ABSTRACT CALCULATION OF CORE LOSSES OF A 6-PHASE INDUCTION MOTOR WITH 3RD HARMONIC CURRENT INJECTION B&Uuml / Y&Uuml / KBAS, AfSin M.S., Department of Electrical and Electronics Engineering Supervisor: Prof. Dr. H. B&uuml / lent ERTAN January 2004, 106 pages The advantages of using a six-phase induction motor for industrial drives, over the conventional three-phase drive can be summarized as improved reliability, reduction on the power ratings for the static converters and harmonic reduction. A technique of injecting third harmonic zero sequence current components in the phase currents to improve the machine torque density was presented recently by another research study. However, to meaninigfully evaluate the performnce of such machines and/or to be able to make good designs / it is necessary to obtain an accurate mathematical model for the loss calculation. The calculation of high frequency loss in this context presents a very difficult problem. In this thesis a modified version of a loss calculation model, which was developed in another MS thesis will be applied to a six-phase induction motor with third harmonic current injection.

Les pertes fer dans une machine électrique sont d'importance capitale, une estimation approximative de ces pertes peu mener à des solutions non viable sur le plan thermique, c'est dans ce contexte qu'il est indispensable d'avoir les caractéristiques les plus précises des matériaux magnétiques utilisés, de plus avec l'engouement récent pour les machines électriques haute vitesse (donc haute fréquence), il est important de caractériser les matériaux à haute fréquence. Dans les travaux de cette thèse, un système de mesure haute fréquence (1 T - 10 kHz) en champ unidirectionnel a été mis en place et des modèles de pertes magnétiques hautes fréquences ont été étudiés et discutés. Les champs magnétiques circulant dans une machine électrique sont de type alternatifs dans une direction donnée ou des champs elliptiques et tournants. C'est dans ce contexte qu'une caractérisation et un modèle en champ tournant ont été proposés. Enfin, dans le cas où le stator d'une machine électrique est découpé d'un seul tenant, la direction de découpe par rapport àla direction de laminage change d'un pas dentaire à un autre, pour cela une étude sur l'anisotropie des matériaux FeSi non orientés a été menée. / Iron losses in electrical machine applications are of paramount importance, an approximate estimation of these losses can easily lead to a thermally unsustainable solution, in this context, it is essential to get exactly the magnetic characteristics of the magnetic materials used, moreover, with the recent interest for high speed electrical machines (high frequency), It is important to characterize magnetic materials at high frequency. In this work, a high frequency characterizing system (1 T - 10 kHz) under unidirectional field has been proposed and magnetic losses models has been studied and discussed. Magnetic fields in electrical machines could be alternative in one direction, elliptical or circular. In this context, a characterization under rotating field and a magnetic loss model has been proposed. Finally, when stator steel sheets are cut all in one piece, the cutting direction with regard to the rolling direction will change from one tooth pitch to another, for that a study of the FeSi non oriented anisotropy has been performed.

Le travail présenté porte sur la définition et le développement d’un circuit magnétique pour moteurs à haut rendement de faible et moyenne puissances. Il est réalisé avec des tôles à Grains Orientés (GO) non-segmentées. Des expérimentations réalisées en champ unidirectionnel, destinées à comparer les caractéristiques globales de la structure GO à celles obtenues sur un assemblage classique composé de tôles à grains Non-Orientés (NO), permettent de conclure quant à l’efficacité de l’association proposée en termes de pertes fer. Des investigations au niveau local, accompagnées d’une modélisation numérique, conduisent à une analyse de la répartition interne du flux magnétique dans la structure, permettant de l’optimiser. Cette technique d’assemblage est ensuite testée en champ tournant sur des moteurs statiques. Les performances obtenues, sont de nouveau comparées à celles relevées sur une maquette NO. L’étape finale consiste à tester le principe développé sur des moteurs à induction réalisés avec la configuration GO. Diverses caractéristiques sont relevées ou estimées (norme CEI) et comparées à celles de la machine NO d’origine. L’efficacité de la structure GOse traduit par une réduction notable des pertes fer, notamment statiques, conduisant à accroître sensiblement le rendement global de la machine. / The work presented is focused on the design and development of a magnetic circuit for high efficiency motors of medium and small powers. It is built with non-segmented laminations of Grain Oriented (GO) steel. Experimentations on magnetic circuits excited under unidirectional magnetic field are performed. Such tests aim the comparison of the GO structure global characteristics with those of a classic one composed of Non-Oriented (NO) steel, allowing seeing the superiority of the GO structure in terms of iron losses. Local experimentations, followed by a numerical model, allow the analysis of the local distribution of the magnetic flux within the structure, leading to its optimisation. Such technique of assembly is then tested under rotational magnetic field. In that context, several experimentations are performed and its performance is compared with the one of a NO prototype. The final stage consists in testing the developed structure in induction motors built withthis GO assembly. Several characteristics are measured or estimated (IEC standard) and compared with those obtained on the initial NO motor. The GO structure efficiency leads to a remarkable reduction of the static losses, allowing the increase of the global efficiency of the motor.

