Resumo: As máquinas síncronas de ímãs permanentes têm a vantagem de não consumir energia para a criação do campo magnético no rotor. O propósito específico desta Tese é o projeto, a construção e a avaliação de uma máquina com grande número de polos, de enrolamentos concentrados, com ímãs permanentes inseridos no interior do rotor, com duas formas geométricas diferentes: um com ímãs alinhados e a outra com ímãs inclinados axialmente. As justificativas para este estudo foram a possibilidade de eliminação de multiplicadores mecânicos de velocidade e sistemas auxiliares de excitação em centrais geradoras de energia. O projeto usou um motor de indução trifásico com rotor gaiola de esquilo de 250W de 12 polos. Partindo dos próprios dados construtivos do estator, calculou-se a densidade de fluxo magnético, especificando os ímãs permanentes de neodímio. No desenvolvimento foi construído um novo rotor modular e simples. Posteriormente, a máquina foi avaliada em laboratório com o objetivo de verificar a quantidade e a qualidade da energia com a máquina atuando como gerador. Por último, os resultados encontrados na avaliação da máquina funcionando como gerador com ímãs alinhados revelaram distorção harmônica total (DHT) 16%, capacidade de geração 475W a 221V - 60Hz e como aspecto desfavorável o alto torque de travamento. Com ímãs inclinados, DHT de 7 a 8%, capacidade de geração de 236W a 195V - 60Hz e baixo torque de travamento. Este trabalho mostra que os ímãs inclinados modularmente são uma opção de máquinas elétricas com satisfatório desempenho da máquina como gerador de energia com razoável qualidade no contexto de geração distribuída de pequena potência. Além das condições técnicas têm-se o baixo custo e a manutenção reduzida do gerador com ímãs inclinados em relação aos geradores síncronos convencionais / Abstract: Synchronous machines of permanent magnets present the advantage of no power consumption for the creation of the magnetic field in the rotor. The specific purpose of this thesis is the project, its construction and the evaluation of a multi-pole of concentrated coils with permanent magnets inserted in the rotor by two different geometrical forms: aligned and skewed magnets. The vindications for this study were the possibility of eliminating both the mechanical speed reducers and the excitation energy systems in electrical powerplants. The project used a three-phase induction motor (squirrel cage rotor type) of 250W and 12 poles. Starting from the original stator constructive data, we proceeded the calculi of the magnetic flux density to determine the remanent flux of the neodymium permanent magnets. In the development of the work, a new simple and modular rotor was constructed. Subsequently, the machine was evaluated in a laboratory with the purpose of checking the quantity and quality of energy produced operating as a generator. The results obtained in the evaluation of the motor operating as a generator equipped with aligned magnets were 16% of total harmonic distortion (THD), with a generating capacity of 475W at 221V - 60 Hz, though with an adverse aspect of needing a high inertial torque (cogging torque). The machine working with skewed magnets produced 7 and 8% of total harmonic distortion (THD), with a generating capacity of 236W at 195V - 60 Hz and a low cogging torque. This work demonstrated that the modular skewed magnet is an option of electrical machines presenting satisfactory performance as a generator with a reasonable quality in the context of small distributed power generation. Besides the technical conditions, it should also be considered the low cost and reduced maintenance of skewed magnets in relation to the conventional synchronous generators / Orientador: Teófilo Miguel de Souza / Coorientador: Inácio Bianchi / Banca: Rubens Alves Dias / Banca: Jose Feliciano Adami / Banca: Osiris Canciglieri Junior / Banca: Marcio Zamboti Fortes / Doutor

This thesis is concerned with student understanding of key concepts in electrical engineering teaching within higher education. Anecdotal evidence suggests that many students struggle to understand threshold concepts and therefore encounter difficulties in learning theoretical models which are underpinned by such theoretical concepts. This research utilised a mixed methods approach to investigate the factors that influence student understanding of key theoretical concepts within electrical engineering. The initial study used a questionnaire to evaluate student understanding of concepts which were identified by teaching staff as being core to a particular module. The study identified that students commenced the module with poor understanding and that instruction on the module ELC040 Electrical Machines and Systems did not lead to improved understanding of core concepts. This suggests that the roots of student misunderstanding lay elsewhere. Desk research was subsequently employed to explore the sources of student misunderstandings. Performance data was analysed and demonstrated that the roots of the student misunderstanding of Electrical Machine Theory lay in the pre-requisite module Electrical Power B. Students routinely failed to achieve high levels of understanding in this module and as a result were unable to successfully build upon it in the third year module. Semi-structured interviews were then undertaken with Part C students who were undertaking the Electrical Machines and Systems module. In addition, structured interviews were administered with the Part B students. The interviews aimed to establish the study practices adopted by students across both years. The study showed that students found the ELA001 module difficult, and the majority believe that most other students felt the same way as they did. Students provided evidence of poor study techniques, by reporting last minute sessions to complete coursework and last minute revision for exams. This research informed the development of an interactive learning tool which was piloted on a small cohort of students. The research has also established that there are many influences on the development of student understanding of threshold concepts within electrical engineering and argues for a more active style of teaching in order to address student misunderstanding.

