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I. INTRODUCTION
For the past several years permanent magnet (PM)
synchronous machines have found wide applications in electric
vehicles and hybrid electric vehicles (EV/HEVs) [1 to 5]. To
fulfil the targets regarding the high torque density, operation
speed, and efficiency, low rotor losses, thermal aspects, and
noise and vibrations problems, many manufacturers select
complex distributed winding with high number of coils per
pole for their machine designs such as in Toyota Prius-2010, or
BMW-i3 [6, 7]. The main merit on this winding type is the
high quality of the magneto motive force (MMF) and the
resulting air-gap flux density generated by it. Generally, for the
distributed windings, increasing the number of coils per pole
improves the winding MMF waveform quality, and this results
in solving many problems concerning the rotor losses, rotor
heating, and noise and vibrations, however, on the other side
the winding complexity and manufacturing process also
increases simultaneously. Further, this winding type is
characterized also with several other disadvantages such as
overlapping coils, large end-winding length, low slot filling
factor and so one [8].
A typical machine example for HEV application is
presented in Fig. 1a). The outer diameter of the machine is
260mm, active length is 50mm, and the total length is 160mm
[6]. Fig. 1b) illustrates the axial cross-section view of the
machine. It can be seen here that, the core axial length
represents about 1/3 of the total machine length, while for the
Dieter Gerling
Institute of Electrical Drives
Universitaet der Bundeswehr Muenchen
D-85577 Neubiberg, Germany
dieter.gerling@unibw.de
end-winding it is required about 2/3 of the total machine
length. Since, only the machine active length is responsible for
the effective torque and power, the end-winding components in
the end regions generate only Ohmic losses and other parasitic
effects. Of course, if the available axial space is even shorter,
then the active length of the machine becomes shorter and the
power density of the machine decreases significantly. An
alternative solution is to use tooth concentrated winding which
have short end-winding length, however, as results of high
MMF harmonics this winding type generate high rotor losses,
noise and vibrations, and also rotor heating problems [8, 9],
and, up to now this winding type is excluded for such
application as main traction drive machine. Therefore, to
overcome the drawbacks and problems with the distributed
windings concerning to the Ohmic losses, manufacturing
complexity, and packaging, however, simultaneously to use the
merits of this winding type concerning the MMF waveform
quality, in this paper we present a novel stator cage winding
for the electric machines that is proposed in [11]. The new
winding type is characterized with a simple construction and
manufacturing, extremely short end winding length, high
quality MMF waveform, high winding factor for the
fundamental wave, and greater fault tolerance. Thanks the
high quality of the MMF distribution this winding type is
suitable for different machine types. Considering the main
drawbacks of PM machines such as, cost of the permanent
magnets, risk of demagnetization, additional control effort, and
so on, the main objective of this work was to present a new
asynchronous machine (ASM) with stator cage winding as an
a)
b)
Fig. 1. a). PM machine with distributed winding, b). Axial cross-section view
2
uk = U cos t p (k 1)
+ u , k
Q
S
(1)
QS
p
(2)
Stator core
End-connection
Ring
End-connection
Ring
Phase
Windings
a)
a)
b)
Fig. 2. a). New stator core with the winding, b). Stator cage winding
b)
Fig. 4. New stator construction; a). Massive conductors inserted in the stator
slots, b). Die casting of the stator winding
1.5
Conv. Winding
New Winding
a)
MMF [ p.u. ]
1
0.5
0
-0.5
-1
a)
b)
Fig. 6. Heat flux path; a). Conventional stator, b). New stator
-1.5
0
2
3
4
theta [rad. degree]
Conv. Winding
New Winding
1
MMF [ p.u. ]
0.8
0.6
0.4
b)
0.2
0
0
10
15
20
Space Harmonics
Fig. 5. Comparison of MMF characteristics; a). MMF distribution, b). MMF
space harmonics
Fig. 7. New cooling method with cooling channel mounted on the end-ring
lateral side
2
iS , k = I cos t p (k 1)
QS
a)
0.5
0
-0.5
-1
-1.5
0
2
3
4
theta [rad. degree]
1.5
1
b)
0.5
0
-0.5
-1
-1.5
0
2
3
4
theta [rad. degree]
(3)
MMF [ p.u. ]
1.5
MMF [ p.u. ]
2
iS , k = I C cos t p ( k 1)
Q
=1
S
(4)
MMF [ p.u. ]
1
0
-1
MMF [ p.u. ]
2
3
4
theta [rad. degree]
Copper
Aluminium
Copper
Aluminium
UDC
375 V
24 V
Maximal torque
600 Nm
600 Nm
Maximal speed
13000 rpm
13000 rpm
0.5
0
0
10
15
Space Harmonics
20
Tesla ASM
ISCAD ASM
speed [rpm]
5300
5300
Torque [Nm]
600
600
21,4
8,6
14,9
1,2
1,14
efficiency [%]
89,8
94,7
A. Electromagnetic Analysis
The maximal load operation point (600Nm&5300rpm) is
selected for comparison of both machine types. The following
analysis is performed using 2D finite elements methods
(FEM). During determination of Ohmic losses for the
ISCAD-ASM, the skin and proximity effect in the stator bars is
considered in the FE model. Table-II compares the machine
losses and efficiency under the maximal operation load
condition. Considering the Ohmic losses which represent the
dominant losses for the both machines, it can be seen here that
with the new ISCAD-ASM design these losses are reduced for
about 50% even Alumminium material is used for the stator
and rotor cage. It is important to point out that, the main factor
for loss reduction in the new machine design is the efficient
use of the total machine length and also the high fill factor
(100%) for the stator winding. Further simulation results for
the considered load condition are given in following Figs. 10
and 11.
a)
b)
Fig. 10. Flux density distribution und the maximal load; a). ISCAD-ASM,
b). Tesla model-S ASM
ISCAD ASM
Outer diameter
Specification
253 mm
253 mm
270 mm
270 mm
Active length
154 mm
250 mm
Air-gap length
0,5 mm
0,5 mm
Number of poles
60
60
74
73
Fig. 11. Torque response for the maximal load for the ISCAD-ASM
B. Thermal Analysis
During the thermal analysis, the both machines are
assumed to be mounted inside a water cooled jacked with the
[C]
REFERENCES
V. CONCLUSIONS
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
[14]
a)
b)
Fig. 12. Temperature rise in the stator and rotor winding for the maximal load