O presente trabalho objetiva o estudo, obtenção e caracterização da liga magnética macia Fe-Si-P produzida por metalurgia do pó convencional visando à futura aplicação em núcleos de máquinas elétricas, atualmente fabricados por estampagem de chapas. Escolheu-se com base em testes prévios a liga Fe-3%Si-0,75%P. Para a obtenção da liga, foi utilizada a rota de mecâno-síntese com diferentes tempos de moagem: 1 h, 3 h e 9 h, além do material sem moagem para comparação. Na sequência compactaram-se uniaxialmente a frio os corpos de prova a 600 MPa seguido de sinterização a 1150 ºC em atmosfera de gás argônio. A análise da influência do tempo de moagem nas propriedades físicas, mecânicas, magnéticas e elétricas no material sinterizado foi a meta central deste trabalho. A caracterização das propriedades físicas mostrou uma redução da densidade aparente do pó moído, um aumento da distribuição do tamanho de partícula e redução do mesmo com o aumento do tempo de moagem. No que se refere às propriedades magnéticas, evidenciou-se que o material moído durante 3h apresentou os melhores resultados de indução de saturação (1,15 T), apesar do aumento na coercitividade já previsto devido ao processo de mecâno-síntese. Além disso, a difração de raios-X detectou a formação da liga através da solução sólida dos elementos P e Si na matriz ferrita. A análise metalográfica revelou a diminuição do tamanho de grãos com o aumento do tempo de moagem. Por fim, realizou-se a simulação do protótipo para análise do desempenho do material visando à aplicação futura. Esta, realizada pelo método de elementos finitos em um núcleo de um gerador síncrono com ímãs permanentes de NdFeB resultou em uma densidade de fluxo (1,95T) para o material com 3h de moagem e um torque de apenas 13% inferior se comparado ao gerador convencional produzido com núcleos de chapas de aço elétrico. / The present work aims to study, obtaining and characterization of Fe-Si-P soft magnetic alloy produced by conventional powder metallurgy intended for the future application in electrical machines cores, currently manufactured by sheet metal forming. The alloy Fe-3%Si-0,75%P was chosen based on previous tests. To obtain the alloy was used mechanical alloying route with different milling times: 1 h, 3 h and 9 h, and the material without milling for comparison. In the sequence, the specimens were uniaxially cold compacted at 600 MPa followed by sintering at 1150 ° C in an atmosphere of argon. The analysis of the influence of milling time on the physical, mechanical, magnetic and electric properties of the sintered material was the central goal of this work. The physical properties characterization showed a reduction in the bulk apparent density of the milled powder, an increase in particle size distribution and reduction thereof with increasing milling time. As regards magnetic properties, it was observed that the milled material for 3 hours showed the best results of saturation induction (1.15 T), despite the increase in the coercivity as expected due to the inherent mechanical alloying process. Furthermore, the X-ray diffraction detected the alloy formation through the solid solution of P and Si elements in the ferrite matrix. The metallographic analysis showed the decrease in grain size with increasing milling time. Finally, were performed a simulation prototype for analysis of material performance in order to future implement. This, held by finite element method on a synchronous generator core with NdFeB permanent magnets, resulting in a flux density (1.95 T) for the material with 3h of milling and a torque of only 13% lower compared to conventional generator produced with cores of electric steel sheet.

