Elektrische Maschinen werden heutzutage auf mannigfaltigen Gebieten eingesetzt. Sie verrichten ihre Aufgaben in leistungsstarken Industrieantrieben für Erzmühlen oder Stahlwalzen, als Synchrongeneratoren zur Elektroenergieerzeugung, in Fertigungsanlagen wie Backstraßen oder Fließbänder oder auch im Verkehr, in Zügen oder verstärkt nun auch in Automobilen. Sie erleichtern uns aber auch den Alltag an Stellen, wo sie oft gar nicht wahrgenommen werden. Sie ermöglichen nützliche Helferlein im Auto mithilfe von Servomotoren – Scheibenwischer, Fensterheber oder Seitenspiegelverstellung sind nur ausgewählte Beispiele. Aber auch Fensterrollläden, Klimaanlagen oder Fahrstühle benötigen elektrische Antriebe. Darüber hinaus verstecken sich sie sich als Klein- und Kleinstmaschinen in medizinischen Geräten wie dem Zahnarztbohrer oder in Pflegeprodukten des täglichen Bedarfs von der Haarschneidemaschine, über den Nasenhaartrimmer und Föhn bis hin zur elektrischen Zahnbürste. Da Elektromotoren also in immer mehr Geräten stecken, müssen auch immer größere Stückzahlen gefertigt werden, die am besten nichts kosten. Es besteht somit die große Herausforderung all die Bedürfnisse ressourcenschonend und kostengünstig zu bedienen. Aus diesem Gedanken heraus entstand am Lehrstuhl die Idee, Wicklungen elektrischer Kleinmaschinen zu drucken. Dies geschieht mithilfe der Siebdrucktechnik, wie es schon heute bei RFID-Chips die Regel ist. Es handelt sich also um ein erprobtes Verfahren, das eine günstige Fertigung großer Stückzahlen erlaubt. Erste Erfahrungen wurden bereits gesammelt, hier sei auf [10], [11] und [12] verwiesen. Im Rahmen dieser Diplomarbeit sollen diese Grundlagen nun ausgebaut, gefestigt, sowie erweitert werden. Um einen Eindruck und Überblick zu gewinnen, wird im Folgenden eine Reihe elektrischer Kleinmaschinen entworfen. Hierbei sollen Probleme ausfindig gemacht, Lösungen eruiert und Abweichungen zum konventionellen Entwurf aufgezeigt werden. Im Rahmen dessen werden Berechnungsvorschriften für siebgedruckte Wicklungen abgeleitet und diese schließlich zur Berechnung einer Maschinenreihe mit verschiedenen Außendurchmessern und Längen genutzt. Am Ende der Arbeit sollen ausgewählte Motoren aus der berechneten Reihe stehen, an denen Messungen stattfinden um die verwendeten Algorithmen zu verifizieren.

This thesis proposes innovative methods to extract information embedded in the frequency and time domain response of the transformer winding, and utilizes them to suggest solutions to a few tasks that have until now been thought difficult, if not impossible, to resolve. Pursuing this philosophy originated from the basic under- standing that the response of any physical system (behaving largely as a linear time invariant system) has embedded information that characterizes it completely. So, the prerequisite is to evolve ways to extract this information from measured responses. Once that is done, a variety of interesting applications can be envisaged. The two applications considered in this thesis are- •Investigate indirect measurement of the series capacitance of a transformer winding using the measured frequency or time domain response •Explore the possibility of increasing the physical resolution of the ladder network used to model a fully interleaved-disk winding In the former application, since direct measurement of series capacitance is impossible, alternatives based on indirect measurement were also not attempted. Similarly, in the latter application, the upper limit is known to be fixed by the number of distinctly observable peaks in the magnitude frequency response, so the question of increasing this limit was also never explored. Solutions to these tasks are proposed after a systematic analysis of frequency/time domain responses of a winding, initially modeled as a lumped parameter ladder network, to extract correlations that exist between them and winding parameters, and finally examine how these relations can be exploited together with the measured responses. Each of the five chapters is dedicated to describe the solution to one task. In each chapter, analytical formulation is presented first, followed by experimental results. Good agreement with the predicted results demonstrates its practicability. In final summary, indirect measurement of the series capacitance of a winding and en- hancing physical resolution of a ladder network model to represent a fully interleaved- disk winding was successfully demonstrated and they are the main contributions of this thesis.

Electrical machines in electrified heavy-duty vehicles are subjected to dynamic temperature loadings during normal operation due to the different driving conditions. The Electrical Insulation System (EIS) in a stator winding is aged as an effect of these dynamic thermal loads. The thermal loads are usually high constant temperatures and thermal cycling. The high average constant thermal load is well-known in the electrical machine industry but little is known about the effect of temperature cycling. In this project, the ageing of the EIS in stator windings due to temperature cycling is examined. In this project, computational simulations of different simplified models that represent the electrical insulation system are made to analyse the thermo-mechanical stresses that is induced due to thermal cycling. Furthermore, a test object was designed and simulated to replicate the stress levels obtained from the simulations. The test object is to ease the physical testing of electrical insulation system. Testing a complete stator takes time and has the disadvantage of having a high mass, therefore a test object is designed and a test method is provided. The results from the finite element analysis indicate that the mechanical stresses induced will affect the lifetime of the electrical insulation system. A sensitivity study of several thermal cycling parameters was performed, the stator core length, the cycle rate and the temperature cycle amplitude. The results obtained indicate that the stator core length is too short to have a significant effect on the thermo-mechanical stresses induced. The results of the sensitivity study of the temperature cycle rate and the temperature cycle amplitude showed that these parameters increase the thermo-mechanical stresses induced. The results from the simulations of the test object is similar to the results from the simulations of the stator windings, which means that the tests object is valid for testing. The test method that is most appropriate is the power cycling test method, because it replicates the actual application of stator windings. The thermally induced stresses exposing the slot insulation exceeds the yield strength of the material, therefore plastic deformation may occur only after one thermal cycle. The other components in the stator are exposed to stresses below the yield strength. The thermally induced stresses exposing the slot insulation are high enough to low cycle fatigue the electrical insulation system, thus thermo-mechanical fatigue is an ageing factor of the electrical insulation system.

