Energy Transfer on Rotating Shafts Using PMPrinted Winding Machine

M. Bassetti, F. Braghin, F. Castelli-Dezza, M. F. Iacchetti, M. M. Maglio

Abstract The application of an energy transmission system to a rotating shaft by using a counter-weighted-freewheeled-rotor permanent magnet synchronous machine is analyzed in this paper. This solution avoids slip rings and can generate a power amount which can be significantly higher if compared to other contact-less solutions. The guidelines for the design of such a machine are discussed by considering the maximization of the power transmission. To this purpose, an analytical model of the conversion system including generator, diode bridge rectifier and dc-dc converter is formulated. The results of a case study concerning the application of the system to a rotating shaft are presented and discussed.

Index Terms Design Optimization, DC rectifier modeling, Energy Transmission, PCB winding, PM machine.

NERGY transfer to a rotating system can be very useful in a lot of applications: for instance in telemetry systems for rotating shaft. Brushes and slip rings are the most common and easy solutions in order to transmit power and signals: their operation has been deeply investigated in literature [1]-[3]. Massive wearing, bad contacts and the presence of electrical components in the proximity of the rotating parts should be avoided in order to obtain a more stable and robust energy transfer equipment and to avoid a short maintenance rate time. A contact-less energy transfer system could not only avoid wearing contacts but also could be feasible in particular environment where the access is not easy and contacts avoiding increases safety. To this purpose, also the energy transfer via electromagnetic induction has been largely investigated [4]-[6]. The main drawback of this kind of systems is that the distance between the feeding system and the receiving one should be very short. High frequencies used for generating the magnetic field, can help to counter the low value of the flux density in the free space linking the rotating system but the distances required in order to have a good power transfer remain low. Moreover, using static electrical disposal near the rotating shaft can be very critical as it can be damaged by the shaft vibrations and change its efficiency throughout the operating time. This paper investigates the energy transfer amount of an alternative solution consisting in a small Permanent Magnet Synchronous Generator (PMSG) which is directly mounted on the shaft. In particular, the stator winding is linked to the shaft whereas the rotor permanent magnet array is linked to a rolling bearing. A suitable counter-weight prevents the revolution of the PM array during the shaft rotation. In this way, the whole system can be encapsulated on the shaft
M. Bassetti, F. Braghin and F. Castelli-Dezza are with the Department of Mechanics, Politecnico di Milano, Milan - ITALY (e-mail: francesco.cacstellidezza, marco.bassetti, francesco.braghin@polimi.it). M. F. Iacchetti and M. M. Maglio are with the Departement of Electrical Engineering, Politecnico di Milano, Milan ITALY (e-mail: matteo.iacchetti@polimi.it, matteo.maglio@mail.polimi.it,).

I.

INTRODUCTION

without requiring any external mechanical connections nor constraints. However the small available space makes the design of such a PMSG a challenging task. The aim of this paper is to evaluate the maximum power extraction allowed by this solution and to give some guidelines for the design of such a machine. The paper is structured as follows. Section II describes the features of the system. The magnetic circuit and the winding structure of the PMSG are detailed in Section III. Some geometrical constraints are discussed in Section IV, whereas the electrical parameters of the considered PMSG are deduced as a function of the main geometrical dimensions in section V. In Section VI a steady state model of the electronic conversion system is formulated. In Section VII the machine and the converter steady state equations are merged in an analytical procedure which allows to evaluate the maximum power extraction as a function of the winding data. A case study concerning a low speed shaft is presented and some results are discussed. II. SYSTEM DESCRIPTION

The system the author want to focus on consists of a PMSG built within a bearing structure mounted on the shaft. In this way a small part of the energy involved in the shaft rotation is transferred through the PMSG to the electrical components mounted on the shaft. This solution allows to transfer the energy directly on the rotating parts without using external-linked disposals nearby the shaft. A sketch of the whole structure is shown in Fig. 1. As unique restriction, the shaft axis must be horizontal.
shaft rolling-bearing PMs PCB with windings non-magnetic shell

iron annulus

counter-weight

Fig. 1 Exploded scheme of the PMSG mounted on the shaft

Thanks to the Printed Circuit Board (PCB) technology, it is possible to realize a very compact winding on a disk mounted on the shaft. The bearing internal track is mounted on the shaft and consequently it turns with it. On the external track an iron annulus is placed in order to mount the PMs as shown in Fig. 3. A cup-shaped structure mounted on the external bearing track houses a second iron annulus which provides the magnetic flux path closure. Thanks to a counter-weight placed at the bottom of the enclosure cup (see Fig. 1), the external bearing track together with the magnets are kept still. In this way, the

