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O trabalho apresenta o desenvolvimento de uma metodologia denominada modelo de núcleo reduzido, aplicada para avaliar o desempenho de máquinas elétricas no que tange a geometria e materiais empregados na fabricação do núcleo completo. Para fins de validação da metodologia utiliza-se um Atuador Planar de Indução Trifásico com dois graus de liberdade, comparando os resultados numéricos e experimentais. Através desta metodologia, pode-se realizar a análise dos fenômenos eletromagnéticos ocorridos no núcleo completo por meio da avaliação de seu modelo reduzido, composto neste caso por 33% do núcleo completo empregado no Atuador Planar de Indução Trifásico. A comprovação da metodologia do modelo de núcleo reduzido ocorreu através da fabricação de uma bancada de testes, composta por uma célula de carga para realizar aquisição da força de propulsão planar, interface de potência e os núcleos reduzidos com seguintes materiais ferromagnéticos: compósitos SMC 1P Somaloy 500®, Ferro resinado e Aço ABNT 1020. Com auxilio da estrutura de testes, validou-se o modelo numérico dos três núcleos reduzidos quanto a força de propulsão planar. Na análise dos dados experimentais e numéricos, o material Ferro resinado apresentou a diferença 14% referente a força de propulsão planar, sendo a maior diferença entre os materiais estudados. Com a convergência dos resultados experimental e numéricos, realiza-se a comparação numérica entre os núcleos reduzidos e completos utilizando-se os três materiais ferromagnéticos. A análise numérica do núcleo reduzido com o material SMC 1P Somaloy 500® apresentou o fator de relação médio da força de propulsão planar de 2,65 em relação ao núcleo completo. O núcleo completo com Aço ABNT 1020 resultou no consumo médio de 56,7Watts para gerar a força de propulsão planar de 1 Newton. Dessa forma, proporciona-se uma ferramenta de maior rapidez para fabricação e avaliação do desempenho de materiais ferromagnéticos utilizados no núcleo completo da máquina elétrica. / This paper presents the development of a methodology denominated low core model applied to evaluate the performance of electrical machines with respect to geometry and materials used in manufacturing of the complete core. For validation purposes of the methodology is used a Planar Three-phase Induction Actuator with two degrees of freedom, comparing the experimental and numerical results. Through this methodology, it is possible to perform the analysis of electromagnetic phenomena occurring in the complete core based evaluation of the reduced model, made in this case with 33% of the full core employed in the Planar Three-phase Induction Actuator. The verification of the reduced core model methodology occurred through the manufacture of a testing bench, which is composed of a load cell to realize the acquisition of the planar propulsion force, potency interface and reduced cores with the following ferromagnetic materials: SMC 1P Somaloy 500® composites, resinated Iron and Steel ABNT 1020. With the help of the test structure, it was validated the numerical model of the three reduced cores regarding to the planar propulsion force. In the analysis of experimental and numerical data, the resinated Iron material showed a 14% difference concerning the strength of the planar propulsion, which is the biggest difference between the materials studied. With the convergence of the experimental and numerical results, a numerical comparison is performed between the reduced and complete cores using the three ferromagnetic materials. The numerical analysis of the reduced core with the SMC 1P Somaloy 500® material showed the average ratio of the planar factor propulsive force of 2.65 when compared with the complete core. The complete core with ABNT 1020 Steel resulted in an average consumption of 56.7 Watts to generate a planar propulsive force of 1 Newton. Thus, it is provided a faster tool for manufacturing and evaluation of ferromagnetic materials performance used in the complete core of the electric machine.