This assignment is based on the tolerance problems that occur with the radial dimensions or RR-dimensions for the windings. The purpose is to identify the various parameters that affect said RR-dimensions and where these parameters originate from to be able to assure quality of the winding process. The RR-dimension has a tolerance of + 2,2 and - 1,1 mm, but it is only the positive tolerance that cause problems. The case study is based on a mixture of quantitative and qualitative methods. Quantitative data collections of dimensions for leaders and how the RR-measurement are affected by them, analysis of tolerances and how well they are adapted for their purpose. Qualitative observations, experiments and semi-structured interviews have also been conducted to gain a deeper understanding of the problem. The results show that tolerance problems originate from several different factors. The first factor is the debatable tolerance setting on some conductors, mainly the thin CTC conductors that do not have a high radial dimension. These conductors have tolerances that do not fill a purpose because it does not ensure the quality for the winding. The conductors need a tighter tolerance spectrum for the positive direction to be fully functional. The air gap that can occur between the conductors is also a cause of error. This stems from the fact that it is not possible to achieve a sufficiently high force when tensioning the disc. This can also occur from the uneven surface of the CTC-conductor that can create gaps. Another cause of error that affects the dimension is the number of turns for a disc. When a disc is wound with a high number of turns it will lead tothat the influencing factors have a higher amount of turns to effect on. This means that a small increase of the conductor's nominal dimension or small air gaps has a large impact on the overall RR-dimension. / För att kvalitetssäkra transformator- och reaktorlindningarna hos företaget Hitachi ABB skade utsatta toleranserna för varje lindning uppfyllas för att kunna fortsätta vidare i produktionslinan. Arbetet är grundat utifrån de förekommande variationerna hos lindningarnas mått i radiell riktning (RR-mått. Arbetets syfte är att undersöka Hitachi ABB:s lindningsproduktion för att finna de faktorer som ger upphov till måttvariationer hos RRmåttet. De identifierade faktorerna ska användas för att kvalitetssäkra företagets lindningsprocess. Färdigställt arbete ska användas som grund för företagets fortsatta arbetekring kvalitetssäkring. RR-måttet har en tolerans på + 2,2 och – 1,1 mm, däremot är detendast de variationer i positivt led där problem uppstår. Vid ett för högt mått genomförs enutredning för att se över om lindningen kan brukas ändå eller utifall de för höga måttet i radiell riktning påverkar prestandan samt montering. Arbetet är en fallstudie utfört med en blandning av kvantitativa och kvalitativa metoder. Denkvantitativa datainsamlingens syfte är att undersöka ledares mått i lindningar för att se hur RR-måttet påverkas måttsättning och varvantal. Den kvantitativa datainsamlingen genomför också analyser av toleranser och hur väl anpassade de är för sitt syfte. Kvalitativa observationer, experiment och halvstrukturerade interjuver har genomförts för att skapa en djupare förståelse kring problemet.Resultatet visar att de variationer som uppstår hos RR-måttet påverkas av flera olika faktorer.Variationer hos RR-måttet uppstår främst för lindningar där en CTC-ledare används. En påverkande faktor är toleransvidden för ledarna, främst för de tunna CTC-ledarna. Ledarna lindas runt varandra där ledarens mått staplas på varandra för att bilda ett RR-mått. För de tunna CTC-ledarna bör en mindre toleransvidd användas, mer specifikt en lägre positiv tolerans likt de platta ledarna för att kunna kvalitetssäkra lindningen. En annan påverkandefaktor är de luftspalter som uppstår mellan ledarna. Luftspalter härstammar ifrån att det integår att uppnå tillräckligt hög kraft vid spänning av en skiva alternativt från CTC-ledarens knöliga yta. Utöver dessa två faktorer har antalet lindade varv för en skiva en påverkan förtoleransstapling. Fler varv resulterar i att små måttavvikelser för ledare påverkar det totala måttet, vilket innebär att de luftspalter som kan uppstå blir fler när antalet varv ökar.

