Motor Generator p25

Glenn Research Center
HIGH SPEED PERMANENT MAGNET

SYNCHRONOUS MOTOR / GENERATOR DESIGN
FOR FLYWHEEL APPLICATIONS
Aleksandr Nagorny, Ph.D.
National Research Council
Outline
Introduction
Selection of the Rated Point
The major requirements for flywheel M/G in space applications
Meeting design requirements
M/G Main Materials Selection
Lamination Thickness Selection
Modeling tools
M/G Preliminary Design Process
Permanent Magnet Material Selection
The RMxprt Analytical Design Output
Armature Reaction and Demagnetization Calculation
M/G 2D Finite Element Modeling
Concluding Observations and Recommendations
References
Acknowledgements
Introduction
The motor / generator design is a part of work
performed at NASA Glenn Research Center devoted
to the development of flywheel modules for use in
satellite energy storage and attitude control systems.
The benefits of flywheel module as an energy storage
device in spacecraft application compared to the
chemical batteries are the following: higher energy
and power densities, deeper depth of discharge,
broader operating temperature range.
Flywheel can be used as a source of momentum for
attitude control, giving the opportunity to combine two
satellite subsystems into one and reduce the overall
volume and mass.
Selection of the Rated Point
Determination of the
output power
The output power
determination is based on
the load profiles during
the load cycles.
From t=0 to t=60 min it is
a charge (motor mode),
from t=60 to t=90 min it is
a discharge (generator
mode).
In each point the net
torque of M/G is equal
T
net
=T
ES
+T
AC
Where T
ES
is the torque
component required for
the energy storage, and
T
AC
is the component
required for the attitude
control.
Flywheel Combined Energy Storage and Attitude
Control Output Power Determination
-1.5
-1
-0.5
0
0.5
1
0 20 40 60 80 100
Time of Cycle, min
T
o
r
q
u
e
,

N
m
-8000
-6000
-4000
-2000
0
2000
4000
6000
O
u
t
p
u
t

P
o
w
e
r
,

W
Torque Tes Net Torque Torque ac Output Power
The major requirements for flywheel M/G in space
applications
Relatively high electrical frequency of voltages and currents
High specific power
High efficiency, low total losses
Low THD at the back emf waveform
Low cogging torque values
Low rotor losses
High thermal endurance, ability to operate in vacuum without
intensive cooling
Meeting design requirements
High specific power:
Right selection of the M/G configuration
Application of high magnetic energy permanent magnet
materials
Application of high permeability core lamination materials
High efficiency, low total losses:
Choice of an AC permanent magnet synchronous machine
with the zero fundamental frequency rotor magnetic and
conductive losses
Application of core lamination materials with low specific
losses
Application of thin diameter stranded wires for the stator
armature conductors to reduce the high frequency skin effect
losses
Meeting design requirements (contd)
Low THD at the back emf waveform and
low cogging torque value.
Could be achieved by the reducing the
high frequency spatial mmf harmonics
by the following methods:
Make the magnet pole arcs short
pitched
Two layer short pitched stator winding
Skewing of the stator core in axial
direction
Relatively large non-magnetic gap;
Small value for slot opening to slot
pitch ratio
Special shape for the stator teeth
(dummy slots)
Lamination of permanent magnets in
axial direction
Low value of the rotor losses:
The main components of the rotor losses :
Back iron loss;
Eddy current loss in permanent magnet material;
M/G carbon fiber sleeve loss;
Windage loss.
The first three components of the rotor losses are caused by the
high frequency spatial mmf harmonics. The measures to reduce
them are the same as described on previous slide. The effective
measure against the back iron losses is lamination of the back
iron core.
High thermal endurance:
High thermal endurance can be achieved by using the
appropriate materials for the stator and rotor parts:
Stator and rotor core lamination materials
Wire insulation
Slot insulation
Winding parts insulation
Motor leads insulation
Permanent magnet materials
Rotor carbon fiber composite.
For the current M/G design all the materials except carbon
fiber composite have the rated temperature above 200 C.
M/G Main Materials Selection
Using of prospective materials
The major motor materials that can affect the motor
performance are the following
core ferromagnetic materials
permanent magnet materials
magnet wires
winding insulation
Core ferromagnetic materials
Two major characteristics of the core ferromagnetic materials
can affect the motor performance
the maximum saturation flux density
specific losses
Modeling tools
Ansoft Corporation RMxprt software is used for the
preliminary motor design.
The advantages of the RMxprt software are the following:
The ability to get an easy and fast response in a convenient
form
The output data can be easily exported to other Ansoft
software (Maxwell 2D, Simplorer)
The program can perform optimization of the input
parameters
M/G Preliminary Design Process
The numerous design iterations were completed to meet the
motor requirements in motor and generator mode.
Different rotor configurations, permanent magnet and core
materials and M/G geometry were optimized using the
RMxprt parametric analysis mode.
The highest level of the output power in a combination
of relatively low back EMF THD level was obtained for
the surface mounted arc shaped magnet configuration
Permanent Magnet Material Selection
NdFe group has higher remanent magnetization and energy
product.
SmCo has a better thermal characteristic.
M/G Output Power in Generator Mode for different PM Materials
5336.96
6075.79
6387.41
7779.15
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
SmCo 24 SmCo 28 NdFe 30 NdFe 38
Type of Magnet Material
W
Lamination Thickness Selection
At high frequencies (1.2
kHz) and high flux
densities (2.0 T) the
specific iron loss is
proportional to the square
of lamination thickness.
For the reduction of the
iron loss, the lamination
thickness should have a
low value (in our case
0.004).
Specific Iron Loss versus Lamination Thickness f or High
Saturation Cobalt Iron Alloy at 1200 Hz and 2 T
y = 539416x
2
+ 5783.6x + 13.285
R
2
= 1
0
50
100
150
200
250
0 0.0025 0.005 0.0075 0.01 0.0125 0.015
Lamination Thickness, Inch
S
p
e
c
i
f
i
c

