Axial flux permanent magnet (AFPM) machines have recently attracted significant attention due to several reasons, such as their specific form factor, potentially higher torque density and lower losses, feasibility of increasing the number of poles, and facilitating innovative machine structures for emerging applications. One such machine design, which has promising, high efficiency particularly at higher speeds, is of the coreless AFPM type and has been studied in the dissertation together with more conventional AFPM topologies that employ a ferromagnetic core. A challenge in designing coreless AFPM machines is estimating the eddy current losses. This work proposes a new hybrid analytical and numerical finite element (FE) based method for calculating ac eddy current losses in windings and demonstrates its applicability for axial flux electric machines. The method takes into account 3D field effects in order to achieve accurate results and yet greatly reduce computational efforts. It is also shown that hybrid methods based on 2D FE models, which require semi-empirical correction factors, may over-estimate the eddy current losses. The new 3D FE-based method is advantageous as it employs minimum simplifications and considers the end turns in the eddy current path, the magnetic flux density variation along the effective length of coils, and the field fringing and leakage, which ultimately increases the accuracy of simulations. After exemplifying the practice and benefits of employing a combined design of experiments and response surface methodology for the comparative design of coreless and conventional AFPM machines with cores, an innovative approach is proposed for integrated design, prototyping, and testing efforts. It is shown that extensive sensitivity analysis can be utilized to systematically study the manufacturing tolerances and identify whether the causes for out of specification performance are detectable. The electromagnetic flux path in AFPM machines is substantially 3D and cannot be satisfactorily analyzed through simplified 2D simulations, requiring laborious 3D models for performance prediction. The use of computationally expensive 3D models becomes even more challenging for optimal design studies, in which case, thousands of candidate design evaluations are required, making the conventional approaches impractical. In this dissertation a new two-level surrogate assisted differential evolution multi-objective optimization algorithm (SAMODE) is developed in order to optimally and accurately design the electric machine with a minimum number of expensive 3D design evaluations. The developed surrogate assisted optimization algorithm is used to comparatively and systematically design several AFPM machines. The studies include exploring the effects of pole count on the machine performance and cost limits, and the systematic comparison of optimally designed single-sided and double-sided AFPM machines. For the case studies, the new optimization algorithm reduced the required number of FEA design evaluations from thousands to less than two hundred. The new methods, developed and presented in the dissertation, maybe directly applicable or extended to a wide class of electrical machines and in particular to those of the PM-excited synchronous type. The benefits of the new eddy current loss calculation and of the optimization method are mostly relevant and significant for electrical machines with a rather complicated magnetic flux path, such is the case of axial flux and of transvers flux topologies, which are a main subject of current research in the field worldwide.

Insulating sheets, impregnants and encapsulation materials commonly used for winding insulation offer low thermal conductivities. This leads to an increased heating of the winding of electrical machines and to the existence of hotspots. The electromagnetical utilization of the machine has to be reduced with respect to the allowed maximum winding temperature. In this paper, the development and experimental investigation of novel polysiloxane composites with ceramic fillers are presented. The materials are tested by means of impregnated and encapsulated samples of a round-wire winding as well as the main insulation of electrical steel sheets and laminated cores. Numerical models are implemented for determining the equivalent thermal conductivity of the winding compound comprising the enameled wire and the impregnant. Based on the example of a permanent-magnet synchronous machine with outer-rotor in modular construction, the potential for increasing the electromagnetical utilization is shown.

Electrification and energy efficiency are two important aspects in present scenarios describing a sustainable future. Electric motors constitute a large fractionof industry’s electricity demand today, and it is expected to remain high inthe future. Electrification of the transport sector is expected in a sustainabledevelopment scenario, leading to a large increase in electric vehicles. Theirpropulsion systems will contain one or several motors.Development of new energy efficient motors and generators requires highresolution methods for studying and describing heat transfer phenomena. Thissince temperature level affects a motors efficiency and effective and efficientcooling allows for using less active material in the motor.In this work simulations of temperature distribution in a motor for tractionapplications are performed with different specifications of the loss distributionand distribution of coolant flow. Simulation results are compared to measuredvalues. The comparison shows how the simulation results differ in comparisonto the measurements. It can be concluded that attention needs to be paid tohow the simulation is defined when comparing to measured data.In establishing high resolution simulation approaches, the heat transfersystem constituting of an impinging jet on a flat plate is considered as aprototype problem. A Large-Eddy Simulation (LES) approach is employed tostudy the heat transfer and gather heat transfer data. Statistical analysis ofsampled heat transfer data shows behavior which is previously unpublished.The application of Proper Orthogonal Decomposition (POD), on the heattransfer field, and Extended Proper Orthogonal Decomposition (EPOD), linkingheat transfer modes with fluid flow modes, regarding the impinging jet systemis performed for the first time. The results show a clear correlation betweenstructures in the heat transfer field and structures in the fluid flow field.The investigated simulation methods and approaches can be employed instudies of heat transfer in electric machines.