Hydropower is the most important power balancing resource in the Swedish electrical power system, regulating the power supply to match the load. Consequently, several hydropower plants have periods of stand-by operation where the power production is absent but where several devices within a plant are still active. Such a device is the step-up power transformer, which during stand-by operation still generates no-load energy losses. These losses can accumulate to a considerable amount of energy and costs during the long technical lifetime of the apparatus. One option to minimize these no-load energy losses is by turning the transformer off when its generating unit is in stand-by operation. However, when this transformer operational change has been explained to experts in the field, the most common response has been that a more frequent reenergizing of a transformer leads to higher risks for errors or transformer breakdowns. This study aimed to analytically investigate three effects from this operational change. First, the potential of fatigue failure for the windings due to the increased sequences of inrush current. Secondly, the thermal cycling as a consequence of change in present losses. Lastly, the energy and economic saving potentials for hydropower plants where this operational adjustment is applied. The study used both established as well as analytical tools explicitly created for this study. These were then applied on currently active transformers in different plant categories in Fortum’s hydropower fleet.  The study primarily showed three things. Firstly, risk of fatigue failure due to the increased presence of inrush currents did not affect the transformer’s technical lifetime. Secondly, the thermal cycling changes were slightly larger with absent no-load losses during stand-by operation. The average temperature for the transformer decreased, which in general is seen as a positive indicator for a longer insulation lifetime and thus the transformer’s technical lifetime. Finally, the created frameworks showed the potential of saving energy and money for all plant categories, where the potential grew with the installed production capacity and the stand-by operation timeshare. Despite the simplifications made to describe the complex reality of a transformer operating in a hydropower plant, this thesis contributes to lay a foundation for future investigation of an easy adjustment to avoid unnecessary energy losses and costs for transformers in hydropower plants.

Syfte – Syftet för denna studie var att utveckla en sensorlös modell som beräknar en estimeradtemperatur i en BLDC-motors statorlindningar, detta för att undersöka hur väl det går attskydda handhållna produkter mot oaktsam användning och för att kunna motverka körningunder höga temperaturer, vilket skulle kunna förlänga livslängden för handhållna produkter. Metod – Denna studie har använt forskningsmetoden Design Science Research för att utvecklaen artefakt som sensorlöst estimerar temperatur i en BLDC-motors statorlindningar.Artefaktens prestanda för den estimerade temperaturen var noggrannhet, precision ochkonvergeringstid, vilket utvärderats genom analys av kvantitativa data som samlats in underolika experiment. Resultat – Den utvecklade artefakten i studien baserades på en kombination av CurrentInjection och Lumped Parameter Thermal Network samt ett Kalman Filter, artefaktensprestanda uppfyllde inte Husqvarna AB:s krav. Artefaktens precision och noggrannhet för att estimera temperatur i en BLDCmotorsstatorlindningar blev 7,2 °C ± 23,8 °C och dess konvergeringstid blev 7,3 sför dess medelvärde och 18,4 s för dess precision. Implikationer – Denna studie och dess resultat kan användas som en hänvisning på hur välen kombination av Current Injection, Lumped Parameter Thermal Network och Kalman Filterkan estimera temperaturen i statorlindningar för BLDC-motorer med en resistans på 20 mΩ,induktans på 10 uH, nominell hastighet på ~20 000 RPM med terminering av typen Delta ochsom är icke salient. Begränsningar – Studiens begränsningar listas nedan. Utvecklingstiden för artefakten utfördes under begränsad tid. Vilket bidragit till mindre optimering av artefakterna. Vilket bidragit till färre iterationer av artefakter. Artefakten utvärderas endast på VESC hårdvara och dess mjukvara som grund.Artefaktens prestanda påverkas av noggrannheten samt precisionen vidmätning av ström och spänning. Experimenten som utfördes var begränsade. Hade intervallen som experimenten utfördes gällande temperatur, hastighetoch dynamisk last varit större skulle artefaktens prestanda kunna bli undersökti mer verkliga förhållanden. En bättre bromsbänk och en klimatkammareskulle använts. Endast en BLDC motor utvärderades. Utvärdering av fler motorer skulle kunna visa på skillnader i prestanda förartefakten mellan olika mindre motorer, det vill säga visa på dess generellatillämpbarhet. Analys av artefaktens prestanda vid enbart konvergerande tillstånd utfördes inte. Vilket skulle kunna visa på om artefaktens prestanda vid enbart konvergeradetillstånd hade uppfyllt Husqvarna AB:s krav. Nyckelord – Estimera Temperatur, BLDC-motor, Statorlindningar, Current Injection,Lumped Parameter Thermal Network, Kalman Filter, VESC / Purpose – The purpose of this study was to develop a sensorless model that calculates anestimated temperature in a stator winding of a BLDC motor, to investigate how well it is possibleto protect handheld products from inadvertent use and to be able to counteract operation underhigh temperatures, which could prolong service life of the handheld products. Method – This study has used the research method Design Science Research to develop anartifact that sensorlessly estimates temperature in a BLDC motor's stator windings. Theperformance of the artifact