Although the design principles of the Switched Reluctance Machines (SRMs) are available in different fragments in numerous bibliography positions, there no exists the complex design procedure of whole drive system taking into account the SR Machine, control system and supply device as well. The hybrid design method for SRM drives with application of new analytical calculation methods, finite element method and simulation models is proposed in this thesis. The calculation/design system is characterised by important effectivity and reliability. The new possibilities in analytical determination of saturation effects and core losses under various modes of control, including sensorless method, are also taken into account. The correctness of the proposed design algorithms are verified by laboratory tests made on three motor prototypes manufactured in industry for concrete application. This dissertation provides the elements indispensable for more accurate and complex analysis and design of drives with switch reluctance motors. The elements of electrical motor and control system design as well as the considerations on the choice of supply device and controller subsystems are jointed in the thesis for final receiving of the design tool for considered industrial drive system.

This master’s thesis studies additional losses generated in the induction motor powered from inverter. The first chapter was used for literature search and it mentions valuable publications. The second chapter discusses the different types of losses in the induction motor. The third chapter describes other negative effects on motor caused by inverter, the fourth one defines possible measuring methods, which would lead to the quantification of additional losses. The fifth chapter introduces the electromotor tested as well as the measuring instruments used. The last chapter presents pivotal results of the measurement in the testing room.

Although the design principles of the Switched Reluctance Machines (SRMs) are available in different fragments in numerous bibliography positions, there no exists the complex design procedure of whole drive system taking into account the SR Machine, control system and supply device as well. The hybrid design method for SRM drives with application of new analytical calculation methods, finite element method and simulation models is proposed in this thesis. The calculation/design system is characterised by important effectivity and reliability. The new possibilities in analytical determination of saturation effects and core losses under various modes of control, including sensorless method, are also taken into account. The correctness of the proposed design algorithms are verified by laboratory tests made on three motor prototypes manufactured in industry for concrete application. This dissertation provides the elements indispensable for more accurate and complex analysis and design of drives with switch reluctance motors. The elements of electrical motor and control system design as well as the considerations on the choice of supply device and controller subsystems are jointed in the thesis for final receiving of the design tool for considered industrial drive system.

