A major portion of this thesis is devoted to the Whisper 200 wind turbine model in Matlab-Simulink environment. The turbine is installed at the Department of Electrical Power Engineering, FEEC BUT. In the model, several types of simulations can be executed. On that basis, the power curve and mathematical relationships between wind speed and other physical quantities, such as RPM, electic current, and voltage, were obtained. Comparisons of the simulations' results with measurement data illustrate adequate agreement, but limitations of the model remain significant, as is exhaustively documented and commented upon in the thesis. As a partial advancement towards elimination of the model's deficiencies, conditions for substantial performance improvements of the dynamic simulation have been elaborately derived.

Tato dizertační práce se zabývá návrhem původního motor-generátoru s axiálním tokem a buzením permanetními magnety, zkonstruovaným specificky pro hybridní elektrický autobus. Návrhové zadání pro tento stroj přineslo požadavky, které vedly k této unikátní topologii tak, aby byl dosažen výkon, účinnost a rozměry stroje. Tato partikulární topologie motor-generátoru s axiálním tokem je výsledkem literární rešerše, kterou následoval výběr koncepce stroje s představeným návrhem jako výsledkem těchto procesů. Přístup k návrhu stroje s axiálním tokem sledoval „multi-fyzikální“ koncepci, která pracuje s návrhem elektromagnetickým, tepelným, mechanickým, včetně návrhu řízení, v jedné iteraci. Tím je v konečném návrhu zajištěna rovnováha mezi těmito inženýrskými disciplínami. Pro samotný návrh stroje byla vyvinuta sada výpočtových a analytických nástrojů, které byly podloženy metodou konečných prvků tak, aby samotný návrh stroje byl přesnější a spolehlivější. Modelování somtného elektrického stroje a celého pohonu poskytlo představu o výkonnosti a účinnosti celého subsytému v rozmanitých operačních podmínkách. Rovněž poukázal na optimizační potenciál pro návrh řízení subsystému ve smyslu maximalizace účinnosti celého pohonu. Bylo postaveno několik prototypů tohoto stroje, které prošly intensivním testováním jak na úrovni sybsytému, tak systému. Samotné výsledky testů jsou diskutovány a porovnány s analytickými výpočty parametrů stroje. Poznatky získané z prvního prototypu stroje pak sloužily k představení možností, jak zjednodušit výrobu a montáž stroje v příští generaci. Tato práce zaznamenává jednotlivé kroky během všech fází vývoje elektrického stroje s axiálním tokem, počínaje výběrem konceptu stroje, konče sumarizací zkušeností získaných z první generace prototypu tohoto stroje.

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

This master thesis investigates the possibilities for performance improvements of synchronous machines with unidirectional application.The literature review part presents theories and applications of asymmetrical machine. Four categories regarding asymmetrical machine, namely mixed pole, saturation mitigation, pole shifting and asymmetrical pole shaping, are summarized. It is shown that asymmetrical concept offers characteristic improvement in one or both rotational directions. A field winding synchronous model was used in FEM simulation (FLUX 2D). Armature reaction effecton this machine is investigated. It is found that armature reaction has different effects with varying current angle.Two ideas regarding asymmetrical pole shaping are investigated. First of all, pole shoe cutting idea is investigated. It leads to increased airgap length and less output torque. Secondly, progressive airgap idea shows reduced armature reaction effect and improved power factor, but higher torque ripple.Furthermore, an improved idea is suggested to reduce the torque ripple. Performance improvement by assisted permanent magnet is also studied. Four ideas of this field are investigated. It is found that permanent magnet can be used to reduce saturation, improve power factor and output torque. The reasons for limited improvements are analyzed.