for the estimated temperature is accuracy, precision, andconvergence time, which was evaluated by analysing quantitative data collected during differentexperiments. Findings – The artifact developed in the study is based on a combination of Current Injectionand Lumped Parameter Thermal Network and a Kalman Filter, the performance of the artifactdid not meet Husqvarna AB's requirements. The precision and accuracy of the artifact for estimating temperature in a statorwinding of a BLDC motor was 7,2 °C ± 23,8 °C and its convergence time was 7,3 sfor its mean and 18,4 s for its precision. Implications – This study and its results can be used as a reference regarding how well acombination of Current Injection, Lumped Parameter Thermal Network and Kalman Filter canestimate the temperature in stator windings for non-salient BLDC motors with a resistance of20 mΩ, inductance of 10 uH, nominal speed of ~20 000 RPM with termination of the Deltatype. Limitations – The limitations of the study are listed below. The development time for the artifact was performed for a limited time. Which has contributed to less optimization of the artifacts. Which has contributed to fewer iterations of artifacts. The artifact is evaluated only on VESC hardware and its software as a basis.The performance of the artifact is affected by the accuracy and precision inmeasuring current and voltage. The experiments performed were limited. Had the intervals at which the experiments were performed regardingtemperature, speed and dynamic load been greater, the performance of theartifact could have been examined in more real conditions. A better brakebench and a climate chamber would be used. Only one BLDC motor was evaluated. Evaluation of more motors could show differences in the performance of theartifact between different smaller motors, that is, show its general applicability. Analysis of the performance of the artifact in convergent states alone was notperformed. Which could show if the performance of the artifact could fulfill HusqvarnaAB's requirements if the analysis were only performed in convergingconditions. Keywords – Estimate Temperature, BLDC Motor, Stator Windings, Current Injection,Lumped Parameter Thermal Network, Kalman Filter, VESC

The aim of this master thesis is to design and analyse a FSCW PMaSynRM (Permanent Magnet assisted Synchronous Reluctance Motor) for industrial applications. The design process includes analytical calculations (initial design and PM amount minimization) and nite element method (FEM) based design optimization. An overcompensated design is proved to be advantageous for a 10-pole reluctance motor. A comparative analysis with other rotor topologies was made, where motor performance, temperature e ects and production costs are taken into account. Detailed curves which describe eciency, power factor and current with respect to ambient temperature are studied for the proposed motor designs at di erent working points. The demagnetization risk is also taken into account and the safe working temperature ranges have been dened for all the considered motors. The results show that the initial motor design with 10 poles/12 slots PMaSynRM with NdFeB magnets has poor performance in terms of eciency and power factor, with huge amount of PM inserted. This is mainly due to the lack of reluctance torque for this relatively higher number of poles solution. Moreover, it has been found in literature and conrmed in this investigation that this negative e ect for the 10-pole motor is amplied due to the presence of the concentrated winding. Indeed, it is shown by simulations that the motor performance is improved by employing 8 poles/12 slots PMaSynRM conguration with a relatively lower NdFeB magnet amount, thanks to the improved rotor anisotropy. The 10 poles/12 slots interior permanent magnet (IPM) and surface mounted permanent magnet (SMPM) topologies present higher performance due to the e ective utilization of PM, mainly or completely producing the torque. Hence, IPM and SMPM do not su er the lack of anisotropy. / Syftet med detta examensarbete ar att utforma och analysera en FSCW PMaSynRM (Permanent Magnet assisted Synchronous Reluctance Motor) for industriella applikationer. Designprocessen omfattar analytiska berakningar (ursprungliga konstruktion och PM belopp minimering) och nita elementmetoden (FEM) baserad design optimering. En overkompenserad design visat sig vara fordelaktigt for en 10-polig reluktansmotor. En jamforande analys med andra rotor topologier gjordes, dar motor prestanda, temperature ekter och produktionskostnader beaktas. Detaljerade kurvor som beskriver e ektivitet, e ektfaktor och strom med avseende pa omgivningstemperatur studeras for de foreslagna motorn for vid olika arbetspunkter. Den avmagnetisering risken ocksa beaktas och sakerhetstemperaturomraden har denierats for alla ansag motorerna. Resultaten visar att den initiala motordesign med 10-polig/12 spar PMaSynRM med NdFeB magneter har daliga e ektivitet och e ektfaktor, med enorma mangder PM insatt. Detta ar framst pa grund av bristen pa reluktansvridmomentet for denna relativt hogre poltal losning. Dessutom har man funnit i litteraturen och bekraftat i denna unders okning att denna negativa e ekt for 10-polig motorn forstarks pa grund av narvaron av den koncentrerade lindningen. Faktum ar att det framgar av simuleringar att motorprestanda forbattras med en 8-polig/12 spar PMaSynRM konguration med en relativt lagre NdFeB magnet belopp, tack vare den forbattrade rotor anisotropi. Den 10-polig/12 spar interior permanentmagnet (IPM) och ytmonterade permanent magnet (SMPM) topologier presentera hogre prestanda tack vare ett e ektivt utnyttjande av PM och deras produktion vridmoment, huvudsakligen eller helt anfortrotts PM effekten.