Cette thèse traite de la conception de systèmes électromécaniques, en particulier des machines électriques dédiées à des applications de traction. La démarche adoptée allie précision des résultats et réduction du temps de calcul du processus. A cet égard, deux thèmes ont été abordés dans cette thèse. Le premier thème concerne la modélisation de machines électriques et l’utilisation de méthodes semi-numériques. Une architecture de réseau de réluctances est proposée pour analyser les performances de machines à flux axial. Elle permet la prise en compte de l'aspect temporel et la caractéristique non-linéaire des matériaux ferromagnétiques. Des modèles basés sur la méthode des éléments finis ont été établis pour valider les résultats de modélisation. Le faible écart entre modèles numériques et semi-numériques montre le bien fondé des méthodes proposées. Des dimensionnements offrant un compromis entre précision de la solution finale et temps de calcul font l’objet du second thème de la thèse. La technique du Space Mapping est connue pour son efficacité, elle permet d'exploiter à moindre coût un modèle précis. Deux techniques qui en dérivent sont proposées en associant la modélisation par réseau de réluctances et des techniques d'optimisation. La première repose sur la modélisation de l'erreur entre des modèles de précisions différentes par une fonction à bases radiales. La deuxième intègre la correction de l'erreur dans la résolution des réseaux de réluctances en couplant les modèles linéaire et non-linéaire d'une machine électrique. / This thesis proposes contributions in design methodologies for electromechanical systems, in particularly electrical machines. The proposed strategy allies precision and reduction in simulation time. Thus, two themes were studied. The first theme concerns electromagnetic modeling by means of semi-numerical models. Reluctance’s network topology is proposed in order to analyze performances of permanent magnet axial flux machines. It can take into account the temporal aspect and the non-linearity of ferromagnetic materials. Finite element models were established in order to compare and validate the proposed modeling strategy. Thus, the small error between models (less than 5%) shows the efficiency of the models. Sizing based on optimization techniques, offering a compromise between final solution and computation time, are treated in the second theme of this thesis. Space Mapping is known as an efficient optimization technique, which enables exploiting costly models without being prohibited by computation time. Two derived techniques are proposed and applied to design the axial flux machines. The first, proposes the modeling of the error between models with different precision through radial basis function. The second embeds error correction in the magnetic equivalent circuit resolution in order to couple linear and non-linear models of an electrical machine.