Com o advento da internet, a comunicação entre sistemas remotos foi amplamente facilitada, tornando viável a aplicação de sistemas supervisórios através dela, principalmente via protocolo TCP/IP. Embora esses sistemas já sejam empregados na indústria, principalmente utilizando como driver os controladores lógicos programáveis (CLP\'s), a implementação de qualquer sistema mais simples de supervisionamento teria um custo elevado, devido tanto ao preço do hardware quanto do software envolvido. Além disso, os programas supervisórios existentes fornecem um número limitado de recursos de visualização, que se restringem principalmente ao software. Assim, o que se propõe nesse trabalho é um sistema supervisório de baixo custo, via TCP/IP, aplicado em máquinas elétricas, mas que pode ser generalizado na supervisão de outros tipos de sistemas, onde o monitoramento remoto é necessário. Além da exibição convencional dos parâmetros supervisionados através de gráficos e labels, o sistema permite também que esses sejam exibidos através de painéis eletrônicos, fornecendo assim, uma nova interface visual ao usuário com o intuito de facilitar sua supervisão. / The advent of internet simplified the comunication between remote systems, allowing the application of supervisory systems through the internet, mainly using the TCP/IP protocol. Although these systems have already been employed in industry, using the Programmer Logic Controller (PLC\'s) as driver, the implementation of any simple supervisory system could have an expensive cost, due to the prices of hardware and software employed. Moreover, the existing supervisory systems provide limited visual resources, restricted to the used software. So, this work presents a low cost supervisory system, via TCP/IP, applied to electric machines but it can be generalized in the supervision of differents types of systems, where the remote monitoring is necessary. Besides the conventional displaying of the monitored parameters through graphics and labels, the developed system allows the exhibition of the supervisioned parameters using eletronic panels, providing an alternative visual interface to the user so that their supervision becomes easier.