Le projet d'avion électrique vise à remplacer les vecteurs énergétiques que sont les fluides hydrauliques et l'air comprimé par le courant électrique et d'obtenir en conséquence une diminution significative de la consommation en carburant Dans cette thèse, nous proposons deux solutions : la première dans un souci d'accroitre la disponibilités des actionneurs électriques et la seconde pour la traction au sol (taxiage d'avion). Dans la première étude, nous nous plaçons dans le cadre d'un actionneur pour lequel il est demandé une redondance électrique. Ceci peut être le cas d'un actionneur de mode « normal », redondé par un actionneur de type secours, mais où les fiabilités cumulées ne sont pas suffisantes, et où la partie électrique et la commande du système dit normal est redondé. Nous proposons une topologie de moteur synchrone à aimants permanents à bobinage à plots à deux étoiles découplées magnétiquement et à courant de court-circuit limité. Pour les machines à plots, nous avons établi un modèle semi analytique dans le but de prédire l'amplitude de la résultante des forces radiales agissant sur le rotor de cette machine en cas de fonctionnement en modes sain et dégradé. Nous avons établi le modèle de cette machine en vue de la commande et nous avons validé expérimentalement ce principe de conception sur un prototype dimensionné au laboratoire et réalisé par une société du groupe SAFRAN. Dans la seconde étude, nous avons investigué sur l'utilisation de moteurs multi-enroulements permettant de répondre au mieux à un cahier des charges exigeant pour une application de traction d'aéronefs: le « green taxiing ». Le principe est de permettre de faire varier le coefficient de couple d'un moteur de manière à optimiser la masse du moteur mais aussi les contraintes sur le convertisseur qui l'alimente permettant d'atteindre de larges plages de vitesse. Le modèle en vue de l'alimentation a été développé et validé par une comparaison à une résolution par éléments finis en magnétodynamique / The more electrical aircraft project aims at replacing most of current power generation sources by electrical ones. Consequently this replacement might generate a significant decrease of the fuel consumption. Through this thesis we determine two electrical solutions allowing on the one hand the increase of disponibility level of the actuators and on the other handthe aircraft taxiing by electrical means. We firstly focused on electrical actuators that require electrical redundancy. A first mean to achieve this redundancy is to use two actuators. Nevertheless this solution is not relevant under the reliability constraint because the global failure rate is increased. A double star permanent magnet synchronous motor with concentrated winding is proposed in which a special care was taken to the short circuit current limitation and the magnetic decoupling between the two star winding. We established a semi-analytic model for this kind of motors to predict the amplitude of the resultant of the radial forces acting on the rotor of the machine when operating under normal and faulty operation. We established the model of the machine in order to determine the command strategy. We experimentally validated all of the design principles mentioned above through a prototype designed in the laboratory and built by one of the SAFRAN group company. We secondly investigated on the way to apply the multi winding principles to a brand new project linked to the aircraft taxiing called “green taxiing”. The goal is to obtain a motor topology that allows operating on a wide speed range thanks to the command strategy and the change of its torque coefficient. We established the model of the machine and we compared the results given by this ingenious model to the results given by a finite element resolution using a transient magnetic application

Οι μετατροπείς ηλεκτρονικών ισχύος χρησιμοποιούνται σε ένα ευρύ φάσμα εφαρμογών μικρής και μεγάλης ισχύος. Στην πλειονότητά τους οι μετατροπείς αυτοί περιλαμβάνουν μαγνητικά στοιχεία (μετασχηματιστές – πηνία), οι απώλειες ισχύος των οποίων καθορίζουν σε μεγάλο βαθμό την απόδοση της εκάστοτε διάταξης. Είναι λοιπόν μεγάλης σημασίας η ανάπτυξη θεωρητικών μοντέλων, αλλά και πειραματικών μεθόδων, για τον ακριβή προσδιορισμό των απωλειών των μαγνητικών στοιχείων, ώστε να είναι εφικτός ο βέλτιστος σχεδιασμός τους, με τελικό πάντα στόχο την εξοικονόμηση ενέργειας. Οι στόχοι της διατριβής κινούνται σε δύο βασικούς άξονες: α) Να γίνει διερεύνηση των φαινομένων που επηρεάζουν τις απώλειες χαλκού σε τυλίγματα που αποτελούνται από στρώσεις αγωγών, αλλά και να αναπτυχθεί ένα μοντέλο για τον υπολογισμό των απωλειών χαλκού σε τυλίγματα αγωγών κυκλικής διατομής με τυχαία κατανομή αυτών στο διαθέσιμο χώρο. β) Να γίνει ανάπτυξη μιας ολοκληρωμένης μεθοδολογίας λήψης πειραματικών μετρήσεων σε μαγνητικά στοιχεία μέσα από τη διερεύνηση των διαφόρων παραγόντων πειραματικών σφαλμάτων και τη σχεδίαση μετατροπέα συντονισμού κατάλληλου για τη διέγερση μαγνητικών στοιχείων με ημιτονοειδή τάση υψηλής συχνότητας. Στο πρώτο μέρος της διατριβής (κεφάλαια Κεφ. 1, Κεφ. 2 και Κεφ. 3) γίνεται μια γενική περιγραφή των φυσικών φαινομένων που λαμβάνουν χώρα στα μαγνητικά στοιχεία όταν αυτά διαρρέονται από ρεύμα περιοδικά