978-1-4673-0141-1/12/$26.00 2012 IEEE

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system operates as a PMSG whose rotor is at standstill and whose stator is rotating together with the shaft. III. MAGNETIC CIRCUIT AND WINDING STRUCTURE In order to realize a free-wheeled disk which houses the PMs, the external track of a rolling-bearing is used. The author focused on a high diameter shaft for which this application is designed for. The features of the selected bearing are reported in Table I.
TABLE I BEARING FEATURES

conductor of a coil as well as between two adjacent coils. Three groups of q coils are placed in each pole pitch with a suitable shift, in order to obtain a three phase winding. Thus this could be considered as an ordinary three-phase double layer winding with just one conductor per layer and per slot. However, in this case, the slot is a purely fictitious (positional) notion. By considering this analogy, it is useful to indicate with the symbol q the number of coils per polephase. In order to maximize the Electromotive Force (EMF), a full-pitch winding is considered i.e. y = (y = coil span, = pole pitch).
b dq y= Dav dmin
Fig. 4 Winding detail and related geometrical dimensions.

D[mm] D1[mm] d[mm] d1[mm]

Fig. 2 Bearing considered in this case study.

240 213 160 186

Fig. 3 shows a schematic radial section of the machine: the PMs only fill the annulus defined by the bearing external track, and the printed winding is located on a PCB in the area facing the PMs. The external track height is 13 mm. Consequently the area for the printed-winding construction should be restricted to this region.
non-magnetic shell PM hm Dav g PCB l iron annulus

IV. GEOMETRICAL CONSTRAINTS Focusing on the winding construction, two distances dq and dmin can be defined: dq is measured between the external corners of two adjacent parallel strips, whereas dmin is the minimum distance between two adjacent strips. Due to the low voltage levels, the value of dmin is mainly related to the PCB manufacturing process. Since the main geometrical dimensions l and Dav are chosen according to the shaft diameter and to the available space, the stator winding is completely defined by the number of poles p and the coils per pole-phase q. The strip width b can be related to p and q by considering that the total number of turns of the three phase winding must exactly fill the perimeter of the average circumference, i.e.:

printed winding zone

shaft axis

Fig. 3 Schematic radial section of the machine. The external track of the bearing supports the PM array through a suited back-iron ring. The closure of the magnetic path is through a second iron annulus which is connected to the external track by a non-magnetic shell.

The small space available as well as the high mechanical robustness and reliability required suggest the choice of the printed winding technology. This coreless structure allows a more reliable construction, because it guarantees compactness and reduces the total mass of the rotating active parts as well as the centrifugal force. Printed windings are frequently used in hard-disk drives as the slotless armature coil reduces the cogging torque as well as the inertia [7]-[9]. As a drawback, printed windings are characterized by a low volume of copper and then also by a high resistance. Furthermore, the significant equivalent airgap due to the PCB thickness and to the two mechanical air-gaps at the sides, reduces the value of the main inductance and so requires a noticeable PM height in order to achieve a proper flux density level in the air-gap. A scheme of the stator windings is shown in Fig. 4: the diamond shape [7] of the coil turns and the double layer disposition allow to place the active conductors close each other, without overlapping. In fact, the left and the right side of each coil are placed on the top and on the bottom layer respectively. Fig. 4 shows, as an example, the detail of a single coil: suited vias at each internal and external corner establish the electrical connection between the two

3pq

D av b + d min = D av b = sin d min . sin 3pq

(1)

Moreover, the angle is given by:

pl = atan D . av From (1) and (2) the following expression of b arises: b( p, q ) = D av pl sin atan d min . 3pq D av (2)

(3)

The higher are p and q, the smaller is the width b and the higher will be the winding resistance, as will be shown in the next section. The thermal exchange efficiency limits the current density in the strip and then put a constraint on the minimum value of b. Some indicative values for b in PCBs can be found in suited nomographs [8]. However for an accurate evaluation, a thermal model of the machine should be developed. In any case, b cannot be reduced below a minimum value depending on the PCB manufacturing technology.