O presente trabalho objetiva o estudo, obtenção e caracterização da liga magnética macia Fe-Si-P produzida por metalurgia do pó convencional visando à futura aplicação em núcleos de máquinas elétricas, atualmente fabricados por estampagem de chapas. Escolheu-se com base em testes prévios a liga Fe-3%Si-0,75%P. Para a obtenção da liga, foi utilizada a rota de mecâno-síntese com diferentes tempos de moagem: 1 h, 3 h e 9 h, além do material sem moagem para comparação. Na sequência compactaram-se uniaxialmente a frio os corpos de prova a 600 MPa seguido de sinterização a 1150 ºC em atmosfera de gás argônio. A análise da influência do tempo de moagem nas propriedades físicas, mecânicas, magnéticas e elétricas no material sinterizado foi a meta central deste trabalho. A caracterização das propriedades físicas mostrou uma redução da densidade aparente do pó moído, um aumento da distribuição do tamanho de partícula e redução do mesmo com o aumento do tempo de moagem. No que se refere às propriedades magnéticas, evidenciou-se que o material moído durante 3h apresentou os melhores resultados de indução de saturação (1,15 T), apesar do aumento na coercitividade já previsto devido ao processo de mecâno-síntese. Além disso, a difração de raios-X detectou a formação da liga através da solução sólida dos elementos P e Si na matriz ferrita. A análise metalográfica revelou a diminuição do tamanho de grãos com o aumento do tempo de moagem. Por fim, realizou-se a simulação do protótipo para análise do desempenho do material visando à aplicação futura. Esta, realizada pelo método de elementos finitos em um núcleo de um gerador síncrono com ímãs permanentes de NdFeB resultou em uma densidade de fluxo (1,95T) para o material com 3h de moagem e um torque de apenas 13% inferior se comparado ao gerador convencional produzido com núcleos de chapas de aço elétrico. / The present work aims to study, obtaining and characterization of Fe-Si-P soft magnetic alloy produced by conventional powder metallurgy intended for the future application in electrical machines cores, currently manufactured by sheet metal forming. The alloy Fe-3%Si-0,75%P was chosen based on previous tests. To obtain the alloy was used mechanical alloying route with different milling times: 1 h, 3 h and 9 h, and the material without milling for comparison. In the sequence, the specimens were uniaxially cold compacted at 600 MPa followed by sintering at 1150 ° C in an atmosphere of argon. The analysis of the influence of milling time on the physical, mechanical, magnetic and electric properties of the sintered material was the central goal of this work. The physical properties characterization showed a reduction in the bulk apparent density of the milled powder, an increase in particle size distribution and reduction thereof with increasing milling time. As regards magnetic properties, it was observed that the milled material for 3 hours showed the best results of saturation induction (1.15 T), despite the increase in the coercivity as expected due to the inherent mechanical alloying process. Furthermore, the X-ray diffraction detected the alloy formation through the solid solution of P and Si elements in the ferrite matrix. The metallographic analysis showed the decrease in grain size with increasing milling time. Finally, were performed a simulation prototype for analysis of material performance in order to future implement. This, held by finite element method on a synchronous generator core with NdFeB permanent magnets, resulting in a flux density (1.95 T) for the material with 3h of milling and a torque of only 13% lower compared to conventional generator produced with cores of electric steel sheet.

O presente trabalho objetiva o estudo, obtenção e caracterização da liga magnética macia Fe-Si-P produzida por metalurgia do pó convencional visando à futura aplicação em núcleos de máquinas elétricas, atualmente fabricados por estampagem de chapas. Escolheu-se com base em testes prévios a liga Fe-3%Si-0,75%P. Para a obtenção da liga, foi utilizada a rota de mecâno-síntese com diferentes tempos de moagem: 1 h, 3 h e 9 h, além do material sem moagem para comparação. Na sequência compactaram-se uniaxialmente a frio os corpos de prova a 600 MPa seguido de sinterização a 1150 ºC em atmosfera de gás argônio. A análise da influência do tempo de moagem nas propriedades físicas, mecânicas, magnéticas e elétricas no material sinterizado foi a meta central deste trabalho. A caracterização das propriedades físicas mostrou uma redução da densidade aparente do pó moído, um aumento da distribuição do