L
o
s
s
,

W
/
k
g
The RMxprt Analytical Design Output
6 Number of Conductors per Slot:
0.728 Length of Stator Core (inch):
2.9 Inner Diameter of Stator (inch):
5.75 Outer Diameter of Stator (inch):
24 Number of Stator Slots:
STATOR DATA
SmCo Type of Magnet:
0.27 Max. Thickness of Magnet (inch):
0.728 Length of Rotor (inch):
1.51 Inner Diameter (inch):
0.105 Non Magnetic Gap, inch
ROTOR DATA
7.55 7.55 Total Net Weight (lb):
1.482 1.452 Rated Torque (N.m):
50000 50000 Synchronous Speed (rpm):
98.164 98.168 Efficiency (%):
72.016 72.594 Line Current RMS (A):
0.015 0.016 Cogging Torque (N.m):
0.964 0.964 THD of Induced Voltage (%):
115 115 Operating Temperature (C):
1666.67 1666.67 Frequency (Hz):
4 4 Number of Poles:
61 61 Rated Voltage (V):
7.6 7.6 Rated Output Power (kW):
Generator
Mode
Motor
Mode M/G parameters at rated point
Cogging Torque
-0.02
-0.015
-0.01
-0.005
0
0.005
0.01
0.015
0.02
0 50 100 150 200 250 300 350 400
Electric Angle, Degrees
T
o
r
q
u
e
,

N
m
Output Power Versus Torque Angle
-5000
0
5000
10000
15000
20000
25000
30000
0 25 50 75 100 125 150 175 200
Angle, Degrees
P
o
w
e
r
,

W
Efficiency Versus Torque Angle
0
20
40
60
80
100
0 20 40 60 80 100 120 140 160 180 200
Torque Angle, Degrees
E
f
f
i
c
i
e
n
c
y
,

%
Current Versus Torque Angle
0
100
200
300
400
500
600
0 20 40 60 80 100 120 140 160 180 200
Torque Angle, Degrees
C
u
r
r
e
n
t
,