In the last years electric vehicles gained importance as a more sustainable alternative to traditional vehicles. The introduction of an electric powertrain leads to lower air-pollution emissions but it also involves the introduction of new materials in the product life cycle, e. g., the rare earths and lithium contained in the motor and in the batteries. Those materials have an environmental impact and they need to be disposed properly. The aim of this thesis is to have a quantitative knowledge of the environmental balance linked to the use of a different powertrain. Furthermore, this study explores how this balance can be modified improving the recycling and the end of life management. Specifically in this thesis, an average electric scooter has been chosen as a case study. The electric scooter is used as object of comparison with a traditional internal-combustion-engine scooter. The choice of a two-wheeled mean of transport is linked to the low level of facilities involved. This report first includes a definition of the case of study; this section also presents a description of the technologies taken into exam. It is also presented the result of interviews with dismantlers to depict the current process of EoL management of a scooter. The central part of thesis deals with different recycling scenarios. With the help of the Material Hygiene mind-set, a qualitative analysis and different recycling scenarios are proposed. The recycling scenarios involve the component of the electric powertrain that are peculiar of the electric vehicle. They mainly are the electric motor and the lithium battery pack. The last part of the analysis encompasses a Life Cycle Assessment of an average electric scooter to give a quantitative meaning to the life cycle comparison and to assess the environmental benefits of the proposed recycling scenarios. To perform the Life Cycle Assessment a software, SimaPro 7.3, is used. This software lets the user insert the bill of materials of the product and it associates to each material its environmental loads according to the database EcoInvent v.2.2. Keywords: electric scooter, lithium battery, permanent magnet, neodymium, Material Hygiene, Design for Disassembly, Life Cycle Assessment, LCA / Negli ultimi anni i veicoli elettrici sono emersi come un ’alternativa sostenibile ai veicoli tradizionali. L’introduzione di un gruppo propulsore elettrico permette emissioni inquinanti più basse ma comporta anche l’introduzione di nuovi materiali nel ciclo di vita del prodotto, e.g., le terre rare e il litio contenuti rispettivamente nel motore e nelle batterie. Questi materiali hanno un impatto ambientale e hanno bisogno di essere trattati correttamente. Lo scopo di questa tesi è di avere una comprensione quantitativa del bilancio dal punto di vista ambientale legato al l’adozione di sistema di propulsione elettrico. Inoltre, è indagato come questo bilanco possa essere influenzato migliorando il ricic laggio e la gestione dell’ultima fase di vita del prodotto. Nello specifico, in questa tesi, uno scooter elettrico è stato scelto come caso di studio. Lo scopo è di comparare questo scooter con uno tradizionale considerando il ciclo di vita del prodotto. Il mezzo di trasporto a due ruote è stato scelto perché considerato più semplice da modellare in quanto privo di componenti non inerenti al trasporto (es. aria condizionata, hi-fi, etc.). Questo report anzitutto include una definizione del caso di studio, questa sezione presenta anche una descrizione delle principali tecnologie coinvolte nel prodotto studiato. In questa parte del lavoro è anche riportato il risultato di interviste a rottamatori di scooter per illustrare l’attuale iter di rottamazione di uno scooter. La parte centrale della tesi tratta i differenti scenari di riciclaggio. Sfruttando la mentalità Material Hygiene vengono proposte un’analisi qualitativa e differenti scenari di rici claggio. Gli scenari di riciclaggio coinvologono il progettista a livelli differenti. Questi scenari riguardano i componenti del sistema di propulsione elettrico. Essi sono principalmente il motore elettrico e le batterie al litio. L’ultima parte dell’analisi riguarda il Life Cycle Assessment di uno scooter elettrico al fine di dare un significato quantitativo al confronto tra i cicli di vita delle due alternative. Inoltre, il life cycle assessment ha lo scopo di verificare e quantificare i benefici di impatto ambientale collegati all’adozione degli scenari di riciclaggio proposti. Per svolgere il Life Cycle Assessment è stato usato un sofware, SimaPro 7.3. Questo software permette all’utente di inserire l’elenco dei materiali di un prodotto e di associare a ciascun materiale il proprio impatto ambientale. Il software ha a disposizione per la modellazione i database di impatto ambientale EcoInvent 2.2. Parole chiave: scooter elettrico, batteria al litio, magnete permanente, neodimio, Material Hygiene, Design for Disassembly, Life Cycle Assessment, LCA