tamanho de partícula e redução do mesmo com o aumento do tempo de moagem. No que se refere às propriedades magnéticas, evidenciou-se que o material moído durante 3h apresentou os melhores resultados de indução de saturação (1,15 T), apesar do aumento na coercitividade já previsto devido ao processo de mecâno-síntese. Além disso, a difração de raios-X detectou a formação da liga através da solução sólida dos elementos P e Si na matriz ferrita. A análise metalográfica revelou a diminuição do tamanho de grãos com o aumento do tempo de moagem. Por fim, realizou-se a simulação do protótipo para análise do desempenho do material visando à aplicação futura. Esta, realizada pelo método de elementos finitos em um núcleo de um gerador síncrono com ímãs permanentes de NdFeB resultou em uma densidade de fluxo (1,95T) para o material com 3h de moagem e um torque de apenas 13% inferior se comparado ao gerador convencional produzido com núcleos de chapas de aço elétrico. / The present work aims to study, obtaining and characterization of Fe-Si-P soft magnetic alloy produced by conventional powder metallurgy intended for the future application in electrical machines cores, currently manufactured by sheet metal forming. The alloy Fe-3%Si-0,75%P was chosen based on previous tests. To obtain the alloy was used mechanical alloying route with different milling times: 1 h, 3 h and 9 h, and the material without milling for comparison. In the sequence, the specimens were uniaxially cold compacted at 600 MPa followed by sintering at 1150 ° C in an atmosphere of argon. The analysis of the influence of milling time on the physical, mechanical, magnetic and electric properties of the sintered material was the central goal of this work. The physical properties characterization showed a reduction in the bulk apparent density of the milled powder, an increase in particle size distribution and reduction thereof with increasing milling time. As regards magnetic properties, it was observed that the milled material for 3 hours showed the best results of saturation induction (1.15 T), despite the increase in the coercivity as expected due to the inherent mechanical alloying process. Furthermore, the X-ray diffraction detected the alloy formation through the solid solution of P and Si elements in the ferrite matrix. The metallographic analysis showed the decrease in grain size with increasing milling time. Finally, were performed a simulation prototype for analysis of material performance in order to future implement. This, held by finite element method on a synchronous generator core with NdFeB permanent magnets, resulting in a flux density (1.95 T) for the material with 3h of milling and a torque of only 13% lower compared to conventional generator produced with cores of electric steel sheet.

Dans le domaine de l'électrotechnique, la simulation numérique permet de s'affranchir d'essais qui peuvent être coûteux ou difficiles à réaliser. La Méthode des Éléments Finis est ainsi devenue une approche de référence dans ce contexte car elle permet d'obtenir des résultats précis sur des systèmes aux géométries complexes. Or, la simulation numérique d’un dispositif électrotechnique peut s’avérer coûteuse en temps de calcul du fait d’un nombre d’inconnues et de pas de temps important, ainsi que de fortes non-linéarités des matériaux ferromagnétiques. Il est alors nécessaire de mettre en œuvre des techniques permettant de réduire les temps de calcul nécessaires à la résolution de tels modèles numériques. Les méthodes de réduction de modèles semblent bien adaptées à ce type de problèmes car elles ont déjà été appliquées avec succès dans de nombreux domaines de l’ingénierie, notamment en mécanique des fluides et du solide. Une première catégorie de méthodes permet de rechercher la solution dans une base réduite afin de diminuer le nombre d’inconnues du modèle numérique. Pour ce type d’approche, les méthodes les plus connues sont la Proper Orthogonal Decomposition, la Proper Generalized Decomposition et la Projection d’Arnoldi. Une seconde catégorie regroupe les approches permettant de réduire le coût de calcul dû aux phénomènes non linéaires, grâce à des méthodes d’interpolation telles que l‘Empirical Interpolation Method et la Gappy POD. Cette thèse CIFRE a ainsi été effectuée dans le cadre du LAMEL (laboratoire commun entre le L2EP et EDF R&D) avec pour but d’identifier et d’implémenter les méthodes de réduction les mieux adaptées à l’électrotechnique. Celles-ci devront être capables de réduire le coût de calcul tout en prenant en compte le mouvement du rotor, les