En plus des aspects électrique, magnétique, vibro-acoustique et mécanique, les considérations thermiques doivent être prises en compte lors des phases de conception et d’optimisation des machines électriques. Ce mémoire se porte sur l’analyse et la simulation du comportement thermique des machines électriques Totalement Fermées et Non Ventilées (TFNV) et plus particulièrement sur le cas de la machine Synchro-réluctante (Synchrel), utilisée comme actionneur d’embrayage. Un modèle thermique détaillé (MTD), décrivant le comportement thermique de la machine Synchrel est conçu. Ce MTD proposé est construit grâce à une combinaison de la méthode à Constantes Localisées (CL) et d’une technique numérique de type Mécanique des Fluides Numériques (MFN). La première méthode est dédiée à la modélisation des transferts conductifs et radiatifs. La seconde permet de modéliser le mécanisme de refroidissement par convection naturelle autour de la machine Synchrel. Compte-tenu de l’importance du mode de refroidissement sur l’évolution des températures critiques, l’approche MFN peut apporter plus de précision. Par contre, elle nécessite des temps de calcul importants ce qui freine son utilisation. Afin de surmonter cette problématique, les résultats numériques obtenus pour des points de fonctionnement particuliers sont utilisés afin de définir des relations de corrélation analytiques. Cette analyse numérique est accompagnée d’une démarche expérimentale afin d’élaborer les corrélations expérimentales correspondantes. L’étude montre que les solutions numériques peuvent converger vers des solutions plus précises si l’on tient compte des données d’incertitudes introduites par cette approche. La deuxième problématique traitée est la détermination des Résistances Thermiques de Contact (RTCs) des machines électriques. Elles constituent des paramètres clefs dans la définition du MTD complet. La démarche de détermination des RTCs est basée sur deux approches d’identification paramétrique. La première est basée sur des observations expérimentales du comportement thermique de la machine. La seconde est basée sur une approche mathématique de réduction de modèle. Les valeurs déterminées sont cohérentes avec la littérature, bien que la machine Synchrel diffère en topologie, taille et puissance. En utilisant la corrélation d’origine numérique du phénomène de convection externe, le MTD complet est alors utilisé afin d’évaluer la variation de température due à l’erreur introduite par la MFN. En utilisant la corrélation expérimentale, le MTD complet est validé. Les approches d’identification paramétrique conduisent à la construction de deux modèles thermiques de second ordre de la machine. Ces modèles permettent la surveillance du comportement thermique du bobinage et du carter. Ces deux modèles simplifiés font montre d’une prédictibilité satisfaisante au regard de leur simplicité. / In addition to electrical, magnetic, vibro-acoustic and mechanical aspects, thermal considerations must be taken into account during the design and optimization of electrical machines. This study focuses on the analysis and the simulation of the thermal behavior of Totally Enclosed Non Ventilated (TENV) electric machines, specifically a Synchro-reluctant motor (Synchrel) in the context of an automotive application : a clutch actuator. A detailed thermal model (MTD) describing the thermal behavior of the Synchrel machine is designed. This proposed MTD is based on a combination of the Lumped Parameter Thermal Network method (LPTN) and the Computational Fluid Dynamics (CFD) methods. The first method is dedicated to model the conductive and radiative heat transfers. CFD techniques are dedicated to model the cooling mechanism based on the natural convection around the Synchrel machine. Since the critical temperature is very sensitive to the cooling mode, the CFD approach is used in this study to provide more accurate results. On the other hand, it requires considerable computing time, which prevents its use in design studies based on optimization methods. In order to overcome this problem, only some numerical results obtained for particular operating points are used to define an analytical correlation based on the numerical calculation relations. This numerical analysis goes with an experimental approach in order to elaborate the corresponding experimental correlations. This study shows that numerical solutions can present a good accuracy, if uncertainty data introduced by this approach are taken into account. The second research problem addressed in this study is the determination of the Contact Thermal Resistances (RTCs), which are key parameters in the definition of the MTD. The determination procedure of the RTCs is based on two parametric identification approaches. The first one is experimental and based on some observations of the thermal behavior of the machine. The second one is based on a mathematical model reduction approach. The determined values are consistent with results from literature, although the Synchrel machine differs in topology, size and power. Using the numerical correlations, the MTD is used to evaluate the temperature deviation due to error terms introduced by the CFD approach. Then, using these experimental correlations, the MTD’s quality can be checked and approved. Parametric identification approaches lead to the construction of two secondorder thermal models of the machine. These models allow monitoring the thermal behavior of the winding and the casing. Both simplified models show satisfactory predictability with respect to their great simplicity.

Dans un contexte ou la question de la préservation de l'environnement est devenue un sujet sociétal majeur, la recherche de nouvelles technologies pour remplacer la voiture à essence constitue un véritable enjeu industriel. Les véhicules hybrides et électriques sont une alternative prometteuse aux véhicules conventionnels. Ce travail de thèse porte sur la conception et l'optimisation des machines électriques pour la motorisation de ces voitures.Au cours de ces travaux, nous avons développé une nouvelle méthodologie de dimensionnement et d'optimisation des machines synchrones à double excitation. L'intérêt de cette méthode est son bon compromis entre la précision et le temps de calcul et sa capacité d'adaptation à plusieurs types de machines. Le second volet de la thèse est consacré à la proposition d'une nouvelle structure de machine synchrone à rotor bobiné. Une technique originale de compensation de la réaction magnétique d'induit est mise en place, elle consiste en l'insertion d'aimants secondaires permettant de créer un flux dans l'axe q de la machine. Ce dernier a pour rôle d'affaiblir le flux de la réaction magnétique d'induit. / In a context where the question of the environmental protection has become a major social problem, research new technologies to replace the gasoline car is a real industrial challenge. The hybrid and electric vehicles are a promising alternative to conventional vehicles. This thesis focuses on the design and optimization of electrical machines for electric and hybrid cars.In this work, we developed a new methodology for design and optimization of hybrid excitation synchronous machines. The advantage of this method is its good compromise between accuracy and computation time and its ability to be adapted to a wide range of machines. The second part of this thesis is devoted to the development of a new structure of a wound rotor synchronous machine. A novel technique for compensating the armature reaction of this machine is introduced, it involves the insertion of secondary magnets to produce a quadratic axis flux (q-axis), this latter has the function of weakening the armature reaction flux.