μεταβαλλόμενο στο χρόνο, τα φαινόμενα δηλαδή της μαγνητικής υστέρησης και της ανάπτυξης δινορρευμάτων στο μαγνητικό υλικό του πυρήνα και τα φαινόμενα επιδερμικό και γειτνίασης, που οφείλονται στην ανάπτυξη δινορρευμάτων στα τυλίγματα. Επίσης, γίνεται παράθεση και αξιολόγηση των σπουδαιότερων ως τώρα θεωρητικών εργασιών που πραγματεύονται τα παραπάνω φαινόμενα και χρησιμοποιούνται για τον υπολογισμό των απωλειών που σχετίζονται με αυτά. Στο δεύτερο μέρος της διατριβής, (κεφάλαια Κεφ. 4 και Κεφ. 5) πρώτα γίνεται η παράθεση των τριών κλασικών μοντέλων για τον υπολογισμό των απωλειών χαλκού σε τυλίγματα που απαρτίζονται από στρώσεις και με τη βοήθεια λογισμικού πεπερασμένων στοιχείων διερευνάται η ακρίβεια και το πεδίο εφαρμογής καθενός εξ’ αυτών. Προκύπτει πως το μοντέλο του Dowell δίνει σαφώς πιο ακριβή αποτελέσματα και πως οι αποκλίσεις των μοντέλων από τα πραγματικά (σύμφωνα με τις προσομοιώσεις) αποτελέσματα οφείλεται στην αδυναμίας τους να λάβουν σωστά υπόψη τη δισδιάστατη ανάπτυξη του μαγνητικού πεδίου και τις πυκνότητας ρεύματος όταν αυξάνεται η συχνότητα ή όταν μειώνεται ο παράγοντας πλήρωσης χαλκού. Διερευνάται το φαινόμενο παρυφής σε τυλίγματα στρώσεων που αποτελούνται είτε από αγωγούς κυκλικής διατομής είτε από φύλλα χαλκού και περιγράφεται ποσοτικά και ποιοτικά η επίδρασή του στην τιμή της ενεργού αντίστασης, η οποία προκύπτει πως εμφανίζεται αυξημένη μόνο σε συχνότητες περί τη βασική αρμονική του ρεύματος. Μελετάται επίσης η γεωμετρική ανάπτυξη του φαινομένου στο χώρο του τυλίγματος και διαπιστώνεται η γενικά επιφανειακή του επίδραση που ελαχιστοποιεί την πιθανή εμφάνιση τοπικής υπερθέρμανσης. Ακόμη, για τυλίγματα στρώσεων με αγωγούς κυκλικής διατομής, αναλύεται η διαφοροποίηση στην τιμή της ενεργού αντίστασης μεταξύ των περιπτώσεων της τετραγωνικής και της εξαγωνικής διάταξης των αγωγών και αναδεικνύεται η μείωσή της στη δεύτερη περίπτωση. Ακολούθως αναπτύσσεται ένα νέο μοντέλο για τον υπολογισμό των απωλειών χαλκού σε τυλίγματα αγωγών κυκλικής διατομής που έχουν τοποθετηθεί στο παράθυρο του μαγνητικού στοιχείου με τυχαίο τρόπο, πράγμα το οποίο αποτελεί μια κοινότυπη σχεδιαστική πρακτική. Για τη διατύπωση της νέας έκφρασης χρησιμοποιούνται τα αριθμητικά αποτελέσματα πληθώρας προσομοιώσεων που έγιναν με το λογισμικό πεπερασμένων στοιχείων και αναζητείται η κατάλληλη εξίσωση περιγραφής τους. Η αναζήτηση αυτή στηρίζονται σε μεθόδους ελαχιστοποίησης του σφάλματος, που εδώ εφαρμόζονται με τη βοήθεια κατάλληλων λογισμικών. Η εξίσωση που τελικά προκύπτει είναι απλή και περιέχει μόνο τρεις εύκολα προσδιορίσιμες παραμέτρους σχετιζόμενες άμεσα με γνωστές κατασκευαστικές παραμέτρους. Δείχνεται πως η νέα έκφραση μπορεί να εφαρμοστεί και στην περίπτωση πολύκλωνου αγωγού και διερευνάται ως προς την ευαισθησία της σε σφάλματα μέτρησης κατά τον προσδιορισμό του πάχους του τυλίγματος, ενώ επίσης προτείνεται μια απλούστερη προσεγγιστική έκφραση για τις χαμηλές συχνότητες. Τέλος, η ισχύς της νέας έκφρασης επαληθεύεται με τη βοήθεια πειραματικών μετρήσεων. Η πρώτη εργασία που παρουσιάζεται στο τρίτο μέρος της διατριβής (κεφάλαια Κεφ. 6 και Κεφ. 7) είναι η σχεδίαση και κατασκευή ενός μετατροπέα συντονισμού κατάλληλου για την τροφοδότηση μαγνητικών στοιχείων με καθαρά ημιτονοειδή τάση υψηλής συχνότητας (ως και 1MHz) και πλάτους αρκετών εκατοντάδων Volt, σε επίπεδα ισχύος αρκετών δεκάδων Watt, για την πραγματοποίηση μετρήσεων σε αυτά. Η θεωρητική και πειραματική διερεύνηση των παραγόντων που επηρεάζουν τη λειτουργία του μετατροπέα αναδεικνύει την αλληλένδετη σημασία των σχεδιαστικών επιλογών τόσο στο κύκλωμα ισχύος όσο και στο ηλεκτρονικό κύκλωμα ελέγχου και οδηγεί στην κατάλληλη διαστασιολόγηση των στοιχείων που χρησιμοποιούνται σε αυτά τα δύο κυκλώματα έτσι ώστε να γίνει εφικτή η διεύρυνση του φάσματος συχνοτήτων λειτουργίας του μετατροπέα, η ελαχιστοποίηση του αρμονικού περιεχομένου και η μεγιστοποίηση του πλάτους της τάσης εξόδου. Στη συνέχεια περιγράφονται μέθοδοι μετρήσεων των απωλειών μαγνητικών στοιχείων και λήψης του βρόχου υστέρησης του μαγνητικού υλικού των πυρήνων τους. Αναλύονται οι διάφοροι παράγοντες σφάλματος και γίνονται μετρήσεις τόσο για τον προσδιορισμό των ειδικών απωλειών φερρίτη όσο και για τη λήψη του βρόχου υστέρησης φερριτών σε διάφορες συχνότητες. Προτείνονται μεθοδολογίες διόρθωσης του αποτελέσματος για τις απώλειες υστέρησης, όπως αυτές προκύπτουν από το εμβαδόν του μετρούμενου βρόχου υστέρησης, όταν υπάρχει γνωστό σφάλμα φάσης κατά τη λήψη της κυματομορφών της μαγνητικής έντασης και της μαγνητικής επαγωγής. Τέλος, εξηγείται η μείωση στις υψηλές συχνότητες της ενεργού αντίστασης των τυλιγμάτων όταν αυξάνεται η θερμοκρασία και δίνονται κάποια ενδεικτικά γραφικά παραδείγματα για τη σχετική διόρθωση για τυπικές αυξήσεις της θερμοκρασίας σε μαγνητικά στοιχεία. / Power electronics converters are used in a wide range of both low and high power applications. Most of these converters include magnetic components (transformers – inductors), the power losses of which determine in a major degree their efficiency. It is therefore very important to the power electronics converter designers to have available the proper theoretical models and experimental methods for the accurate determination of the magnetic component losses in order to make optimum design choices and achieve an