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V. MACHINE PARAMETER COMPUTATION The PMSG is represented by its steady state equivalent circuit in Fig. 5: E is the rms value of the EMF, R and L are the phase resistance and the synchronous inductance, =2fm p/2 is the electrical circular frequency.

Nph=2qp. In fact, in order to increase the EMF at very low speed, no parallel paths are used. Thus
E = 2 f N ph k w = 2 f m p 2 q k w . (6)

L
2 E sin( t )
Fig. 5 Phase equivalent circuit of the PMSG

where kw is the winding factor for the main harmonic (p poles), f is the electrical frequency and fm the mechanical frequency (f = fm p/2). Since here a full pitch winding is considered, kw reduces to the distribution factor: kw = 1 . 2q sin ( 6q ) (7)

In order to estimate the EMF, the axial flux machine can be handled as a linear machine by considering the circumference at the average diameter Dav [10]. The distribution of the magnetic induction in the air-gap of such equivalent 2D arrangement can be analytically evaluated by formulating the related field problem in terms of vector potential and by using the variable separation technique [11]. The fundamental (p poles) amplitude of the magnetic flux density in the middle of the air-gap can be written as 4 g B r sin a m cosh tanh hm 2 2 , B1 = rev g + cosh g tanh h sinh m 0

The average length of a winding turn is:

l turn = pl l = l sin atan sin D av
1

(8)

Hence, the phase winding resistance is given by R = cu 2pq lturn , sb (9)

(4)

where Br and rev are the residual flux density and the reversible permeability of the permanent magnet material, g is the sum of the mechanical air-gap + PCB thickness, bm is the magnet width, is the pole arc pitch = Dav /p and am = bm /. The computation of the EMF should consider that the flux density distribution crosses a rhombic coil area resulting in the scheme displayed in Fig. 6. Considering the geometry of the winding and the reference axes x and z as in Fig. 6, the fundamental amplitude of the magnetic flux linked with a single turn is given by:
/ 2 l x /

where s is the copper strip thickness. Finally, a rough estimation of the synchronous inductance L can be achieved by considering the air-gap permeance related to an equivalent distributed winding with the same p, q and with straight coil sides along l. In this case, the permeance must be halved in order to take into account the rhombic shape of the actual coils. Thus:

(2 p q )2 l 1 3 0 , g eq = g + 0 hm . (10) kw2 2 rec 2 p g eq

=4

0 0

4 B1 sin x dz dx = B1l , 2

(5)

hence the coefficient 4/2 counts for the winding shape.

Strictly speaking, (10) incorporates only the reaction inductance. A more accurate calculation including the leakage calls for the solution of the magnetic field in the air-gap according to the stator current distribution [12]. This aspect is not considered in this work because the low copper volume in the machine produces a resistance which is, at low speed, remarkably higher than the synchronous reactance. Thus the interaction of the generator with the electronic converter interface will be predominantly affected by the stator resistance. VI. MODEL OF THE ELECTRONIC CONVERTER INTERFACE Fig. 7-a shows the electronic converter interface: the machine is connected to a three-phase diode rectifier whose capacitive DC-bus feeds a switching dc-dc converter. As previously mentioned, a low machine EMF at low speed and a significant winding resistance are expected. On the other hand, the DC/DC converter cannot properly operate if the input voltage decreases below a minimum value around few volts. For these reasons, using an accurate steady state equivalent model of the diode rectifier, including the diode voltage drops, is mandatory in order to evaluate the actual power which can be extracted by the PMSG. Such a model is hereafter deduced.

Fig. 6 Winding turn representation for the flux computation

The field fringing at the external and internal circumference boundaries can be taken into account by a reduction coefficient. The rms value of the phase EMF E is calculated as in an ordinary distributed winding by considering that here the number of turns Nph in series per phase is

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a) i0 v0 PMSG C DC/DC

b) e1 e2 e3

R i1 R i2 R i3

D1

D3

D5

i0 V0

1 2 3
D4 D6 D2

in [1,2] is simply the steady state current which is forced by the line-to-line voltage (e1 e2) (V0+2VD ):
( i1 2/0) () =

