Shark -new motor design concept for energy saving- applied to - VBN

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Abstract The aim of this thesis is to document and promote a relatively new concept of designing electrical machine with improved efficiency, without using more or better material. The concept, called Shark, consists in replacing the cylindrical air gap by a non-linear shape obtained by translating specific geometrical pattern on the longitudinal axis of the electrical machine. This shape modification increases the air gap area and thus the energy conversion, taking place in the machine. Whilst other methods of improving the efficiency consider the use of more and/or better magnetic material and/or optimisation of the magnetic circuit of the radial cross-section of the machine, the proposed method makes use of the longitudinal cross-section of the machine. In spite of a few reports claiming the improvement of the efficiency by applying the optimisation of the longitudinal cross-section, none analysis of various air gap shapes and of their influence on the magnetic performance has been reported. Due to a simple geometry, the Switched Reluctance Machine has been selected for demonstration of the Shark principle. Initially, linear and finite element analysis are considered. They provide the basic knowledge of the manner in which various Shark air gap, having different dimensions, influence the energy conversion in the machine. The saturation mechanisms, specific to each Shark profile are analysed and optimum Shark profile and its dimensions are selected for implementation in a demonstration machine. Due to the lack of quick analysis tools, an analytical model of the Shark Switched Reluctance Machine is also proposed in this thesis. This model is conceived by modifying one of the existing models of cylindrical air gap Switched Reluctance Machines, such as to account for the presence of the Shark profiles in the air gap. The calculations are verified by measurement on two demonstration machines, having cylindrical and Shark air gaps. The measurement proved the theory right and measurement of efficiencies proved that the Shark air gap improves the efficiency of a specified machine by two to four % point with respect to a corresponding cylindrical air gap machine. Furthermore, the two Switched Reluctance Machines are compared with other motor technologies such as Induction Motor and Brushless DC Motor. Analysis of the forces produced in the Shark SRM reveals particular aspects, adding some difficulties to assembly the Shark motor. However, the latest assembly technologies provide solution for a simplified assembly of a Shark machine. Calculations of economical aspects demonstrate a small difference in saving between the Shark Switched Reluctance Motor and the Brushless DC Motor considered in this project. ii
Nomenclature Abbreviations IM standard efficiency Induction Motor SRM Switched Reluctance Motor CSRM Cylindrical air gap Switched Reluctance Motor Shark SRM Shark air gap Switched Reluctance Motor BLDCM HEM BrushLess DC permanent-magnet Motor High Efficiency Motor MEC Magnetic Equivalent Circuit FEA Finite Element Analysis FEM Finite Element Model W co-energy Symbols W conv converted energy ∆ W co-energy variation between the converted energy and the sum of the converted and stored energy W f stored energy P in input power P out output power P Cu conductive loss P Fe core loss EC conversion ratio ph ω number of phases of the machine speed [rpm] S number of strokes N ph number of turns per phase R ph phase resistance I rms the rms value of the phase current µ 0 µ permeability of the free space permeability of the iron ℜ reluctance − permeance u instantaneous voltage iii
Page 1: Shark -new motor design concept for
Page 8 and 9: i instantaneous current Ψ ϕ flux
Page 13 and 14: Table of contents Preface………
Page 15 and 16: Chapter 1 Introduction Chapter 1 In
Page 17 and 18: Chapter 1 Introduction Table 1.1 Fu
Page 19 and 20: Chapter 1 Introduction The magnetic
Page 21 and 22: Chapter 1 Introduction Fig.1.7 Illu
Page 23 and 24: [Wb] O Wf Wconv Fig. 1.9 Conversion
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Page 27 and 28: Chapter 1 Introduction Based on the
Page 29 and 30: Chapter 1 Introduction Chapter 3, F
Page 31 and 32: Chapter 2 Chapter 2 Linear analysis
Page 33 and 34: Chapter 2 Linear analysis of the Sh
Page 35 and 36: ( y) Chapter 2 Linear analysis of t
Page 45 and 46: ksquare Lsquare L0 Chapter 2 Linear
Page 47 and 48: L Chapter 2 Linear analysis of the
Page 49 and 50: inductance gain 4 3.5 3 2.5 2 1.5 C
Page 53 and 54: Chapter 3 Chapter 3 Finite Element
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Chapter 3 Finite Element modeling o
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1 Chapter 3 Finite Element modeling
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flux linkage [Wb] Chapter 3 Finite
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Chapter 4 Chapter 4 Analytical mode
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Chapter 4 Analytical modelling of t
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N s because there are ph Chapter 4
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where where λ ( , θ ) 102 Chapter
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104 energy gain Chapter 4 Analytica
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106 Chapter 4 Analytical modelling
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112 radial force [N] 1900 1800 1700
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114 radial force [N] Chapter 4 Anal
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120 Chapter 5 Measurement and compa
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turn on angle [deg] 128 10 8 6 4 2
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140 copper loss [W] Chapter 5 Measu
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142 d. Power factor Chapter 5 Measu
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144 f. Specific torque Chapter 5 Me
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148 Chapter 6 Manufacturing conside
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158 Chapter 7 Summary and Conclusio
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Appendix A Design data of Induction
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170 Appendix B Definition of the ai
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178 air gap flux density [T] Append
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Appendix C 180 Appendix C Analytica
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A A A w1 w2 w3 182 = w ⋅ v = w =
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Appendix C.4 184 Appendix C Analyti
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Appendix C.5 Permeance ratio 186 Ap
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Appendix D Appendix D.1 188 Appendi
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190 References [16] T.J.E. Miller,
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192 References Conference, , 27 Jul
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194 Volume: 2 , 1996 , Page(s): 715
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196 References [96] F. Abrahamsen,
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188 References
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