A regular vehicle of today is equipped with an internal combustion engine that runs on either gasoline or diesel, which are fossil fuels from oil reserves that are millions of years old. In all types of combustion processes carbon dioxide and several other emissions are produced. There are none known technologies of today that can reduce the emissions of carbon dioxide from combustion, but the amount that is produced is mainly dependent on the fuel that is used. Combustion of fossil fuels increases the contamination of carbon dioxide in the atmosphere and diminishes the oil resources. The results are global warming and empty oil reserves within a few decades with the current production tempo, in addition to many other pollution effects that are harmful to the environment. A transition towards a society based on sustainable transportation is therefore urgent. The hydrogen fuel cell powered car with an electric propulsion system has the potential to be the car of the future that possesses the required characteristics of no harmful tailpipe emissions. There are some obstacles in the way for an early commercialisation, including the expensive catalysts used today and the lack of an infrastructure based on hydrogen, though. The hybrid electric vehicle, with both a conventional as well as an electric drivetrain, is a natural candidate for making the transition from the conventional car towards the car of the future. This thesis is focused on the design and analysis of permanent magnet machines for a novel hybrid electric vehicle drive system called the Four Quadrant Transducer. A number of electrical machine aspects are identified, including cores of soft magnetic composites, fractional pitch concentrated windings, core segmentation, novel machine topologies and cost effective production methods. The main objective is to analyse and judge the many unconventional machine aspects of which some may have the potential to improve the performance and reduce the cost of permanent magnet machines. Another objective is to study the effects of the use of fossil fuels and describe them with a new perspective and thereby make one small contribution to the debate about energy issues. Much focus has been spent on the theory of concentrated windings for permanent magnet machines. The potential parasitic effects and methods to improve the torque performance have been described. Other topics that have been given a high priority are material and power loss studies. An important contribution to the understanding of iron losses during field-weakening operation has been presented. A comprehensive use of finite element modeling has been done in the analysis combined with measurements on several laboratory prototypes. The Four Quadrant Transducer drivetrain and its two electrical machines intended for a midsized passenger car has been studied. The gearbox can be of a simple single stage type, which reduces the mechanical complexity and makes the traction performance of the vehicle smooth, without gear changes and drops in power. Simulations on a complete hybrid system show that fuel savings of more than 40% compared to a conventional vehicle can be achieved at citytraffic driving. The savings are modest at highway driving, since the engine is required to operate at high power during such conditions, and the support from the electrical system is negligible. The laboratory prototypes have shown that it is possible to manufacture high performance electrical machines with high material utilization and potential for automated production. The described concepts offer cost effective solutions for future drive systems in automotive and industrial applications. A number of weaknesses with the presented constructions have also been characterized, which should serve as guidelines for creating more optimized machines.

<p>A regular vehicle of today is equipped with an internal combustion engine that runs on either gasoline or diesel, which are fossil fuels from oil reserves that are millions of years old. In all types of combustion processes carbon dioxide and several other emissions are produced. There are none known technologies of today that can reduce the emissions of carbon dioxide from combustion, but the amount that is produced is mainly dependent on the fuel that is used. Combustion of fossil fuels increases the contamination of carbon dioxide in the atmosphere and diminishes the oil resources. The results are global warming and empty oil reserves within a few decades with the current production tempo, in addition to many other pollution effects that are harmful to the environment. A transition towards a society based on sustainable transportation is therefore urgent. The hydrogen fuel cell powered car with an electric propulsion system has the potential to be the car of the future that possesses the required characteristics of no harmful tailpipe emissions. There are some obstacles in the way for an early commercialisation, including the expensive catalysts used today and the lack of an infrastructure based on hydrogen, though. The hybrid electric vehicle, with both a conventional as well as an electric drivetrain, is a natural candidate for making the transition from the conventional car towards the car of the future. </p><p>This thesis is focused on the design and analysis of permanent magnet machines for a novel hybrid electric vehicle drive system called the Four Quadrant Transducer. A number of electrical machine aspects are identified, including cores of soft magnetic composites, fractional pitch concentrated windings, core segmentation, novel machine topologies and cost effective production methods. The main objective is to analyse and judge the many unconventional machine aspects of which some may have the potential to improve the performance and reduce the cost of permanent magnet