1 6 E sin + V0 2VD , [1 , 2 ] . (12) 2R 6

Fig. 7. a): electronic converter interface, b) simplified equivalent model

The DC capacitance is considered to be high enough to maintain a rather constant DC voltage V0, so that the DCbus can be modeled by a voltage generator. However, even under the assumption of an infinite DC-bus capacitance, diode rectifiers are quite difficult to model by a purely analytical approach. A three phase diode rectifier feeding a constant voltage dc-bus exhibits four modes of operation. They are often defined with the number of diodes which are simultaneously conducting in the switching patterns, i.e.: 2/0, 2/3/2/0, 2/3, 3/3 [13],[14]. Steady state analytical models in an explicit form have been formulated only for modes 2/0 and 3/3 [15],[16]. The range of existence of mode 2/3/2/0 is very small [13]. Moreover, even if it should be the most desirable due to the low harmonic content of the ac currents, the operation in mode 3/3 requires a high ac inductance [15]-[16], whereas the ac impedance of the considered machine is dominated by the stator resistance, especially at low speed. Thus in this application at low speed, due to the low value of the machine inductance, only the modes 2/0 and 2/3 are expected. This suggests to neglect the machine inductance in order to deduce a simplified steady state model of the rectifier. The resulting equivalent circuit of the whole system is shown in Fig. 7-b. The diode voltage drops are taken into account by a threshold forward voltage VD and, if the case, by adding a differential resistance RD to the phase resistance R. a) Mode 2/0. An example of the switching pattern in mode 2/0 is shown in Fig. 8 together with some current and voltage waveforms.
Mode 2/0 e1 e2 e1 e3 V0+2VD e1 e2 i0
D1, D4 D1

The DC current i0 consists of the superposition of current pulses like (12) progressively shifted by /3. The angular period of i0 is /3, so that the average DC current I0 (2/0) is:
( 2/0 ) I0

3 =

( 2/0 ) ( ) d = 1

. (13)

3 6 E cos (V 0 + 2V D ) R 2

b) Mode 2/3. Mode 2/3 occurs if the phase voltage E increases enough to bring the angle 1 in (11) below /6, so that the two positive current pulses of the phase 1 overlap each other. Thus, the value EB of the EMF which defines the boundary between modes 2/0 and 2/3 is deduced as follows: (V + 2VD ) 2 = (V0 + 2VD ) . (14) EB = arcsin 0 3 3 6EB Fig. 9 shows three diode conducting patterns in the mode 2/3 and the current and voltage waveforms.
e 1 e 2 e 1 e 3 V0+2VD i1 3
4 2

Mode 2/3 e1 i0 2 e2 e3

R i1 R R

D1

VD 1 2

i0 V0

e1 5
D1, D2

D1, D6 D1, D6 , D2

D6 D1

VD i0 V0

e1 e2

R i1 R R

VD 1

i0 V0

e1 e2

R i1 R R

D1

VD 1 2

R i1 R R

VD 1 2

i0 V0

e3

3
D2

VD

e3

3 VD
D6 D2

VD

i1 1 2
D1, D6

e1

Fig. 9. Waveforms and conducting diode patterns in mode 2/3.

VD

e3

D6

Fig. 8. Waveform and a conducting diode pattern in mode 2/0

For instance, the diode D1 firstly switches on when the voltage across it overcomes the threshold voltage VD. This occurs at the angle 1 given by:
1 =

Let us focus on the switching angle 4 which depicts the boundary between the patterns (D1,D6) and (D1, D6,D2). For [3,4] the solution (12) still holds, and at = 4 the voltage across D2 equals VD so that D2 switches on. This remark allows to deduce the following expression of 4:
V + 2VD (15) + . 4 = arcsin 0 3 2E 3 Furthermore, the symmetry of the switching intervals with respect to /2 and the /3-periodicity of the DC current i0 allows to calculate the angles 5 and 3: 5 = 4 , 3 = 5 / 3 .

(V + 2VD ) . (11) , = arcsin 0 6 6E

Due to the symmetry of the switching pattern, the first pulse of the current i1 extinguishes at the angle 2 = 5/6 . Since the ac inductance L has been neglected, the current i1

(16)

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Finally, the current related to diode pattern (D1, D6, D2) can be calculated by solving the network in Fig. 9 (bottom right).
i1
( 2 / 3)

(6) which is a function of (p, q) thanks to (1)-(5) and (7). A satisfactory design is achieved by maximizing the amount of the extracted power P0 inside the feasible zone.
too narrow strips 4 P0=2 (W) 4 (W) P0=0 mode 2/3 width limit