In this fast pace world, climate change is one of the primary concerns worldwide. The world is racing towards reducing CO2 emissions by focusing on decreasing energy consumption. Electric motors capture about two-third of the industrial energy consumption, of which the most growing sector is electrical vehicles. The precise design of electric motors requires an optimal estimation of the machine’s performance characteristics. In this master thesis, the impact on core losses of an electric machine (e-machine) due to laser cutting is studied. The impact is derived in terms of a mathematical model which is introduced in a finite element model of an e-machine to attain optimal performance characteristics. A customized Single Sheet Tester (SST) based measuring apparatus is developed. The measuring apparatus is used to characterize the magnetic materials (electrical steel) used in the core of an e-machine. The studies already presented in the literature compromise on maintaining the same material mass while characterizing the magnetic material. Thus, a novel approach is attempted in this work to maintain approximately the same mass for all test samples used for characterization. The samples under test are laser cut possessing different sample widths leading to different distances from the cut edge. The characterized samples are compared for magnetic properties such as permeability and core losses to derive a mathematical model to estimate the impact of degradation in electrical steel. The derived models are implemented in a reference Permanent Magnet Synchronous Machine (PMSM) to analyze the degradation effect on the loss and performance characteristics. The influence of laser cutting impacts drastically the iron losses at an average which increases by about 35 % with a corresponding reduction of 21 % in material permeability. There is an average increase in machine torque by about 2 % and the increase in the total iron losses leads to an average 0.5 % decrease in the efficiency of the machine. The increase in iron losses at lower magnetic flux densities is more significant compared to the saturation region. The maximum degradation effect in the material is nearer to the cutting edge and reduces going away from the cut-edge. The permeability in the material decreases closer to the cut edge and thus the maximum amount of flux gets enforced towards the center because of degradation. / I denna snabba värld är klimatförändringarna en av de främsta problemen världen över. Världen tävlar mot att minska CO2 -utsläppen genom att fokusera på att minska energiförbrukningen. Elmotorer tar upp ungefär två tredjedelar av den industriella energiförbrukningen, varav den mest växande sektorn är elfordon. Den exakta designen av elmotorer kräver en optimal uppskattning av maskinens prestandaegenskaper. I denna masteruppsats studeras inverkan på kärnförluster hos en elektrisk maskin (e-maskin) på grund av laserskärning. Effekten härleds i termer av en matematisk modell som åberopas i en Finite Element Modelling (FEM) av en e-maskin för att uppnå optimala prestandaegenskaper. En skräddarsydd SST-baserad mätapparat utvecklas. Mätapparaten används för att karakterisera de magnetiska material (elektriskt stål) som används i kärnan i en e-maskin. De studier som redan presenterats i litteraturen kompromissar med att bibehålla samma materialmassa samtidigt som de karakteriserar det magnetiska materialet. Således har ett nytt tillvägagångssätt försökts i detta arbete för att bibehålla ungefär samma massa för alla testprover som används för karakterisering. Proverna som testas är laserskurna med olika provbredder vilket leder till olika avstånd från den skurna kanten. De karakteriserade proverna jämförs för magnetiska egenskaper såsom permeabilitet och kärnförluster för att härleda en matematisk modell för att uppskatta effekten av nedbrytning i elektriskt stål. De härledda modellerna implementeras i en referens PMSM för att analysera nedbrytningseffekten på förlust- och prestandaegenskaper. Inverkan av laserskärning påverkar drastiskt järnförlusterna med ett genomsnitt som ökar med cirka 35% med en motsvarande minskning av 21 % i material permeabilitet. Det finns en genomsnittlig ökning av maskinens vridmoment med cirka 2 % och ökningen av de totala järnförlusterna leder till en genomsnittlig minskning av maskinens effektivitet med 0,5 %. Ökningen av järnförluster vid lägre magnetiska flödestätheter är mer signifikant jämfört med mättnadsområdet. Den maximala nedbrytningseffekten i materialet är närmare skäreggen och minskar bortgången från skärkanten. Permeabiliteten i materialet minskar närmare den skurna kanten och sålunda tvingas den maximala mängden flöde in mot mitten på grund av nedbrytning.

Permanent magnet (PM) machines offer several advantages in traction applications such as high efficiencyand high torque per volume ratio. The iron losses in these machines are estimated mostly with empiricallaws taken from other types of machines or with finite element simulations (FEM). In the first part of thisthesis the objective is to define an accurate analytical model for the stator yoke, teeth and rotor of a PMmotor which should work well enough for all operating point (different loads and frequency).This analytical model is found using an iterative process. After building a loss matrix and flux matrix basedon FEM simulations, it is possible to curve fit each of the lines or the rows of the matrix in order to achievethe best fitting for every operating point. This is a very new approach; it was shown that it gives thepossibility, even with a very limited number of FEM simulations, to achieve an accurate estimation of thelosses.The second part of this report focuses on optimizing this analytical method, comparing it with otherpossibilities, analyzing limits and advantages. Special attention is also given to the effects of the losses onthe temperatures in different parts of the machine. In the last part of the thesis, the analytical model isused to test a new control strategy. Its goal is to reduce the total losses of the motor and optimize the ratiobetween torque and total losses for a given driving cycle.