machines. Another objective is to study the effects of the use of fossil fuels and describe them with a new perspective and thereby make one small contribution to the debate about energy issues. Much focus has been spent on the theory of concentrated windings for permanent magnet machines. The potential parasitic effects and methods to improve the torque performance have been described. Other topics that have been given a high priority are material and power loss studies. An important contribution to the understanding of iron losses during field-weakening operation has been presented. A comprehensive use of finite element modeling has been done in the analysis combined with measurements on several laboratory prototypes. </p><p>The Four Quadrant Transducer drivetrain and its two electrical machines intended for a midsized passenger car has been studied. The gearbox can be of a simple single stage type, which reduces the mechanical complexity and makes the traction performance of the vehicle smooth, without gear changes and drops in power. Simulations on a complete hybrid system show that fuel savings of more than 40% compared to a conventional vehicle can be achieved at citytraffic driving. The savings are modest at highway driving, since the engine is required to operate at high power during such conditions, and the support from the electrical system is negligible. The laboratory prototypes have shown that it is possible to manufacture high performance electrical machines with high material utilization and potential for automated production. The described concepts offer cost effective solutions for future drive systems in automotive and industrial applications. A number of weaknesses with the presented constructions have also been characterized, which should serve as guidelines for creating more optimized machines. </p>

O trabalho apresenta o desenvolvimento de uma metodologia denominada modelo de núcleo reduzido, aplicada para avaliar o desempenho de máquinas elétricas no que tange a geometria e materiais empregados na fabricação do núcleo completo. Para fins de validação da metodologia utiliza-se um Atuador Planar de Indução Trifásico com dois graus de liberdade, comparando os resultados numéricos e experimentais. Através desta metodologia, pode-se realizar a análise dos fenômenos eletromagnéticos ocorridos no núcleo completo por meio da avaliação de seu modelo reduzido, composto neste caso por 33% do núcleo completo empregado no Atuador Planar de Indução Trifásico. A comprovação da metodologia do modelo de núcleo reduzido ocorreu através da fabricação de uma bancada de testes, composta por uma célula de carga para realizar aquisição da força de propulsão planar, interface de potência e os núcleos reduzidos com seguintes materiais ferromagnéticos: compósitos SMC 1P Somaloy 500®, Ferro resinado e Aço ABNT 1020. Com auxilio da estrutura de testes, validou-se o modelo numérico dos três núcleos reduzidos quanto a força de propulsão planar. Na análise dos dados experimentais e numéricos, o material Ferro resinado apresentou a diferença 14% referente a força de propulsão planar, sendo a maior diferença entre os materiais estudados. Com a convergência dos resultados experimental e numéricos, realiza-se a comparação numérica entre os núcleos reduzidos e completos utilizando-se os três materiais ferromagnéticos. A análise numérica do núcleo reduzido com o material SMC 1P Somaloy 500® apresentou o fator de relação médio da força de propulsão planar de 2,65 em relação ao núcleo completo. O núcleo completo com Aço ABNT 1020 resultou no consumo médio de 56,7Watts para gerar a força de propulsão planar de 1 Newton. Dessa forma, proporciona-se uma ferramenta de maior rapidez para fabricação e avaliação do desempenho de materiais ferromagnéticos utilizados no núcleo completo da máquina elétrica. / This paper presents the development of a methodology denominated low core model applied to evaluate the performance of electrical machines with respect to geometry and materials used in manufacturing of the complete core. For validation purposes of the methodology is used a Planar Three-phase Induction Actuator with two degrees of freedom, comparing the experimental and numerical results. Through this methodology, it is possible to perform the analysis of electromagnetic phenomena occurring in the complete core based evaluation of the reduced model, made in this case with 33% of the full core employed in the Planar Three-phase Induction Actuator. The verification of the reduced core model methodology occurred through the manufacture of a testing bench, which is composed of a load cell to realize the acquisition of the planar propulsion force, potency interface and reduced cores with the following ferromagnetic materials: SMC 1P Somaloy 500® composites, resinated Iron and Steel ABNT 1020. With the help of the test structure, it was validated the numerical model of the three reduced cores regarding to the planar propulsion force. In the analysis of experimental and numerical data, the resinated Iron material showed a 14% difference concerning the strength of the planar propulsion, which is the biggest difference between the materials studied. With the convergence of the experimental and numerical results, a numerical comparison is performed between the reduced and complete cores using the three ferromagnetic materials. The numerical analysis of the reduced core with the SMC 1P Somaloy 500® material showed the average ratio of the planar factor propulsive force of 2.65 when compared with the complete core. The complete core with ABNT 1020 Steel resulted in an average consumption of 56.7 Watts to generate a planar propulsive force of 1 Newton. Thus, it is provided a faster tool for manufacturing and evaluation of ferromagnetic materials performance used in the complete core of the electric machine.