( ) =

1 2 2 E sin (V 0 + 2V D ) , [4 , 5 ] . (17) R 3

From (12) and (17) the average DC current I0 (2/3) results:

5 4 3 (2/0) ( 2 / 3) (2/3) I0 (18) = i 0 ( ) d + i 0 ( ) d . 4 3 The resulting expression is reported in (19) at the bottom of the page.

q
3

6 (W)

7 (W)

no conduction 2 2/0-2/3 boundary 12 16 20 24 28 2/0

PERFORMANCE EVALUATION AND WINDING DESIGN IN A CASE STUDY By using (13) or (19) depending on the operation mode and by considering also (1)-(9), the converted power P0 can be expressed as a function of the parameters p and q. This way a systematic analysis can be performed by evaluating P0 for every reasonable pair (p, q). The results are summarized in a very meaningful way by drawing the isoP0 contour lines of the surface P0 (p, q) in the plane (p,q). In the same plane, equation (3), together with the constraint on the minimum value of b, is represented by a line which delimits the feasibility zone. This procedure has been applied to a case study concerning the design of a PMSG for energy transfer on a shaft rotating at 180 r/min (fm = 3 Hz). The main geometrical quantities are reported in Table II. The PM material is NeFeB N35H (Br = 1.017 (T), rev / 0 = 1.058 at 80C) The PM height has been set four times the total air-gap including the PCB thickness, in order to achieve a proper flux density in the air-gap. Shottky diodes STPS1L40A (VDmax = 0.42V) for the rectifier as well as a minimum DC voltage V0 = 4V have been considered. A copper resistivity cu = 2.15108 (m) at 80 C has been assumed. VII.
TABLE II. GEOMETRICAL DATA FOR THE CASE STUDY l g hm Dav (mm) (mm) (mm) (mm) 227 13 3.2 am dmin s bmin (mm) (mm) (mm) 0.4 0.105 0.6

p 32

36

40

44

48

Fig. 10. P0 contour lines (continuous), minimum strip width constraint (dashed) (from (3) with bmin=0.6 (mm)), boundary between modes 2/0 and 2/3 (dash-dot) for the case study whose data are reported in Table II. The shaft rotates at 180 (r/min) (fm =3 Hz), diode voltage drop VD = 0.42 (V).

Of course the winding feasibility also requires p integer and even and q integer. For instance, a satisfactory design can be achieved by choosing q =3 and p =34. In fact, lower values of p are more desirable in order to limit the electrical frequency when the shaft speed increases. With this choice, (corresponding to the dot marked in Fig. 10) the transferred dc power, is P0 = 6.19 W and the other electrical quantities are reported in Table III. In particular, the phase reactance at the frequency fm p/2 = 48 Hz is: X = 0.042 , i.e. X R/30. This justifies the approximation L=0 which has been invoked in the steady state model of the bridge rectifier.
TABLE III. FINAL ELECTRICAL PARAMETERS FOR THE CASE STUDY p 34 q 3 f (Hz) 48 E (V) R L P0 () (mH) (W)

3.619 1.245 0.130 6.19

12.8 0.75

Fig. 10 shows the resulting P0 contour lines in the plane (p,q) together with the limit line due to (3) and bmin = 0.6 (mm). Furthermore, also the boundary line (dash-dot) between modes 2/0 and 2/3 is traced: this is simply the contour line related to (14-2), where EB must be replaced by

Here the diode characteristic has been simply modeled by a constant voltage drop, however a differential resistance could be also lumped in R. Anyway, the diode voltage drop have an enormous impact on the performances of the whole system. This is confirmed by Fig. 11, which reports the P0 contour lines in the case VD = 1.1 (V) (VDmax of the diode 1N4002). Notice that the maximum power is roughly halved with respect to the previous case. In particular, with the choice p=34 and q=3, it results P0 = 3.72 (W).