Lors de la phase de dimensionnement d’un générateur électrique, des choix préliminaires imposent généralement la topologie. Cette thèse a pour objectif d’apporter une aide décisionnelle au choix des structures de générateurs de fortes puissances. L’intérêt des machines à haute efficacité énergétique est porté par des objectifs environnementaux forts. En conséquence, maîtriser et comprendre l’origine des pertes dans les machines de production d’électricité est un enjeu capital. Ainsi, une méthodologie de calculs de pertes fer est développée pour des générateurs de fortes puissances.Dans les secteurs de la production et conversion d’énergie, les Machines Synchrones à Double Excitation présentent un fort potentiel pour répondre aux défis de la transition énergétique. Dès lors, il est important de quantifier l’impact de ces nouvelles structures par rapport aux solutions existantes. Cette thèse propose une modélisation par méthodes analytiques et semi-analytiques dans l’objectif de concevoir un ensemble de structures de générateurs. La modélisation est également comparée à deux prototypes de fortes puissances, dont un pour une application éolienne à attaque directe.Ensuite, cette modélisation est employée dans un processus de conception par optimisation. Les structures Pareto optimales sont comparées suivant différents cahiers des charges. Ces optimisations permettent de mettre en avant des gains significatifs par rapport aux solutions existantes notamment sur des données statistiques de fonctionnement éolien. / During the design phase of an electrical generator, the topology is generally imposed by preliminary criteria. This thesis aims at providing a decision support for the choice of high power generator structures. The interest for high efficiency machines is driven by strong environmental objectives. Consequently, understanding the origin of losses in power generation machines is a major issue. Thus, a methodology for iron loss calculation is developed for high power generators.In the energy production and conversion sectors, Hybrid Excitation Synchronous Machines have a great potential to respond to the challenges of energy transition. It is important to quantify the impact of these new structures compared with existing solutions. This thesis proposes analytical and lumped models to design a set of generator structures. The modeling approach is also compared with two high power generators, including one for a direct drive wind turbine. Then, this modeling is used in an optimization design process. The optimal Pareto structures are compared according to different specifications. These optimized designs show significant gains compared to the existing solutions, especially on wind profile from a Weibull probability density function.

This thesis analyzes the power losses in induction machines and how the losses depend on the harmonic content of the applied voltages. Two cases are compared, one case where a machine is fed with a sinusoidial voltage and one case with a modular multilevel converter (M2C). The sine is representing an ideal grid while the M2C represents a case with harmonic content. The usage of converters for electrical drive systems is increasing due to advantages when the rotor speed could be variable by changing the frequency of the voltage. This is usually increasing the efficiency of the overall system, but is also adding harmonics fed to the machine and switching losses in the converter. Low switching losses in the inverter usually create higher harmonic content that instead increases the losses of the machine. The M2C is then proposed as a converter topology that can keep the harmonic content low while keeping the switching losses relatively low. This study focuses on the iron losses, the part of the total losses that is most hard to predict or measure. Today’s methods used to calculate the iron losses are often rough approximations that do not take the impact of the harmonic content of voltage into consideration, even though the iron losses are dependent on the harmonics. Experimental results in the study show that the losses of a M2C-fed case do not differ much from a sine-fed case. The difference could be explained by low increase of iron losses caused by the small harmonic content from the M2C. The increase of iron losses was linked to the harmonic content of the voltage. / Detta examensarbete analyserar effektförluster i induktionsmaskiner och hur förlusterna beror på övertonsinnehållet i den matande spänningen. Två fall kommer att jämföras, ett fall där en maskin är matad från en sinus spänning och ett fall med en modulär multinivå omvandlare (M2C). Sinusen representerar ett idealt nät medan M2C representerar ett fall med övertonsinnehåll. Användning av omvandlare för elekriska drivsystem ökar på grund av fördelarna när rotorhastighet kan varieras genom att ändra frekvensen från den matande växelriktaren. Detta ökar vanligtvis verkningsgraden på det sammanlagda systemet, men detta bidrar även med övertonsinnehåll matat till maskinen och switchförluster i omvandlaren. Låga switchförluster i omvandlaren medför oftast ett högt övertonsinnehåll som istället ökar förlusterna i maskinen. M2C är därför föreslaget som en teknik som håller övertonsinnehållet lågt medan switchförlusterna är relativt låga. Denna studie fokuserar på järnförluster, den del av de totala förlusterna som är som svårast att förutse eller mäta. De metoder som finns för att beräkna järnförlusterna är vanligtvis grova skattningar som inte tar hänsyn till inverkan från spänningens övertoninnehåll, även om järnförluster beror på övertonerna i stor utsträckning. Experimentella resultat i studien visar att förlusterna i ett M2C-matat fall inte avviker i stor utsträkning jämte ett sinusmatat fall. Skillnanen kan förklaras utifrån den lilla ökningen av järnförluster från det låga övertonsinnehållet från M2C:n. Järnförlusterna ses vara kopplade till övertonsinnehållet i spänningen.