A
The RMxprt Analytical Design Output (contd)
Flux Density Distribution in the Air Gap (RMxprt)
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
0 50 100 150 200 250 300 350 400
Electrical Angle, Degrees
F
l
u
x

D
e
n
s
i
t
y
,

T
The RMxprt Analytical Design Output vs FEA
Flux Density Distribution in the air-gap.
0.002" from the surface of mannets FEA
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
0 1 2 3 4
Position in the air-gap, inch
B
,

T
Flux density distribution in the air-gap,
0.053" from the surface of magnets FEA
-0.8
-0.6
-0.4
-0.2
0
0.2
0.4
0.6
0.8
0 1 2 3 4
Position in the air gap, inch
B
,

T
Flux density distribution in the air-gap, 0.002" from the stator bore FEA
-1.2
-0.8
-0.4
0
0.4
0.8
1.2
0 1 2 3 4
Position in the air gap, inch
B
,

T
FEA shows higher flux density in the air-gap than RMxprt
Study of M/G Characteristics During the Duty Cycle
M/G Frequency
0
200
400
600
800
1000
1200
1400
1600
1800
0 10 20 30 40 50 60 70 80 90 100
Time, min
F
r
e
q
u
e
n
c
y
,

H
z
M/G Voltage
0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70 80 90 100
Time, min
V
o
l
t
a
g
e
,

V
M/G Armature Current
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
0 10 20 30 40 50 60 70 80 90 100
Time,min
C
u
r
r
e
n
t
,

A
M/G Total Loss
0
20
40
60
80
100
120
0 10 20 30 40 50 60 70 80 90 100
Time. min
L
o
s
s
,

W
M/G Output Power
-5000
-4000
-3000
-2000
-1000
0
1000
2000
3000
4000
5000
0 10 20 30 40 50 60 70 80 90 100
Time, min
P
o
w
e
r
,

W
M/G Efficency
93.5
94.0
94.5
95.0
95.5
96.0
96.5
97.0
97.5
98.0
98.5
0 10 20 30 40 50 60 70 80 90 100 Time, min
E
f
f
i
c
i
e
n
c
y
,

%
The RMxprt Analytical Design Output (contd)
Armature Reaction and Demagnetization
Calculation
( )
+ =
s t
Hc
s t
Hc Hc
100
1
Samarium Cobalt (Sintered) S2769 Demagnetization Lines at Different Temperatures
0
0.2
0.4
0.6
0.8
1
1.2
-900000 -800000 -700000 -600000 -500000 -400000 -300000 -200000 -100000 0
Hc, A/m
B
r
,

T
20C
200C
Permanent magnet demagnetization curves are sensitive to the
temperature
( )
+ =
s t
B
s t
r
Br Br
100
1
The common method to check the demagnetization of the permanent
magnets due to the armature reaction is described in T.J. Miller's book
[1]. The disadvantage of this method is the assumption that the
permanent magnet pole has uniform saturation.
r
Rg
P
m0
Fa
R
L
g
L
M r r
A B =
m
m rec
mo
l
A
P