In this paper, electrification of hydraulic systems is proposed using high-efficiency permanent magnet (PM) motors and wide bandgap power electronic drives. Direct driven hydraulics (DDH) is selected because of its higher efficiency compared to other conventional technologies such as valve-controlled systems. The DDH is directly driven by a servomotor. The ratings and design guidelines for a servomotor used in DDH applications are provided in this paper. Specifically, a surface permanent magnet synchronous machine (SPMSM) is designed. Finally, a state-of-the-art inverter using silicon carbide wide bandgap devices are designed for high performance operation.

In the aviation industry, safety and robustness are the number one priorities, which is why they use well-tested systems such as hydraulic actuators. However, drawbacks such as high weight and maintenance have pushed the industry toward newer, electrical, actuators that are more efficient and lighter. Electrical actuators, on the other hand, have some reliability issues. In particular, short circuits in the stator windings of Permanent-Magnet SynchronousMotors (PMSMs), referred to as Inter-Turn Short Faults (ITSFs), are the dominating faults, and is the focus of this thesis. ITSFs are usually challenging to detect and often do not become noticeable until the fault has propagated, and the motor is on the verge of being destroyed. This thesis investigates the possibility of detecting ITSFs in a PMSM, at an early stage when only one turn is shorted. The method is limited to finding the faults using ML algorithms. Both an experiential PMSM and a simulated model of the experimental PMSM, with the ability to induce an ITSF, were used to collect the data. Several Machine Learning (ML) models were developed, and then trained and tested with the collected data. The results show that four of the tested ML models, being: Random Forest, Gaussian SVM, KNN, and the CNN, all achieve an accuracy exceeding 95%, and that the fault can be found at an early stage in a PMSM with three coils connected in parallel in each phase. The results also show that the ML models are able to identify the ITSF when the simulated data is downsampled to the same frequency as the experimental data. We conclude that the ML models, provided in this study, can be used to detect an ITSF in a simulated PMSM, at an early stage when only one turn is shorted, and that there is great potential for them to detect ITSFs in a physical motor as well.

Im binären Mn-Ga-System wurde für Legierungen mit 55 at.% bis 65 at.% Mangan die Phasenbildung der L10-Phase mit Röntgenbeugung und Differenzialkalorimetrie untersucht. Nach der Herstellung der L10-Phase in allen Legierungen erfolgte eine Untersuchung der intrinsischen magnetischen Eigenschaften. Die Mn55Ga45-Legierung zeigte dabei die höchste Sättigungsmagnetisierung mit µ0Ms = 0,81 T. Für diese Legierung erfolgten deshalb Versuche zur Verbesserung der extrinsischen Eigenschaften. Dazu wurden Pulver gemahlen und die Möglichkeit der Ausrichtung im Magnetfeld untersucht. Dabei konnte ein Texturgrad von 0,45 für Pulver mit einer Partikelgröße kleiner 10 µm erreicht und die Koerzitivfeldstärke um das 7-fache gegenüber der Volumenprobe erhöht werden. Weiterhin konnten die Pulverproben durch Heißkompaktieren bei 400 °C erneut zu einer Volumenprobe gepresst werden. Die dabei erhaltene Probe besitzt eine Koerzitivfeldstärke von 0,16 T und eine leicht reduzierte Sättigungsmagnetisierung auf Grund einer Packungsdichte von 83 %. Im ternären Mn-Al-Ga-System wurden Proben der Sollzusammensetzung Mn55Al45-xGax mit 5,625 < x < 22,5 hergestellt. Für Legierungen mit x >= 11,86 erwies sich eine Wärmebehandlung bei 600°C für 24 Stunden als ausreichend die reine L10-Phase zu erzeugen. Bei den Legierungen mit einem geringeren Ga-Anteil war eine zweistufige Wärmebehandlung notwendig, um ausschließlich L10 zu erhalten. Nach der ersten Wärmebehandlung bei 1100 °C entstand ein Phasengemisch aus gamma2 und L10(epsilon). Letzteres wurde aus der epsilon-Hochtemperaturphase gebildet. Durch die anschließende Wärmebehandlung bei 500 °C für 24 Stunden konnte die verbleibende gamma2-Phase in L10(gamma2) umgewandelt werden. Untersuchungen der lokalen Legierungszusammensetzung ergaben einen geringeren Mn-Anteil der L10(gamma2)-Phase im Vergleich zu L10(epsilon). Die Unterschiede in den zwei L10-Phasen konnten weiterhin durch eine Reflexaufspaltung in den Röntgenbeugungsaufnahmen sowie der Existenz zweier Curie-Temperaturen bestätigt werden. Die gemessenen Sättigungsmagnetisierungen ergaben eine Superposition beider Phasen und einen maximalen Wert von µ0Ms = 0,85 T. Untersuchungen der thermischen Stabilität der L10-Phasen bei 700 °C zeigten, dass die L10(gamma2)-Phase thermisch stabil ist und sich die L10(epsilon)-Phase langsam in beta-Mn und gamma2 zersetzt. Bei der Zersetzung war im Vergleich zum binären Mn-Al-System eine starke Steigerung der thermischen Stabilität durch die Substitution geringer Mengen Galliums zu erkennen. Über die zersetzungsbedingte Reduktion der Magnetisierung konnten Abschätzungen der Zersetzungskinetik getroffen werden.