effective energy saving. The present work has a twofold goal: a) To investigate the phenomena affecting the copper losses in windings that consist of conductor layers and to develop a new model for the calculation of copper losses in round cross section conductor windings with random distribution of these conductors in the available core window area. b) To develop a complete methodology of making experimental measurements on magnetics components, through the investigation of the several measurement error factors and to design a resonant converter suitable for the excitation of magnetic components with high frequency sinusoidal voltage. In the first part of this thesis (chapters Ch. 1, Ch. 2 and Ch. 3) there is a general description of the physical phenomena that take place in magnetic components when a periodically time variable current flows through them, i.e. magnetic hysteresis and eddy currents at the magnetic core material and skin as well as proximity effect at the windings, which are due to the development of eddy currents in them. Moreover, there is an overview citation and critical review of the most important by now theoretical works on these issues which are also widely used for the calculation of the losses related to them. In the second part of this thesis (chapters Ch. 4 and Ch.5) there is at first a short review of the three classic models for the calculation of copper losses in windings made of layers and then a finite element software is utilized for the investigation of the accuracy and field of application of each of them. It is shown that Dowell’s model is much more accurate and that the declination of the models from the real (according to simulations) results are due to their inherent inability to properly take into account the two-dimensional distribution of the magnetic field and the current density when the frequency increases or when the filling factor value decreases. The edge effect in layered windings with either round cross section or foil conductors is investigated and a qualitative as well as quantitative description of its effect on the effective resistance is given, showing that there can be an increase in it only at frequencies close to the fundamental frequency of the current waveform. There is also a study about the geometrical extent of the edge effect in the winding volume and it is concluded that the winding is generally affected only on its outer parts, a fact that minimizes the possibility for a hot spot to appear. Moreover, for layered windings with round cross section conductors, a study is carried out about the difference in the effective resistance between the cases of square and hexagonal fit schemes and it is shown that in the second case there can be an appreciable power loss reduction. Following this work, is the development of a new model for the calculation of copper losses in round cross section conductor windings with the several turns placed with a random manner in the available core window area, which is a common design choice. For the extraction of the new expression a computer aided curve fitting process has been applied on a large amount of numerical data coming from finite element simulations. The final equation of the model is simple and incorporates only three easily determinable parameters, directly related to known constructive parameters. It is shown that the new expression can also be applied in the case of stranded wire windings. Its sensitivity to the winding height measurement errors is investigated and a low frequency approximation is proposed. At last, the new expression is validated with experimental measurements. The first work presented in the third part of this thesis (chapters Ch. 6 and Ch. 7) is the design and construction of a resonant converter suitable for the excitation of magnetic components with a clearly sinusoidal voltage of high frequency (up to 1MHz) and amplitude of several hundreds volts, at several tenths of Watts power level, for the implementation of experimental measurements. The theoretical and experimental investigation of the factors affecting the converter performance reveals the interrelated importance of the design choices in the resonant tank and the electronic control board and leads to the proper component selection in both these circuits so as to expand the operating frequency range, minimize the harmonic distortion and maximize the amplitude of the output voltage. Following that, there is a description of the methods available to measure the power losses of magnetic components and acquire the hysteresis loop of their magnetic cores. The several error factors are analyzed and measurements are taken in order to determine the power losses and monitor the hysteresis loop of ferrite materials at several frequencies. Some methods are proposed for the correction of the measured hysteresis losses, if these are determined from area of the hysteresis loop, in the case of a known phase error when recording magnetic intensity or magnetic induction. At last, the reduction with temperature of ohmic resistance at high frequencies is explained and some indicative graphical examples are given for the correction in its calculated value for some typical magnetic component temperature rise values.

