L1 Intro

Industrial Electrical Engineering and Automation
L1 Introduction
Design
of electrical machines
Avo Reinap
Industrial Electrical Engineering and
Automation, LTH
Lund University, Sweden
Power of understanding
energy conversion
material properties
machine construction
Creativity
Power of imagination
integration
production
Machine Design
Avo R
Design of Electrical Machines
Design process
EIEN20 Design of Electrical Machines, IEA, 2014
Avo R
Component and system thinking

Performance and controllability
Cost and manufacturability
Dimensioning and modelling

Multi-dimensional multi-physics
Supply, electronics, application, drive cycle,
Optimizing
Objective vs design parameters
Sensitivity analysis
Avo R
L1 Introduction
Design of electrical machines in Lund
Design of electrical machines in Lund
separation disk
lower half of
claw-pole ring
phase coil
upper half of
claw-pole ring
coil
housing
shaft
housing
magnet
inner core half
outer core half
housing
magnet
claw-pole ring
Powder core motors simple electric circuit and

unconventional magnetic circuit
Different moulding techniques integrability and
manufacturability
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Material and
production
development
Machine design
and evaluation
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Need for electrical actuator
Electrified traction drive

Integrated pump and fan drives
Wind generators
Mechatronics, robotics
L1: Introduction
Course overview
Maintenance
Machine construction overview
As long we going to have electricity there is

always an electrical machine around
Avo R

Lund University, Sweden
L1 Introduction
Other courses (@IEA)

Course (?)
Design of electrical
machines (EIEN20)
Construction + production
Energy conversion
processes + analysis tools
Materials + properties
From component
towards application and
system
Avo R
Power electronics (and

electrical drives)
(EIE015)
Hybrid Vehicle Drives
(MIE100)
Wind Power Systems
(EIEN10)
Mechatronics: Industrial
Product Design (EIEN01)
Avo R
About the course

About the course

Assessment
Approved design report
grants the grade 3. For
higher grade a written
exam is required.
Learning process
14x2 lectures (LP3)
5 weekly home
assignments (LP3)
Course project (LP4)
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10
11
Motivation (U): 6 credits

+ knowledge (as bonus)
Borrowed from Ice Age I
Requirements (R):
28 hours of lectures
42 hours of project
90 hours of self-studies
Easiness (I): I=U/R

Tools: own pc with
Resources: http://iea.lth.se/emk/
Avo R
12
L1 Introduction
Course goal
Motivation
Employed by being creative engineering
challenges to think creatively
Improve your power of understanding and
power of imagination
Actual trends integrability, manufacturability,
sustainability,
Design challenges new technology, new
materials, computational power,
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13
objective of this course is to gain experience

covering the overall design process: design,
actual construction and testing of an
electromagnetic device
Understand the electromechanical design
behind the classical electromagnetic devices
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L1 introduction
L8 design of PMSM
L2 survey of machines:1
L9 losses
L3 calculation method: EC L10 thermal circuits

L4 calculation method: FE L11 design issues
L5 energy conversion
L12 optimization
L6 magnetic circuits
L13 survey of machines:2
L7 electric circuits
L14 home design
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14
Home assignments
15
Lectures
Introduction to computational techniques and

software optimization of a transformer
Thermal analysis of PMSM
Magnetic analysis of PMSM
Design model and optimization of PMSM
Estimation of machine characteristics
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L1 Introduction
Design task 2007

Course Plan
Preliminary course plan for lectures
After two lectures a weekly home assignment will be
given and this suppose to be handed in within a week
Design task is a parallel process with additional
meetings
W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14 W15 W16 W17 W18 W19 W20 W21 W22
L1
L2
L3
L4
L5
L6
L7
L8
L9 L11 L13
L10 L12 L14
P1
P2
P3
P4
P5
P6
LP3 LP3 LP3 LP3 LP3 LP3 LP3 T4 LP4 LP4 LP4 LP4 P
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P13
P9 P11 P14
P10 P12
P7
P8
T5
Design and prototyping

of an electromagnetic toy
DC drive (2007)
Rotating machine whos
is fastest
Linear machine whos is
strongest
Creativity drive who is
most innovative
Supply 1.5 V battery

Design documentation
T5 LP4 LP4 LP4 T6
17
Avo R
18
Number of modulator poles, NRP and gear ratio

2
20
14
18
6
8
16
12
10
22
20
18
14
12
16
10
Number of magnet pole-pairs, NBM
24
22
20
18
16
14
12
10
10
10
12
14
16
18
20
Number of magnet pole-pairs, NAM
Design task 2008
Design task 2009
Avo R
19
550
@120
@200
92
500
91
Design machine for an

axial wind turbine
Use an existing stator &
Select a number of
poles that gives highest
power and smallest
ripple!
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450
89
400
88
87
power Pm [W]
90
efficiency \ny [%]
Complex theory vs
simple experimentation
93
Goal of hands on project:

Study magnetomechanical energy conversion
350
86
300
85
@120
@200
84
20
25
30
35
number of poles, Np
250
40
20
L1 Introduction
Design Task 2011

Design Task 2010

Hands on project that
requires a good
theoretical understanding
Focus on winding layout
and manufacturing
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21
Understanding
Equivalent circuits
Magnetic
Thermal
Measurements
Magnetic
Thermal
Analyses
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Design Task 2013
Coupled thermal and

magnetic analysis to
estimate power capability
Estimation of machine
characteristics based on
series of static analyses
Development of
equivalent circuit models
to predict machine
performance
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22
Design Task 2012
23
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24
L1 Introduction
What is machine, where do I find it?