Este trabalho tem por objetivo a utilização do núcleo de estator de uma máquina elétrica construído a partir do processo da Metalurgia do Pó utilizando a liga ferro com 2% fósforo (Fe2%P). O núcleo obtido substitui o núcleo comercial (laminado) do gerador síncrono de imãs permanentes com potência de 1kW. O gerador elétrico utilizado no trabalho é encontrado em geradores eólicos de pequeno porte. Esta máquina elétrica é um gerador com fluxo axial excitado através de imãs permanentes, sendo nomeada de Torus por utilizar um núcleo em formato toroidal. Foram realizados ensaios de rendimento do gerador em bancada com ambos os núcleos, comercial e o concebido a partir de metalurgia do pó. Com estes ensaios foi possível a comparação do desempenho da máquina com os dois núcleos. O núcleo do estator obtido pelo processo de metalurgia do pó obteve rendimentos elétricos equivalentes ao da máquina utilizando núcleo comercial, porém durante o teste em vazio o gerador com núcleo de Fe2%P apresentou uma potência mecânica de acionamento superior a máquina utilizando núcleo comercial. A máquina com núcleo comercial possui uma eficiência geral de no mínimo oito por cento superior a máquina que utiliza núcleo do estator com Fe2%P. / The purpose of this paper is to use the stator core of an electrical machine built from the Powder Metallurgy process using iron alloy with 2% (Fe 2% P). The core obtained replaces the commercial core (laminated) of the synchronous generator with permanent magnet power of 1kW. The electric generator used at work is found in small wind generators. This electric machine is a generator with an axial flow excited by permanent magnets that have been named Torus for using a core in the toroidal format. Bench Generator performance tests were conducted with both the commercial and the powder metallurgy designed cores. With these tests, a comparison between the machine’s performance and both cores was possible. The stator core obtained by the powder metallurgy process achieved an electrical performance equivalent to that of the machine using the commercial core, however, during the no load test, the generator with the Fe2% P core presented a higher mechanical power drive to that of the machine using the commercial core. The machine with a commercial core has an overall efficiency of at least eight per cent higher than that of the machine that uses the stator core with Fe2%P.

Este trabalho tem como objetivo o projeto, construção e análise do funcionamento de uma máquina elétrica síncrona trifásica com núcleo do rotor produzido a partir da metalurgia do pó e ímãs de neodímio-ferro-boro para aplicação em aerogeradores. Tomando como base a máquina elétrica modelo VTOP da fabricante Grupo Voges, foram realizadas mudanças na forma construtiva dos núcleos do estator e do rotor. O pacote chapas que compõem o núcleo do estator foi montado de maneira que as ranhuras apresentem um ângulo de inclinação de 10º ao longo de toda a extensão da máquina. Para o rotor, foi projetado e construído um núcleo através do processo de metalurgia do pó utilizando como matéria-prima pó de ferro puro. A esse novo núcleo foram acrescentados ímãs de neodímio-ferro-boro. Após a montagem dos componentes, a máquina elétrica foi ensaiada em uma bancada de testes. Paralelamente com a confecção do núcleo foi efetuada a simulação computacional da máquina com três tipos diferentes materiais no núcleo do rotor. Os resultados encontrados indicaram que a metalurgia do pó é uma alternativa viável para produção do núcleo de máquinas elétricas. Entretanto alterações na topologia e na forma de fixação dos ímãs são necessárias para um melhor desempenho. / This work aims at the design, construction and performance analysis of a three-phase synchronous electric machine with a rotor core produced by powder metallurgy and neodymium-iron-boron magnets for application in wind turbines. Based on the electric machine VTOP model of the manufacturer Grupo Voges, changes were carried out in the constructive form of the stator and rotor cores. The bundle of plates that make the role of stator core were mounted with a 10º slope along the entire length of the machine. For the rotor, a core was designed and built by employing powder metallurgy process using pure iron powder as raw material. The neodymium-iron-boron magnets were added to this new core. After assembling the components, the electric machine was tested on a test bench. Simultaneously with the core fabrication, the machine was simulated with three different materials in the rotor core. The results indicated that powder metallurgy is a viable alternative to produce the core of electric machines. However, changes in the topology and shape of the magnets are necessary for better assembly, improving the performance.