MULTILEVEL inverters are the preferred choice of converters for electronic power conversion for high power applications. They are gaining popularity in variety of industrial applications including electric motor drives, transportation, energy management, transmission and distribution of power. A large portion of energy conversion systems comprises of multilevel inverter fed induction motor drives. The multilevel inverters are ideal for such applications, since the switching frequency of the devices can be kept low. In conventional two level inverters, to get nearly sinusoidal phase current waveform, the switching frequency of the inverter is increased and the harmonics in the currents are pushed higher in the frequency spectrum to reduce the size and cost of the filters. But higher switching frequency has its own drawbacks – in particular for medium voltage, high power applications. They cause large dv_/ dt stresses on the motor terminals and the switching devices, leading to increased electromagnetic interference (EMI) problems and higher switching losses. Harmonics in the motor currents can further be minimized by adopting dodecagonal voltage space vector (SV) switching (12-sided polygon). In case of dodecagonal SV switching, the fifth and seventh order (6n , 1, n = odd) harmonics are completely eliminated for the full modulation range including over modulation and twelve step operation in the motor phase voltages and currents. In addition to low order harmonic current suppression, the linear modulation range for dodecagonal SV switching is also more by 6% when compared to that of the conventional hexagonal SV switching. The dodecagonal voltage SV structure is made possible by connecting two inverters with DC-link voltages Vd and 0:366Vd on either side of an open-end winding induction motor. The dodecagonal space vector switching can be used to produce better quality phase voltage and current waveforms and overcome the problem of low order fifth and seventh harmonic currents and to improve the range for linear modulation while reducing the switching frequency of the inverters when compared to that of the conventional hexagonal space vector based inverters. This thesis focuses on three aspects of multilevel dodecagonal space vector structures (i) Two new power circuit topologies that generate a multilevel dodecagonal voltage space vector structure with symmetric triangles, (ii) A multilevel dodecagonal SV structure with nineteen concentric dodecagons, (iii) Pulse width modulation (PWM) timing calculation methods for a general N-level dodecagonal SV structure. (i) Two new power circuit topologies capable of generating multilevel dodecagonal voltage space vector structure with symmetric triangles with minimum number of DC link power supplies and floating capacitor H-bridges are proposed. The first power topology is composed of two hybrid cascaded five level inverters connected to either side of an open end winding induction machine. Each inverter consists of a three level neutral point clamped (NPC) inverter, cascaded with an isolated capacitor fed H-bridge making it a five level inverter. The second topology is a hybrid topology for a normal induction motor (star or delta connected), where the power is fed to the motor only from one side. The proposed scheme retains all the advantages of multilevel topologies as well the advantages of the dodecagonal voltage space vector structure. Both topologies have inherent capacitor balancing for floating H-bridges for all modulation indices including transient operations. The proposed topologies do not require any pre-charging circuitry for startup. PWM timing calculation method for space vector modulation is also explored in this chapter. Due to the symmetric arrangement of congruent triangles within the voltage space vector structure, the timing computation requires only the sampled reference values and does not require any iterative searching, off-line computation, look-up tables or angle estimation. Experimental results for steady state operation and transient operation are also presented to validate the proposed concept. (ii) A multilevel dodecagonal voltage space vector structure with nineteen concentric do-decagons is proposed for the first time. This space vector structure is achieved by connecting two sets of asymmetric hybrid five level inverters on either side of an open-end winding induction motor. The dodecagonal structure is made possible by proper selection of DC-link voltages and switching states of the inverters. In addition to that, a generic and simple method for calculation of PWM timings using only sampled reference values (v and v ) is proposed. This enables the scheme to be used for any closed loop application like vector control. Also, a new switching technique is proposed which ensures minimum switching while eliminating the fifth and seventh order harmonics and suppressing the eleventh and thirteenth harmonics, eliminating the need for bulky filters. The motor phase voltage is a 24-stepped waveform for the entire modulation range thereby reducing the number of switchings of the individual inverter modules. Experimental results for steady state operation, transient operation including start-up have been presented and the results of Fast Fourier Transform (FFT) analysis is also presented for validating the proposed concept. (iii) A method to obtain PWM timings for a general N-level dodecagonal voltage space vector structure using only sampled reference values is proposed. Typical methods that are used to find PWM timings for dodecagonal SV structures use modulation index and the reference vector angle, to get the timings T1 and T2 using trigonometric calculations. This method requires look-up tables and is difficult to implement in closed loop systems. The proposed method requires only two additions to compute these timings. For multilevel case, typical iterative methods need timing calculations (matrix multiplications) to be performed for each triangle. The proposed method is generic and can be extended to any number of levels with symmetric structures and does not require any iterative searching for locating the triangle in which the tip of the reference vector lies. The algorithm outputs the triangle number and the PWM timing values of T0, T1 and T2 which can be set as the compare values for any carrier based PWM module to obtain space vector PWM like switching sequences. Simulation and experimental results for steady state and transient conditions have been presented to validate the proposed method. A 3.7 kW, 415 V, 50 Hz, 4-pole open-end winding induction motor was used for the experimental studies. The semiconductor switches that were used to realize the power circuit for the experiment were 75 A, 1200 V insulated-gate bipolar transistor (IGBT) half-bridge modules (SKM75GB12T4). Opto-isolated gate drivers with desaturation protection (M57962L) were used to drive the IGBTs. For the speed control and PWM timing computation a digital signal processor (DSP-TMS320F28335) with a clock frequency of 150 MHz was used. For modulation frequencies 10 Hz and below, a constant sampling frequency of 1 kHz was used as the frequency modulation ratio is high. For modulation frequencies above 10 Hz, synchronous PWM strategy was used. The time duration Ts is the sampling interval for which the timings T1 , T2 and T0 are calculated. As in the case of any synchronous PWM method, the duration of sampling time (Ts) is a function of the fundamental frequency of the modulating signal. In this case, Ts = 1_.fm • 12n) sec. where fm is fundamental frequency in Hertz and ‘n’ is the number of samples per 30ý dodecagonal sector. The PWM timings and the triangle data (from the DSP) is fed to field programmable gate array (FPGA) (SPARTAN XC3S200) clocked at 50 MHz where the actual gating pulses are generated. The capacitor balancing algorithm and the dead-time modules were implemented within FPGA. No external hardware was used for generation of dead-time. The dead-time block generates a constant dead-time of 2 s for all the switches. Extensive testing was done for steady state operations and transient operations including quick acceleration and start-up to validate the proposed concepts. With the advantages like extension of linear modulation range, elimination of fifth and seventh harmonics in phase voltages and currents for the full modulation range, suppression of eleventh and thirteenth harmonics in phase voltages and currents, reduced device voltage ratings, lesser dv_dt stresses on devices and motor phase windings, lower switching frequency, inherent cascaded H-bridge (CHB) capacitor balancing, the proposed space vector structures, the inverter power circuit topologies, the switching techniques and the PWM timing calculation methods can be considered as viable schemes for medium voltage, high power motor drive applications.