Design Task 2014

Your own interest
One of the electrical
machines that you
study/control at power
electronics
Or something else
Machine
Energy converter
used to perform some

useful work or to provide
transportation
Generation
Transformation
Consumption
ELECTROMAGNETISM
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25
Avo R
Cause-effect, action-reaction
Understanding observation (physics) expression
(maths) creation (innovation)
Classification based on magnet origin (?)

Excitation vs armature
Understanding energy conversion

Thermodynamic arguments (conservation of
energy)
Field analysis (Maxwell stress tensor)
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26
Prior/Parallel knowledge
Electrical machine in a nutshell
27
Ohms Law
1 / 3
Cause of electromagnetic force (torque)
Magnetic flux vs.
electromotive force,
electric current vs.
magnetomotive force
Maxwells equations
Power electronic control
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L1 Introduction
Analyze, Synthesize, Design
Construction, calculation and dimensioning of

electromechanical devices
Computer aided design
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d
g on
Goo standin ic
r
t
unde omagne sion
r
r
t
elec y conve
g
Developed knowledge
29
Avo R
(Controlled)
electric power
Geometry
Materials
Motion
Force
Electro-mechanical energy converter

Electromagnetism intermediates energy conversion
Electric side: DC, AC, pulsed
Mechanic side: linear, rotary motion
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30
Main parts
Actuator
31
Coil or winding to produce variable magnetic

flux
Permanent magnet to produce invariable
magnetic flux
Soft magnetic core to provide an easy path
for the flux in order to facilitate flux linkage or
magnetic coupling between sources and
loads
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32
L1 Introduction
Before we control or
construct an electrical
machine we play with
permanent magnets
The energy conversion
between the electric and
mechanic energy takes
place in presence of the
magnetic field
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Magnetic interaction vs attraction
The traditional five

senses of a human being
exclude ability to achieve
a direct response from
magnetic field that
intermediates the
electromechanical
energy conversion in an
electrical machines
Introduction to magnetism
33
N40 NdFeB magnets
5x20x20 mm
F
M
Attraction or repulsion ca
40 N
M F
Shear ca 27 N including ca
7 N attraction/repulsion
F
M
F
F
M
Avo R
Maxwells Stress Tensor
Attraction ca 8 N
Shear 4 N attraction 3 N
34
Force components
Magnetic force on a
surface according to
magnetic pressure
1
tn
Bn2 Bt2
2 0
B B
tt n t
Bn
tn
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Bt t t
35
Attraction between ferrous material and exciting

magnetic fields due to permanent magnet(s) or coil(s)
resulting in reluctance force/torque
Interaction between electromagnet(s) or/and
permanent magnet(s) cause magnetic force/torque
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36
L1 Introduction
A+
A-
A+
I
How machines work
Magnetic field around

current carrying coil
A+
I
F
M
A+
A+
A-
A-
I
F
F
A+
A-
The principle of operation

of any rotating electric
motor is derived from
Lorenz force.
A+
F
A-
Replace PM by EM
NI=Hl= ca 5kA
Electromagnet vs PM
Electrical machines exploit magnetic interaction
No new topology
The principles of machine design are more than 100 years old
M
Avo R
37
Avo R
According to excitation
EM and PM
Reluctance and inductance
According to supply
According to geometrical arrangement
38
Control of machines
Types of machines
Avo R
Two magnets one in stator the other with the rotor

displacement of these two magnets will create a torque
The magnets can be created directly or induced
The bigger the torque the bigger the machine
39
Field oriented control

Maximise torque product
Consider the limits
And keep losses down
The goal for the design is

quite the same as for the
control
Avo R
40
10
L1 Introduction
Machine=Generator&Motor
Torque is proportional to size and weight

Power is proportional to torque and speed
Avo R
Can you figure out

when the animation
machine operates as
a generator and
when as a motor?
Size of machines
41
T
w
Avo R
Avo R
Classification
Classificationof
electrical
of
electricalmachines
machines
??
w=
=T
Pe
iu=
Pm
42
Questions
Task for tomorrow

1. Find and download
FEMM, start using it!
2. Find and download
Notepad++ , start using
it!
3. Classify electrical
machines, find out
what kind of electrical
machines exists and
how you are able to
group them
?!?
43
What are you expecting

from the course?
Avo R
How would you like to

study the course?
44
11

L1 Intro

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Industrial Electrical Engineering and Automation

Design of Electrical Machines

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2014

Industrial Electrical Engineering and Automation

Industrial Electrical Engineering and Automation

Component and system thinking

Dimensioning and modelling

Design of Electrical Machines

Design of electrical machines in Lund

Design of electrical machines in Lund

Industrial Electrical Engineering and Automation

Industrial Electrical Engineering and Automation

outer core half

Powder core motors simple electric circuit and

Design of Electrical Machines

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Need for electrical actuator

Electrified traction drive

Machine construction overview

As long we going to have electricity there is

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2014

Industrial Electrical Engineering and Automation

Other courses (@IEA)

Industrial Electrical Engineering and Automation

Design of Electrical Machines

Power electronics (and

Design of Electrical Machines

About the course

Industrial Electrical Engineering and Automation

About the course

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2014

Motivation (U): 6 credits

Borrowed from Ice Age I

Easiness (I): I=U/R

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Design of Electrical Machines

objective of this course is to gain experience

L3 calculation method: EC L10 thermal circuits

L13 survey of machines:2

L14 home design

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2014

Industrial Electrical Engineering and Automation

Industrial Electrical Engineering and Automation

Design of Electrical Machines

Introduction to computational techniques and

Design of Electrical Machines

Design task 2007

Industrial Electrical Engineering and Automation

Design and prototyping

Supply 1.5 V battery

T5 LP4 LP4 LP4 T6

Design of Electrical Machines

Design of Electrical Machines

Number of modulator poles, NRP and gear ratio

Number of magnet pole-pairs, NBM

Number of magnet pole-pairs, NAM

Design task 2008