non-linéarités des matériaux ferromagnétiques mais aussi l’environnement électrique et mécanique du dispositif. Enfin, un indicateur évaluant l’erreur commise par le modèle réduit a été développé, offrant ainsi la garantie d’une précision suffisante sur les résultats. / In the electrical engineering field, numerical simulation allows to avoid experiments which can be expensive, difficult to carry out or harmful for the device. In this context, the Finite Element Method has become to be one of the most used approach since it allows to obtain precise results on devices with complex geometries. However, these simulations can be computationally expensive because of a large number of unknowns and time-steps, and of strong nonlinearities of ferromagnetic materials to take into account. Numerical techniques to reduce the computational effort are thus needed. In this context, model order reduction approaches seem well adapted to this kind of problem since they have already been successfully applied to many engineering fields, among others, fluid and solid mechanics. A first class of methods allows to seek the solution in a reduced basis, allowing to dramatically reduce the number of unknowns of the numerical model. The most famous technics are probably the Proper Orthogonal Decomposition, the Proper Generalized Decomposition and the Arnoldi Projection. The second class of approaches consists of methods allowing to reduce the computational cost associated to nonlinearities, using interpolation methods like the Empirical Interpolation Method and the Gappy POD. This Ph.D. has been done within the LAMEL, the joint laboratory between the L2EP and EDF R&D, in order to identify and implement the model order reduction methods which are the most adapted to electrical engineering models. These methods are expected to reduce the computational cost while taking into account the motion of an electrical machine rotor, the nonlinearities of the ferromagnetic materials and also the mechanical and electrical environment of the device. Finally, an error indicator which evaluates the error introduced by the reduction technic has been developed, in order to guarantee the accuracy of the results obtained with the reduced model.

This dissertation thesis deals with the measurement of insulation resistance for rotating electrical machines and polarization indices calculated from them. The first part contains a short theoretical introduction, methods of measurement and basic formulas for calculations. The second part discusses the results obtained in laboratory measurements in both the model and the real coil of high voltage machine. There are also elucidated some of the principles and causes of some phenomena with which the measurement of insulation resistance is encountered. The third part deals with the results of measurements on real machines. There are mainly discussed the dependences of insulation resistance and polarization index on the influences that occur in measurements such as temperature measured insulation, moisture in the insulation, but also the influence of measuring instruments on the measured values. It is also expressed how much these factors affect the measurement results. In addition, this part deals with some other influences that have a negative affect on the measurement of insulation resistance. There is processed a new methodology for measuring insulation resistence in the fourth part of this thesis. The need to develop a metodology of measuring is based on the needs of engineering practice, where is considerable inconsistency of measurement in the present time. Measurement, and often performed on the same machine, are not nowadays often comparable, because measurements are not met even the basic rules resulting from the findings of research and development, which were discovered in the last few decades. Measurement of insulation resistance in our nowdays methodology stagnated on the level of the seventies of 20th century. For this reason, we have developed a new methodology of measurement that takes into account all significant influences affecting the measurement. The purpose of the methodology is to ensure full repeatability and comparability of measurements not only on the same machine but on machines of the same type, in optimal cases, the machines of different types. There are the chapters "The objectives of the work" and "Conclusion" the part of the work. A very important chapter is "The contribution of thesis", which summarizes the original results of this work and results, the use of which is expected in engineering practice.