Este trabalho tem como objetivo o projeto, construção e análise do funcionamento de uma máquina elétrica síncrona trifásica com núcleo do rotor produzido a partir da metalurgia do pó e ímãs de neodímio-ferro-boro para aplicação em aerogeradores. Tomando como base a máquina elétrica modelo VTOP da fabricante Grupo Voges, foram realizadas mudanças na forma construtiva dos núcleos do estator e do rotor. O pacote chapas que compõem o núcleo do estator foi montado de maneira que as ranhuras apresentem um ângulo de inclinação de 10º ao longo de toda a extensão da máquina. Para o rotor, foi projetado e construído um núcleo através do processo de metalurgia do pó utilizando como matéria-prima pó de ferro puro. A esse novo núcleo foram acrescentados ímãs de neodímio-ferro-boro. Após a montagem dos componentes, a máquina elétrica foi ensaiada em uma bancada de testes. Paralelamente com a confecção do núcleo foi efetuada a simulação computacional da máquina com três tipos diferentes materiais no núcleo do rotor. Os resultados encontrados indicaram que a metalurgia do pó é uma alternativa viável para produção do núcleo de máquinas elétricas. Entretanto alterações na topologia e na forma de fixação dos ímãs são necessárias para um melhor desempenho. / This work aims at the design, construction and performance analysis of a three-phase synchronous electric machine with a rotor core produced by powder metallurgy and neodymium-iron-boron magnets for application in wind turbines. Based on the electric machine VTOP model of the manufacturer Grupo Voges, changes were carried out in the constructive form of the stator and rotor cores. The bundle of plates that make the role of stator core were mounted with a 10º slope along the entire length of the machine. For the rotor, a core was designed and built by employing powder metallurgy process using pure iron powder as raw material. The neodymium-iron-boron magnets were added to this new core. After assembling the components, the electric machine was tested on a test bench. Simultaneously with the core fabrication, the machine was simulated with three different materials in the rotor core. The results indicated that powder metallurgy is a viable alternative to produce the core of electric machines. However, changes in the topology and shape of the magnets are necessary for better assembly, improving the performance.

Este trabalho tem por objetivo a utilização do núcleo de estator de uma máquina elétrica construído a partir do processo da Metalurgia do Pó utilizando a liga ferro com 2% fósforo (Fe2%P). O núcleo obtido substitui o núcleo comercial (laminado) do gerador síncrono de imãs permanentes com potência de 1kW. O gerador elétrico utilizado no trabalho é encontrado em geradores eólicos de pequeno porte. Esta máquina elétrica é um gerador com fluxo axial excitado através de imãs permanentes, sendo nomeada de Torus por utilizar um núcleo em formato toroidal. Foram realizados ensaios de rendimento do gerador em bancada com ambos os núcleos, comercial e o concebido a partir de metalurgia do pó. Com estes ensaios foi possível a comparação do desempenho da máquina com os dois núcleos. O núcleo do estator obtido pelo processo de metalurgia do pó obteve rendimentos elétricos equivalentes ao da máquina utilizando núcleo comercial, porém durante o teste em vazio o gerador com núcleo de Fe2%P apresentou uma potência mecânica de acionamento superior a máquina utilizando núcleo comercial. A máquina com núcleo comercial possui uma eficiência geral de no mínimo oito por cento superior a máquina que utiliza núcleo do estator com Fe2%P. / The purpose of this paper is to use the stator core of an electrical machine built from the Powder Metallurgy process using iron alloy with 2% (Fe 2% P). The core obtained replaces the commercial core (laminated) of the synchronous generator with permanent magnet power of 1kW. The electric generator used at work is found in small wind generators. This electric machine is a generator with an axial flow excited by permanent magnets that have been named Torus for using a core in the toroidal format. Bench Generator performance tests were conducted with both the commercial and the powder metallurgy designed cores. With these tests, a comparison between the machine’s performance and both cores was possible. The stator core obtained by the powder metallurgy process achieved an electrical performance equivalent to that of the machine using the commercial core, however, during the no load test, the generator with the Fe2% P core presented a higher mechanical power drive to that of the machine using the commercial core. The machine with a commercial core has an overall efficiency of at least eight per cent higher than that of the machine that uses the stator core with Fe2%P.

