 % variation of inductance. The MRAS kept the control system stable down to −12 %, but only up to +2 % for an overestimation of the inductance. The variation of stator resistance had a limited impact on the stability of both sensorless schemes. / Energieffektivisering av elektriska maskiner är betydelsefullt både ur ett miljömässigt och ekonomiskt perspektiv. Vattenpumpar med en synkron permanentmagnetsmaskin och en integrerad enhet för variabel hastighetsreglering (VFD) utmanar den mer konventionella lösningen baserad på en asynkronmaskin (IM). Den synkrona reluktansmaskinen (SynRM) är ett annat lämpligt alternativ som inte använder permanentmagneter. Det här examensarbetet behandlar huvudsakligen sensorlös reglering av SynRM. Simuleringsmodeller för reglering av en SynRM och en permanentmagnetiserad synkronmaskin med ytmonterade magneter (SPMSM) utvecklades i MATLAB Simulink. Två metoder för sensorlös reglering undersöktes, en på Luenbergers tillståndsobservatör och en baserad på adaptiv modellreferensreglering (MRAS). Systemet för reglering anpassades till metoderna för sensorlös reglering. De undersökta sensorlösa metoderna testades vid nominell hastighet med steg i vridmoment och hastighet. Luenberger observatören kunde köras med bibehållen stabilitet med en SPMSM och MRAS kördes med en SynRM, också den med bibehållen stabilitet. Även känsligheten för variationer i induktans och statorresistans för de sensorlösa reglermetoderna testades. Luenberger observatören kunde bibehålla stabiliteten med en variation i induktans på ±5 %. MRAS kunde bibehålla stabiliteten ner till en estimering av induktansen på −12 % av induktansen. På uppsidan nådde dock MRAS stabilitet endast upp till en överestimering av induktansen på 2 %. Felestimering av statorresistansen hade minimal påverkan på stabiliteten för båda sensorlösa reglermetoderna.

The growing need for simpler and cheaper manufacturing process has led to the research into fractional-slot concentrated-wound (FSCW) motors. This concept has been widely investigated for surface-mounted permanent magnet (SMPM) machines. This thesis studies the same concept applied for synchronous reluctance machines (SynRM). In this thesis, a FSCW, 15 kW, 4-pole, Permanent-Magnet-Assisted Synchronous Reluctance Machine (PMaSynRM) is designed and optimized using finite element method (FEM) based simulations for a set of given technical specifications. Initially, the existing synchronous machine topologies are investigated and later two novel motor designs are introduced and optimized, namely, a FSCW-SynRM and a FSCW-PMaSynRM with ferrite magnets. Moreover, the influence of replacing ferrite material with Neodymium Iron Boron (NdFeB) in the FSCWPMaSynRM is analyzed. Detailed investigations are performed in order to compare the impact of material at different temperatures. Variation of the torque-speed capabilities with temperature and a safe operating temperature range where the magnets are not demagnetized are identified. The variation of overload capability with temperature is also studied. Finally, a comparison between the new proposed designs and other existing standard design topologies is performed. It was found that FSCW-SynRM present lower efficiency, power factor and higher torque ripple than DW-SynRM. However when ferrite magnets are inserted in FSCW-PMaSynRM the efficiency, power factor and the flux-weakening capability exceed the values of the DW-SynRM. Moreover, by using NdFeB instead of ferrite in FSCW-PMaSynRM, the torque ripple, the fluxweakening capability and the overload capability improve and a wider safe temperature range for no demagnetization is achievable. Finally, it is found that DW-PMaSynRM with ferrite presents the same efficiency level as FSCW-PMaSynRM with ferrite, but higher power factor and lower torque ripple. However FSCW-PMaSynRM with ferrite have other advantages, such as shorter end-winding length, good fault-tolerant capability and simpler and cheaper manufacturing process. / Det växande behovet av enklare och billigare tillverkningsprocesser har lett till att den senaste forskningen om elektriska maskiner har fokuserats till maskiner med koncentrerade lindningar (FSCW). Detta koncept har i stor utsträckning undersökts för synkronmaskiner med ytmonterade permanentmagneter (SMPM). Detta projekt studerar samma lindning koncept, tillämpat på synkrona reluktansmaskiner (SynRM). I denna avhandling är en 15 kW, 4-polig, SynRM med FSCW och permanentmagneter (PMaSynRM) utformad och optimerad med användandet av finita elementmetoden (FEM). Simuleringar för en uppsättning givna, tekniska specifikationer har genomförts. Inledningsvis undersöks den befintliga synkronreluktansmaskinen med distribuerad lindning och senare presenteras och optimeras två nya motorkonstruktioner: en FSCW-SynRM respektive en FSCW-PMaSynRM med ferritmagneter. Vidare analyseras påverkan av att ersätta ferritmaterial med neodym-järn-bor (NdFeB) i FSCW-PMaSynRM. Detaljerade undersökningar genomförs för att jämföra effekten av materialen vid olika temperaturer. Variationen av maximal vridmomentet som funktion av hastighet vid olika temperaturer identifierar ett säkert driftstemperaturintervall där magneterna inte avmagnetiseras. Även variationen i överbelastningskapacitet vid olika temperaturer studeras. Slutligen görs en jämförelse mellan den nya föreslagna designen och andra befintliga topologier. Resultaten visar att FSCW-SynRM har lägre effektivitet och effektfaktor, samt högre vridmomentsrippel än DW-SynRM. När ferritmagneter är införda i FSCW-PMaSynRM erhålls emellertid högre värden på effektivitet, effektfaktor och fältförsvagning än i DW-SynRM. Genom att använda NdFeB i stället för ferrit i FSCW-PMaSynRM förbättras dessutom vridmomentet, fältförsvagningskapaciteten och överbelastningskapaciteten, vilket ger ett bredare temperaturområde utan avmagnetisering. Slutligen visar DW-PMaSynRM med ferrit samma effektivitetsnivå som FSCW-PMaSynRM med ferrit, men med högre effektfaktor och lägre vridmomentsrippel. FSCW-PMaSynRM med ferrit har dock andra fördelar, såsom kortare härvänderna, god feltolerans samt enklare och billigare tillverkningsprocess.