0
=
g
g
A
g
R
0
=
g
m
A
A
C =
r
g m
g
B
R P
C
B
) 1 ( +
=

r
g m
g r
m
B
R P
R P
B
) 1 (
1
1
+
+
=
rec
m r
m
B B
H

0
=
g m
g r
rec
R P
R P
PC
0
1
1+
=
m
dem rec
ma
l
F
B

0
=
ma m load
B B B =
Permanent Magnet Demagnetization Curve hm=.300 inch
0.00
1.10
0.0000
0.9043
0.7512
0 0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1.1
1.2
-900000 -800000 -700000 -600000 -500000 -400000 -300000 -200000 -100000 0
H,A/m
B
,
T
Calculation (contd)
A more accurate way to check the demagnetization is FEA.
Using Maxwell 2D Transient solver, the solution for the rated
load should be determined. The relative rotor-stator position
and instantaneous values of the phase currents are
determined.
Then, using position and values obtained by transient
solver, the Maxwell 2D Magnetostatic model can be created
and the flux density distribution in permanent magnets can
be determined.
Calculation (contd)
Calculation (contd)
Flux lines in the motor and flux density vectors without armature
reaction
Ia=0
Calculation (contd)
Ia=387 A
Due to the armature reaction the level of demagnetization in the corner
of the magnet pole is higher than in the other areas of the magnet
Calculation (contd)
Ia=581A
Permanent Magnet Flux Density versus Armature Current
-0.4
-0.2
0
0.2
0.4
0.6
0.8
1
0 100 200 300 400 500 600 700 800
Phase A Current, A
B
,

T
Bm av 20C
B m corn 20C
The average value of flux density in the magnet is still much more than
zero, but the corner area of the magnet is demagnetized
A more accurate solution of M/G
characteristics can be found by
using finite element analysis.
Thus, the accuracy of the results
obtained by RMxprt software
could be verified.
The transient finite element model
includes a rotor and stator core,
conductors, shaft, magnets,
spacers between magnets and a
carbon fiber ring. Thus, all
components of the rotor losses
can be determined with a good
accuracy.
M/G 2D Finite Element Modeling (contd)
Two different approaches were applied to investigate the M/G characteristics:
sinusoidal voltage sources and sinusoidal current sources. Both techniques show
similar results for the motor characteristics.
After transient solution the Magnetostatic solver was used to check the value of the
torque, developed for the specified current values.
Maxwell 2D transient mode solver with
the time-stepping approach was
employed.
The effects of saturation, eddy
currents, slotting, rotor position and
space harmonics are taken into
account.
Because of using two-layer short
pitched winding, where two layers of
the winding have the angular
displacement, there is no mirror
symmetry in this machine. Thus there
was no opportunity to use the master
slave symmetry
Tav=1.6045 Nm
=
A
JdA J l P
1
Eddy current losses were calculated for
permanent magnets, carbon fiber ring
and spacers between magnets.
Pav=8.1 W
Where is the conductivity of material, l
is the depth of an eddy current loop in Z
direction, A is the surface area, J is a
current density.
Could be noticed, that the peaks of eddy
current losses are located under slot
openings. The value of local eddy current
density depends on instantaneous value
of the current in the closest slot.
Centers of eddy current losses
The stator slot skewing causes a force
in axial direction, that can affect the
operation of magnetic bearings. The
following technique was employed to
determine the value of this force.
1) From Maxwell 2D Transient solver, the
relative rotor-stator position and
instantaneous values of phase currents
are found.
2) Using these position and currents
values the Maxwell 3D Magnetostatic
model was created and the force values
versus phase currents were determined,
taking effect of skewing into account.
Force in Axial Direction Caused by Slot Skewing vs
Phase Current
-2
0
2
4
6
8
10
12
0 20 40 60 80 100 120 140
Current, A
F
o
r
c
e
,

N
3D model takes 2 layer winding and slot skewing into account
G3 Flywheel M/G Design
Based on the design
results presented, M/G
as a part of new
flywheel G3 module was
fully designed and the
prototype is planned to
be fabricated this year.
Concluding Observations and Recommendations
Ansoft RMxprt, Maxwell 2D and 3D are powerful tools for electrical
machine design.
Some suggestions to make the use of these programs more
convenient are given below
1. It would be useful as a part of the RMxprt outputs for the
synchronous PM motors and generators to show the
demagnetizing curve of the magnets (with the load and no-load
lines), the energy product line, and the phasor diagram of the rated
point of the machine.
2. The simulation of high frequency synchronous PM machine in
transient mode requires relatively small time steps. Because of this
it takes a lot of computing time to get steady state results for the
transient analysis in 2D and especially in a 3D simulation.
References
1. J. R., Jr Hendershot, T. J. E. Miller, Design of brushless
permanent-magnet motors, Oxford University Press, 1996
Acknowledgements
This work was performed while the author held a National
Research Council Associateship Award at NASA Glenn
Research Center Cleveland Ohio

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