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

Permanent magnet synchronous machines have various advantages and have showed the most superiorperformance for Electric Vehicles. However, modeling them is difficult because of their nonlinearity. In orderto deal with the complexity, the artificial neural network and machine learning models including k-nearest neighbors, decision tree, random forest, and multiple linear regression with a quadratic model are developed to predict electrical parameters and losses as new prediction approaches for the performance of Volvo Cars’ electric vehicles and evaluate their performance. The test operation data of the Volvo Cars Corporation was used to extract and calculate the input and output data for each prediction model. In order to smooth the effects of each input variable, the input data was normalized. In addition, correlation matrices of normalized inputs were produced, which showed a high correlation between rotor temperature and winding resistance in the electrical parameter prediction dataset. They also demonstrated a strong correlation between the winding temperature and the rotor temperature in the loss prediction dataset.Grid search with 5-fold cross validation was implemented to optimize hyperparameters of artificial neuralnetwork and machine learning models. The artificial neural network models performed the best in MSE and R-squared scores for all the electrical parameters and loss prediction. The results indicate that artificial neural networks are more successful at handling complicated nonlinear relationships like those seen in electrical systems compared with other machine learning algorithms. Compared to other machine learning algorithms like decision trees, k-nearest neighbors, and multiple linear regression with a quadratic model, random forest produced superior results. With the exception of q-axis voltage, the decision tree model outperformed the knearestneighbors model in terms of parameter prediction, as measured by MSE and R-squared score. Multiple linear regression with a quadratic model produced the worst results for the electric parameters prediction because the relationship between the input and output was too complex for a multiple quadratic equation to deal with. Random forest models performed better than decision tree models because random forest ensemblehundreds of subset of decision trees and averaging the results. The k-nearest neighbors performed worse for almost all electrical parameters anticipation than the decision tree because it simply chooses the closest points and uses the average as the projected outputs so it was challenging to forecast complex nonlinear relationships. However, it is helpful for handling simple relationships and for understanding relationships in data. In terms of loss prediction, the k-nearest neighbors and decision tree produced similar results in MSE and R-squared score for the electric machine loss and the inverter loss. Their prediction results were worse than the multiple linear regression with a quadratic model, but they performed better than the multiple linear regression with a quadratic model, for forecasting the power difference between electromagnetic power and mechanical power.