Os inversores multiníveis podem se beneficiar de filtros de saída reduzidos devido ao menor conteúdo harmônico do sinal sintetizado, dado que suas saídas possuem menores diferenças de tensão durante seu chaveamento. Sua desvantagem é causada pelo elevado número de chaves controladas normalmente necessário para seu funcionamento, e seus circuitos auxiliares. No objetivo de reduzir o número de chaves utilizadas em um inversor de sete níveis, uma nova topologia para um inversor de sete níveis de tensão é apresentada, construída a partir de duas fontes de tensão assimétricas conectadas em série e seis chaves semicondutoras. Este trabalho analisa os princípios de operação desta topologia e a lógica de chaveamento necessária para seu funcionamento. O arranjo proposto não oferece a possibilidade de redução de tensão sobre as chaves, conforme apresentado nas topologias clássicas de inversores com ponto neutro grampeado a diodo ou capacitor e de células em série, mas reduz a quantidade dos componentes necessários para a composição dos sete níveis, sendo possível utilizá-lo em inversores de baixa tensão, devido à seu menor tamanho e complexidade. O estudo apresenta a estrutura resultante em forma de um inversor monofásico por modulação de largura de pulso com disposição das portadoras em oposição de fase, com sete níveis igualmente espaçados, utilizando apenas seis chaves e duas fontes de tensão com alimentação assimétrica, em que a principal fonte tem o dobro da tensão da outra fonte. O funcionamento da topologia é verificado em simulação e implementação de protótipo de 860W. Uma outra versão também é apresentada analiticamente, com melhor grampeamento da tensão, utilizando oito chaves comandadas com uma lógica mais simplificada. Por fim, algumas propostas são sugeridas para a geração dos dois barramentos de tensão necessários. / Multilevel inverters can benefit from reduced output filters due to the lower harmonic content of the synthesized signal, since their outputs have lower voltage differences during their switching. Its disadvantage is caused by the high number of controlled switches and its auxiliary circuits normally required for its operation. In order to reduce the number of switches used in a seven-level inverter, a new topology for a seven level and its auxiliary circuits inverter is presented, constructed from two asymmetrical voltage sources connected in series and six semiconductor switches. This work analyzes the principles of operation of this topology and the switching logic required for its operation. The proposed arrangement does not offer the possibility of voltage reduction on the switches, as presented in the classical inverters topologies with diode or capacitor clamping or the series connected cells, but it reduces the amount of components necessary for the composition of the seven levels, being possible to use it in low voltages inverters, due to its smaller size and complexity. The study presents the resulting structure in the form of a single-phase inverter, using the pulse-width modulation with phase-contrast carriers technique, with seven equally spaced levels, using only six switches and two voltage sources with asymmetrical voltages, in which the main source has double the voltage of the other. The operation of the topology is checked with simulation and an implementation of a 860W prototype. Another version is also presented analytically, with better voltage clamping, using eight keys controlled with a more simplified logic. Finally, some proposals are suggested for the generation of the two necessary voltage rails.

Submitted to the Department of Electrical Engineering in Fulfilment of the Requirements for the Magister Technologiae in Electrical Engineering at the CAPE PENINSULA UNIVERSITY OF TECHNOLOGY SUPERVISOR: E. VOSS NOVEMBER 2013 / Radial and peripheral displacement of stator teeth in electrical machines is known to be the cause of undesired vibration which leads to noise. This thesis serves to investigate the possibility of physically measuring the radial displacement of stator teeth caused by electromagnetic forces which, to the author’s knowledge, has not yet been achieved. A simplified practical approach is adopted in order to address the inherent difficulties attached to this problem, and the measurement of displacement is done by means of an experimental rig where a tooth is subjected to magnetic force acting over an air gap. Three experiments are carried out, each comprising ten tests, the results of which are compared in order to gain some idea as to the magnitudes of displacement which can be expected over a range of applied air gap flux densities. The aim of this work is to observe the displacement response of magnetised EM core material when acted upon by forces, and to see if the measured results agree with the elastic displacement predicted by a wellknown formula. It will be shown that although the measured results are in the same range as the predicted results, there is a deviation from the predicted linearity due to certain characteristics of the force rig, which are explained. The chosen measurement method is capacitive displacement and is shown to be a viable alternative to the more commonly used search coils and vibrometers in past literatures, especially when measuring displacements on the nano-scale. In addition, this study shows the importance of using 3D finite element software to simulate the electromagnetic model when saturation is present in the core of the test specimen. The important findings of this work are discussed in detail, and some ideas put forward, in an attempt to establish a starting point for future related work in the measurement of electromagnetic forceinduced displacement of stator teeth in electrical machines.