O trabalho apresenta o desenvolvimento de uma metodologia denominada modelo de núcleo reduzido, aplicada para avaliar o desempenho de máquinas elétricas no que tange a geometria e materiais empregados na fabricação do núcleo completo. Para fins de validação da metodologia utiliza-se um Atuador Planar de Indução Trifásico com dois graus de liberdade, comparando os resultados numéricos e experimentais. Através desta metodologia, pode-se realizar a análise dos fenômenos eletromagnéticos ocorridos no núcleo completo por meio da avaliação de seu modelo reduzido, composto neste caso por 33% do núcleo completo empregado no Atuador Planar de Indução Trifásico. A comprovação da metodologia do modelo de núcleo reduzido ocorreu através da fabricação de uma bancada de testes, composta por uma célula de carga para realizar aquisição da força de propulsão planar, interface de potência e os núcleos reduzidos com seguintes materiais ferromagnéticos: compósitos SMC 1P Somaloy 500®, Ferro resinado e Aço ABNT 1020. Com auxilio da estrutura de testes, validou-se o modelo numérico dos três núcleos reduzidos quanto a força de propulsão planar. Na análise dos dados experimentais e numéricos, o material Ferro resinado apresentou a diferença 14% referente a força de propulsão planar, sendo a maior diferença entre os materiais estudados. Com a convergência dos resultados experimental e numéricos, realiza-se a comparação numérica entre os núcleos reduzidos e completos utilizando-se os três materiais ferromagnéticos. A análise numérica do núcleo reduzido com o material SMC 1P Somaloy 500® apresentou o fator de relação médio da força de propulsão planar de 2,65 em relação ao núcleo completo. O núcleo completo com Aço ABNT 1020 resultou no consumo médio de 56,7Watts para gerar a força de propulsão planar de 1 Newton. Dessa forma, proporciona-se uma ferramenta de maior rapidez para fabricação e avaliação do desempenho de materiais ferromagnéticos utilizados no núcleo completo da máquina elétrica. / This paper presents the development of a methodology denominated low core model applied to evaluate the performance of electrical machines with respect to geometry and materials used in manufacturing of the complete core. For validation purposes of the methodology is used a Planar Three-phase Induction Actuator with two degrees of freedom, comparing the experimental and numerical results. Through this methodology, it is possible to perform the analysis of electromagnetic phenomena occurring in the complete core based evaluation of the reduced model, made in this case with 33% of the full core employed in the Planar Three-phase Induction Actuator. The verification of the reduced core model methodology occurred through the manufacture of a testing bench, which is composed of a load cell to realize the acquisition of the planar propulsion force, potency interface and reduced cores with the following ferromagnetic materials: SMC 1P Somaloy 500® composites, resinated Iron and Steel ABNT 1020. With the help of the test structure, it was validated the numerical model of the three reduced cores regarding to the planar propulsion force. In the analysis of experimental and numerical data, the resinated Iron material showed a 14% difference concerning the strength of the planar propulsion, which is the biggest difference between the materials studied. With the convergence of the experimental and numerical results, a numerical comparison is performed between the reduced and complete cores using the three ferromagnetic materials. The numerical analysis of the reduced core with the SMC 1P Somaloy 500® material showed the average ratio of the planar factor propulsive force of 2.65 when compared with the complete core. The complete core with ABNT 1020 Steel resulted in an average consumption of 56.7 Watts to generate a planar propulsive force of 1 Newton. Thus, it is provided a faster tool for manufacturing and evaluation of ferromagnetic materials performance used in the complete core of the electric machine.

Fe-based amorphous powders are fabricated through gas and water atomization using industrial grade raw materials. The atomic structure of the powder is examined by X-Ray Diffraction (XRD). Eight of totally thirteen different compositions are proved completely amorphous or amorphous with traces of crystalline phase in the desired powder particle size (d &gt; 75 μm) and five are crystalline. It reveals that the Glass Forming Ability (GFA) of atomized powders is well correlated to the GFA of as-casted rods or melt-span ribbons. In the present study at least 1.5-2 mm critical size of GFA for a target composition is necessary for the formation of amorphous powders in the desired particle size. The thermal stability of the amorphous powder is examined by Differential Scanning Calorimetry (DSC). Applying the conventional powder metallurgy process the amorphous powders are mixed with the crystalline Somaloy® 110i, a commercial Soft Magnetic Composite (SMC) material from Höganäs AB in Sweden, and made into toroid-shaped components. The components are annealed aiming for improved soft-magnetic properties. The magnetic measurements are taken on copper-wire double coiled toroids. As a result, the total magnetic flux (B), coercivity (HC) and permeability (μmax) is reduced due to the addition of amorphous powders to Somaloy® 110i powder but the core losses (P) is at the same level despite reduced density. An improved soft magnetic property and core loss is revealed by the comparison to recent literature reports on SMC mixing of crystalline and amorphous powders.