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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)

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)

This work utilizes the small-signal impedance-based stability analysis method to develop stability assessment criteria for a single-aisle turboelectric aircraft with aft boundary-layer propulsion (STARC-ABL) system. The impedance-based stability analysis method outperforms other stability analysis methods because it does not require detailed information of individual components for system integration, therefore, a system integrator can just require the vendors to make the individual components meet the impedance specifications to ensure whole system stability. This thesis presents models of a generator, motor, housekeeping loads, and battery all with power electronics interface which form an onboard electrical system and analyzes the relationship between the impedance shape of each component and their physical design and control loop design. Based on the developed small-signal model of the turbine-generator-rectifier subsystem and load subsystem, this thesis analyzes the impact of electromechanical dynamics of the turbofan passed through the generator on the dc distribution system, concluding that the rectifier can mitigate the impact. Finally, to ensure the studied system stable operation during the whole flying profile, the thesis provides impedance specifications of the dc distribution system and verifies the specifications with several cases in time-domain simulations. / M.S. / Electric aircraft propulsion (EAP) technologies have been a trend in the aviation industry for their potential to reduce environmental emissions, increase fuel efficiency and reduce noise for commercial airplanes. Achieving these benefits would be a vital step towards environmental sustainability. However, the development of all-electric aircraft is still limited by the current battery technologies and maintenance systems. The single-aisle turboelectric aircraft with aft boundary-layer (STARC-ABL) propulsion concept is therefore developed by NASA aiming to bridge the gap between the current jet fuel-powered aircraft and future all-electric vehicles. The plane uses electric motors powered by onboard gas turbines and transfers the generated power to other locations of the airplane like the tail fan motor to provide distributed propulsion. Power electronics-based converter converts electricity in one form of electricity to another form, for example, from ac voltage to dc voltage. This conversion of power is very important in the whole society, from small onboard chips to Mega Watts level electrical power system. In the aircraft electrical power system context, power electronics converter plays an important role in the power transfer process especially with the recent trend of using high voltage dc (HVDC) distribution instead of conventional ac distribution for the advantage of increased efficiency and better voltage regulation. The power generated by the electric motors is in ac form. Power electronics converter is used to convert the ac power into dc power and transfer it to the dc bus. Because the power to drive the electric motor to provide distributed propulsion is also in ac form, the dc power needs to be converted back into ac power still through a power electronics converter. With a high penetration of power electronics into the onboard electrical power system and the increase of electrical power level, potential stability issues resulted from the interactions of each subsystem need to be paid attention to. There are mainly two stability-related studies conducted in this work. One is the potential cross-domain dynamic interaction between the mechanical system and the electrical system. The other is a design-oriented study to provide sufficient stability margin in the design process to ensure the electrical system’s stable operation during the whole flying profile. The methodology used in this thesis is the impedance-based stability analysis. The main analyzing process is to find an interface of interest first, then grouped each subsystem into a source subsystem and load subsystem, then extract the source impedance and load impedance respectively, and eventually using the Nyquist Criterion (or in bode plot form) to assess the stability with the impedance modeling results. The two stability-related issues mentioned above are then studied by performing impedance analysis of the system. For the electromechanical dynamics interaction study, this thesis mainly studies the rotor dynamics’ impact on the output impedance of the turbine-generator-rectifier system to assess the mechanical dynamics’ impact on the stability condition of the electrical system. It is found that the rotor dynamics of the turbine is masked by the rectifier; therefore, it does not cause stability problem to the pre-tuned system. For the design-oriented study, this thesis mainly explores and provides the impedance shaping guidelines of each subsystem to ensure the whole system's stable operation. It is found that the stability boundary case is at rated power level, the generator voltage loop bandwidth is expected to be higher than 300Hz, 60˚ to achieve a 6dB, 45˚ stability margin, and load impedance mainly depends on the motor-converter impedance.

Hybrid electric vehicles significantly reduce exhaust emissions and increase fuel economy. Power packs are the most fundamental components in a series powertrain configuration of a hybrid vehicle, which produce the necessary power to run the vehicle. The aim of this project is to design a compact power pack for a series hybrid vehicle, using virtual prototyping. The hybrid electric vehicle characteristics and configurations are analysed, followed by an explanation of the principles of induction machines. A new type of rotary induction machine with an outer rotor construction is designed to be coupled with the novel rotary internal combustion engine with rotating crankcase in order to form the compact power unit for the hybrid vehicle. The starting and generation performance of the designed machine is analysed by an electric machine simulator, called JMAG. ADVISOR software is studied and utilised to simulate the overall vehicle performance, employing different categories of power packs in the powertrain. Results show that the proposed compact power pack has the best performance in terms of fuel economy, emissions and battery charging compared to the existing power unit options. Over the city cycle, fuel economy is increased by up to 47 % with emission reduced by up to 36 % and over the highway cycle, fuel economy is increased by up to 69 % with emission reduced by up to 42 %.