Neste trabalho é proposto o desenvolvimento de um novo microinversor de estágio único para aplicação em sistemas fotovoltaicos. A topologia apresentada é baseada na combinação do conversor Cuk com uma estrutura de indutores chaveados para obtenção de um maior ganho estático e um circuito inversor em ponte completa conectado à rede. A estrutura de indutores chaveados apresentada nesse trabalho reduz esforços de tensão e corrente nas chaves semicondutoras. Com o objetivo de facilitar o controle, a etapa CC do microinversor opera em modo de condução descontínua (DCM). Para injetar corrente senoidal com baixa distorção harmônica à rede, é aplicado às chaves semicondutoras da etapa CC uma modulação por largura de pulso senoidal (SPWM). As chaves semicondutoras do circuito inversor em ponte completa são comandadas na frequência da rede, reduzindo perdas por chaveamento. Por se tratar de uma topologia inédita, são apresentados os modos de operação e a análise matemática do conversor CC-CC Cuk com alto ganho estático. Posteriormente, são realizadas a análise teórica e a estratégia de controle do microinversor proposto. Os resultados experimentais são expostos para discutir o funcionamento da topologia proposta, através de simulações e da implementação de um protótipo de 180 W. / The development of a novel single stage microinverter is proposed. The presented topology is based on the combination of the Cuk converter with a switched inductor structure to obtain a higher static gain, and a full-bridge inverter circuit. The presented switched inductor structure reduces voltage and current stresses on the power switches. In order of simplify the control, the stage CC of the microinverter operate in discontinuous conduction mode (DCM). To inject sinusoidal current with low harmonic distortion to the grid, a sinusoidal pulse width modulation (SPWM) is applied in the power switches. The switches of the full-bridge invertes are commanded in low frequency, in order to reduce switching losses. Operation modes and math analysis of the novel CC-CC converter are presented. Moreover, the math analysis and control strategy of proposed microinverter topology are exposed. Furthermore, experimental results are performed to analyze the proposed topology operation, by software simulations and implementation of a 180 W prototype.

Neste trabalho é proposto o desenvolvimento de um novo microinversor de estágio único para aplicação em sistemas fotovoltaicos. A topologia apresentada é baseada na combinação do conversor Cuk com uma estrutura de indutores chaveados para obtenção de um maior ganho estático e um circuito inversor em ponte completa conectado à rede. A estrutura de indutores chaveados apresentada nesse trabalho reduz esforços de tensão e corrente nas chaves semicondutoras. Com o objetivo de facilitar o controle, a etapa CC do microinversor opera em modo de condução descontínua (DCM). Para injetar corrente senoidal com baixa distorção harmônica à rede, é aplicado às chaves semicondutoras da etapa CC uma modulação por largura de pulso senoidal (SPWM). As chaves semicondutoras do circuito inversor em ponte completa são comandadas na frequência da rede, reduzindo perdas por chaveamento. Por se tratar de uma topologia inédita, são apresentados os modos de operação e a análise matemática do conversor CC-CC Cuk com alto ganho estático. Posteriormente, são realizadas a análise teórica e a estratégia de controle do microinversor proposto. Os resultados experimentais são expostos para discutir o funcionamento da topologia proposta, através de simulações e da implementação de um protótipo de 180 W. / The development of a novel single stage microinverter is proposed. The presented topology is based on the combination of the Cuk converter with a switched inductor structure to obtain a higher static gain, and a full-bridge inverter circuit. The presented switched inductor structure reduces voltage and current stresses on the power switches. In order of simplify the control, the stage CC of the microinverter operate in discontinuous conduction mode (DCM). To inject sinusoidal current with low harmonic distortion to the grid, a sinusoidal pulse width modulation (SPWM) is applied in the power switches. The switches of the full-bridge invertes are commanded in low frequency, in order to reduce switching losses. Operation modes and math analysis of the novel CC-CC converter are presented. Moreover, the math analysis and control strategy of proposed microinverter topology are exposed. Furthermore, experimental results are performed to analyze the proposed topology operation, by software simulations and implementation of a 180 W prototype.