Corrosion protection is very significant for metals in modern society from the view of industrial development. This thesis work project involves a research study that is aimed to investigate the effect of corrosion on the mechanical strength and magnetic properties of four no treated or treated Somaloy® component samples (Somaloy®700 1P,  Somaloy®700 3P, Somaloy®700HR 5P and Somaloy®110i 5P) provided by Höganäs AB and laminated steel sheets by salt spray test. The coatings for protection are phosphoric acid coating, sodium silicate coating, DCA-Modified silicone conformal coating and water-borne single coat paint respectively. Then the protective properties are evaluated by Electrochemical Impedance Spectroscopy (EIS) in 0.1 mol/L NaCl solution after 7 days exposure.   From transverse rupture strength (TRS) and hysteresis loop measurements by salt spray test, although the bar samples are treated coating, the corrosion decreases the mechanical strength to a certain extent more or less over time. For the magnetic properties, the corrosive environments hardly influence the magnetic parameters of the no treated or four types of coatings treated Somaloy® components. But the all kinds of magnetic parameters for laminated ring samples have a great variation after salt spray test.   In the EIS measurements, for the no treated samples, the initial corrosion resistance is only several hundred ohms and decreases after 1 hour, 8 hours and 1day exposure, then increases to a certain extent with time due to the corrosion products formed on the surface. For the sodium silicate coating, the initial corrosion resistance is approximately several ten thousands ohms and decreases rapidly only after 1 day exposure to several hundred ohms due to the sodium silicate film dissolves in the electrolyte solution and has no effective protective property. Then the following corrosion process is almost same as the no treated samples. For the water-borne single coat paint, the initial corrosion resistance can reach to several Giga-ohms and decreases over time, but can still stay at  level, indicating that this coating has a very good and effective protective properties.   EIS experiments indicate that water-borne single coat paint has a more effective protection than sodium silicate coating and can apply a better corrosion protection for the Somaloy® components   Key words: corrosion protection, soft magnetic composites, phosphoric acid coating, sodium silicate coating, DCA-Modified silicone conformal coating , water-borne single coat paint, salt spray test, TRS, hysteresis loop, EIS

As the major electricity consumer, electrical machines play a key role for global energy savings. Machine manufacturers put considerable efforts into the development of more efficient electrical machines for loss reduction and higher power density achievements. A consolidated knowledge of the occurring losses in electrical machines is a basic requirement for efficiency improvements. This thesis deals with iron losses in electrical machines. The major focus is on the influences of the stator core magnetic material due to the machine manufacturing process, temperature influences, and the impact of inverter operation. The first part of the thesis gives an overview of typical losses in electrical machines, with focus put on iron losses. Typical models for predicting iron losses in magnetic materials are presented in a comprehensive literature study. A broad comparison of magnetic materials and the introduction of a new material selection tool conclude this part. Next to the typically used silicon-iron lamination alloys for electrical machines, this thesis investigates also cobalt-iron and nickel-iron lamination sheets. These materials have superior magnetic properties in terms of saturation magnetization and hysteresis losses compared to silicon-iron alloys. The second and major part of the thesis introduces the developed measurement system of this project and presents experimental iron loss investigations. Influences due to machine manufacturing changes are studied, including punching, stacking and welding effects. Furthermore, the effect of pulse-width modulation schemes on the iron losses and machine performance is examined experimentally and with finite-element method simulations. For nickel-iron lamination sheets, a special focus is put on the temperature dependency, since the magnetic characteristics and iron losses change considerably with increasing temperature. Furthermore, thermal stress-relief processes (annealing) are examined for cobalt-iron and nickel-iron alloys by magnetic measurements and microscopic analysis. A thermal method for local iron loss measurements is presented in the last part of the thesis, together with experimental validation on an outer-rotor permanent magnet synchronous machine. / <p>QC 20140516</p>