Este trabalho tem por objetivo a utilização do núcleo de estator de uma máquina elétrica construído a partir do processo da Metalurgia do Pó utilizando a liga ferro com 2% fósforo (Fe2%P). O núcleo obtido substitui o núcleo comercial (laminado) do gerador síncrono de imãs permanentes com potência de 1kW. O gerador elétrico utilizado no trabalho é encontrado em geradores eólicos de pequeno porte. Esta máquina elétrica é um gerador com fluxo axial excitado através de imãs permanentes, sendo nomeada de Torus por utilizar um núcleo em formato toroidal. Foram realizados ensaios de rendimento do gerador em bancada com ambos os núcleos, comercial e o concebido a partir de metalurgia do pó. Com estes ensaios foi possível a comparação do desempenho da máquina com os dois núcleos. O núcleo do estator obtido pelo processo de metalurgia do pó obteve rendimentos elétricos equivalentes ao da máquina utilizando núcleo comercial, porém durante o teste em vazio o gerador com núcleo de Fe2%P apresentou uma potência mecânica de acionamento superior a máquina utilizando núcleo comercial. A máquina com núcleo comercial possui uma eficiência geral de no mínimo oito por cento superior a máquina que utiliza núcleo do estator com Fe2%P. / The purpose of this paper is to use the stator core of an electrical machine built from the Powder Metallurgy process using iron alloy with 2% (Fe 2% P). The core obtained replaces the commercial core (laminated) of the synchronous generator with permanent magnet power of 1kW. The electric generator used at work is found in small wind generators. This electric machine is a generator with an axial flow excited by permanent magnets that have been named Torus for using a core in the toroidal format. Bench Generator performance tests were conducted with both the commercial and the powder metallurgy designed cores. With these tests, a comparison between the machine’s performance and both cores was possible. The stator core obtained by the powder metallurgy process achieved an electrical performance equivalent to that of the machine using the commercial core, however, during the no load test, the generator with the Fe2% P core presented a higher mechanical power drive to that of the machine using the commercial core. The machine with a commercial core has an overall efficiency of at least eight per cent higher than that of the machine that uses the stator core with Fe2%P.

Ce mémoire est centré sur l’application de la technique d’optimisation de type Space Mapping dans le cadre du dimensionnement d’actionneurs électriques pris en compte par des modélisations multi-physiques. L’intérêt particulièrement recherché de ce type de méthode est la réduction potentiellement forte du coût du dimensionnement optimal. Cette volonté de réduction du coût de l’approche optimale s’explique par plusieurs considérations. En premier lieu, la modélisation des actionneurs tend à considérer de plus en plus de phénomènes physiques (tels que les phénomènes magnétiques, électriques, thermiques, mécaniques …) afin de décrire au mieux les phénomènes observés et mesurés. En second lieu il devient alors nécessaire de tenir compte des couplages entre ces physiques afin de traduire au plus juste l’interdépendance de ces phénomènes. Dans ce cadre, un travail particulier a été réalisé concernant la prise en compte des aspects thermiques dans les machines électriques. C’est ainsi qu’un modèle thermique à constantes localisées d’une machine synchrone à aimants permanents a été construit. Pour valider les résultats de calcul et préciser la définition de certain de ses éléments, une démarche expérimentale a été réalisée. Tous ces points, traduits dans le plan numérique, haussent le coût de l’évaluation des performances des actionneurs, et donc celui de leurs dimensionnements. De là, l’utilisation des techniques d’optimisation basées sur des modèles substituts permet d’envisager des réductions significatives des coûts de dimensionnement. La technique de Space Mapping est utilisée dans ce travail comme solution pour trouver un compromis entre la qualité des solutions trouvées et le temps de calcul. Plus particulièrement, elle est utilisée pour résoudre un problème de dimensionnement optimal d’une machine synchrone à aimants permanents assurant la fonction de démarreur dans une application de véhicule hybride. L’approche d’optimisation par Space Mapping a été comparée à celle, plus classique, n’utilisant qu’une seule modélisation de l’actionneur à dimensionner, c’est-à-dire sans modèle substitut. Il est montré que les techniques de Space Mapping sont à même de trouver des solutions de dimensionnement similaires à celles issues d’une approche classique, mais de manière beaucoup plus efficace, i.e. en utilisant un nombre plus faible d’évaluations de la modélisation multi-physique de l’actionneur. / This thesis focuses on the application of the Space Mapping optimization technique in the case of the sizing of electrical actuators taking into account a multi-physical modeling. The main interest in this type of optimization method is to considerably reduce the cost of optimal sizing. The need to use such optimization approach is due to several considerations. First, electrical actuators modeling tends to increasingly require the consideration of several physical phenomena (such as magnetic, electrical thermal and mechanical phenomena) in order to better describe observed and measured phenomena. Besides, it becomes necessary to take into account couplings between the different physical phenomena to precisely calculate the interdependencies between these phenomena. In this context, taking into account the thermal aspect in the case of electrical machines is particularly highlighted. A lumped parameter model of a permanent magnet synchronous machine is built. An experimental procedure has been followed to validate calculation results and define some elements of the proposed model. When implemented numerically, all points mentioned above increase the cost of the calculation of the performances of the electrical actuator, and then the cost of the optimal sizing. Thus, the use of an optimization technique based on surrogate models permits to reduce the optimal sizing cost. Space Mapping technique was used in this work as a solution to find a compromise between the quality of the found results and the calculation time. It is particularly used to solve an optimal sizing problem of a permanent magnet synchronous machine used as starter in a hybrid vehicle application. The Space Mapping optimization approach was compared to a classical one using a unique modeling of sized the electrical actuator : no surrogate model is used in the classical approach. Il is demonstrated that the Space Mapping techniques find optimization results that are similar to those found by the classical approach, yet, in a much more efficiently. Space Mapping techniques require only few calculations of the multi-physical model of the actuator.

Este trabalho tem como objetivo o projeto, construção e análise do funcionamento de uma máquina elétrica síncrona trifásica com núcleo do rotor produzido a partir da metalurgia do pó e ímãs de neodímio-ferro-boro para aplicação em aerogeradores. Tomando como base a máquina elétrica modelo VTOP da fabricante Grupo Voges, foram realizadas mudanças na forma construtiva dos núcleos do estator e do rotor. O pacote chapas que compõem o núcleo do estator foi montado de maneira que as ranhuras apresentem um ângulo de inclinação de 10º ao longo de toda a extensão da máquina. Para o rotor, foi projetado e construído um núcleo através do processo de metalurgia do pó utilizando como matéria-prima pó de ferro puro. A esse novo núcleo foram acrescentados ímãs de neodímio-ferro-boro. Após a montagem dos componentes, a máquina elétrica foi ensaiada em uma bancada de testes. Paralelamente com a confecção do núcleo foi efetuada a simulação computacional da máquina com três tipos diferentes materiais no núcleo do rotor. Os resultados encontrados indicaram que a metalurgia do pó é uma alternativa viável para produção do núcleo de máquinas elétricas. Entretanto alterações na topologia e na forma de fixação dos ímãs são necessárias para um melhor desempenho. / This work aims at the design, construction and performance analysis of a three-phase synchronous electric machine with a rotor core produced by powder metallurgy and neodymium-iron-boron magnets for application in wind turbines. Based on the electric machine VTOP model of the manufacturer Grupo Voges, changes were carried out in the constructive form of the stator and rotor cores. The bundle of plates that make the role of stator core were mounted with a 10º slope along the entire length of the machine. For the rotor, a core was designed and built by employing powder metallurgy process using pure iron powder as raw material. The neodymium-iron-boron magnets were added to this new core. After assembling the components, the electric machine was tested on a test bench. Simultaneously with the core fabrication, the machine was simulated with three different materials in the rotor core. The results indicated that powder metallurgy is a viable alternative to produce the core of electric machines. However, changes in the topology and shape of the magnets are necessary for better assembly, improving the performance.