(2/3) I0 =

3 V0 + 2V D 3 2E ( 4 5 4 2 3 ) 2 cos 3 + 6 cos 4 + 6 + cos 4 cos 5 6 R

(19)

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too narrow strips 4 P0=0 P0=2 (W) mode 2/3 4 (W) no conduction 2/0 2 2/0-2/3 boundary 12 16 20 24 28 width limit

q
3

converter must be properly controlled in order to limit the extracted power to the required value. Moreover at high speed, and so at high frequency, the leakage inductance is more relevant and therefore a more accurate computation has to be thought. These aspects will be examined in a future work. VIII. CONCLUSIONS A contact-less energy transfer system on a rotating shaft has been proposed in this paper. The system is based on a synchronous permanent magnet generator mounted on the shaft. The stator consists of a printed winding connected to the shaft and the rotor is free-wheeled and counterweighted so that no mechanical constraints between the rotor and any structure outside the shaft are required. The generator feeds a diode rectifier and a DC-DC converter. The performances of such a system have been investigated and some design guidelines have been discussed in a case study. In particular the transfer power capability has been evaluated by an approximate steady state model of the diode rectifier including also the voltage drops across the diodes. The results show that even when the shaft is rotating at low speed, the proposed system can transfer a fair amount of power. IX. REFERENCES
G. Roberts, P. Hadfield, M.E. Humphries, F. Bauder, J.N:G. Izquierdo, "Design and evaluation of the power and data contactless transfer device," Aerospace Conference, 1997. Proceedings., IEEE , vol.3, no., pp.523-533 vol.3, 1-8 Feb 1997. [2] L. Brown, D. Kuhlmann-Wilsdorf, W. Jesser, "Testing and Evaluation of Metal Fiber Brush Operation on Slip Rings and Commutators," IEEE Trans. on Components and Packaging Technologies , vol.31, no.2, pp.485-494, June 2008 [3] N. Morita, T. Ueno, T. Otaka, M. Arata, "Comparison of Brush Dynamic Operation Characterisitics for Turbine Generator Steel Collector Ring," Electrical contacts - 2007, the 53rd ieee holm conference on , vol., no., pp.205-210, 16-19 Sept. 2007. [4] C. Byungcho, N. Jaehyun, C. Honnyong, A. Taeyoung, C. Seungwon, Design and implementation of low-profile contactless battery charger using planar printed circuit board windings as energy transfer device, IEEE Trans. Ind. Electron., vol. 51, no. 1, pp. 140147, Feb. 2004. [5] J. de Boeij, E. Lomonova, J. Duarte, A. Vandenput, "Contactless Energy Transfer to a Moving Actuator," Industry Applications Conference, 2006. 41st IAS Annual Meeting. Conference Record of the 2006 IEEE , vol.4, no., pp.2020-2025, 8-12 Oct. 2006. [6] T. Isobe, K. Kobayashi, K. Wakasugi, R. Shimada, "Efficiency improvement of contactless energy transfer systems using series compensation device named MERS," Power Electronics and Applications (EPE 2011), Proceedings of the 2011-14th European Conference on , vol., no., pp.1-10, Aug. 30 2011-Sept. 1 2011. [7] Mi-Ching Tsai; Liang-Yi Hsu; , "Design of a Miniature Axial-Flux Spindle Motor With Rhomboidal PCB Winding," Magnetics, IEEE Transactions on , vol.42, no.10, pp.3488-3490, Oct. 2006 [8] T.S. Low, M.A. Jabbar, T.S. Tan, "Design aspects and performance of a slotless PM motor for hard disk drives," Industry Applications Magazine, IEEE , vol.3, no.6, pp.43-51, Nov/Dec 1997. [9] G.H. Jang, J.H. Chang, "Development of an axial-gap spindle motor for computer hard disk drives using PCB winding and dual air gaps," Magnetics, IEEE Transactions on , vol.38, no.5, pp. 3297- 3299, Sep 2002. [10] A. Parviainen, M. Niemela, J. Pyronen, Modeling of axial flux permanent-magnet machines, IEEE Trans. Ind. Appl., vol.40, no. 5, pp. 1333-1340, Sept./Oct. 2004. [11] M-J. Chung, D. G. Gweon, Modeling of the armature slotting effect in the magnetic field distribution of a linear permanent magnet motor, in Arch. Elektrotech., 202, vol. 84, pp. 101-108. [12] J.H. Davis, "Inductances of Printed Circuit Windings," Power Apparatus and Systems, IEEE Transactions on , vol.PAS-93, no.4, pp.1076-1082, July 1974. [1]

p 32

36

40

44

48

Fig. 11. P0 contour lines (continuous), minimum strip width constraint (dashed) (with bmin=0.6 (mm)), boundary between modes 2/0 and 2/3 (dash-dot) for the case study whose data are reported in Table II. The shaft rotates at 180 (r/min) (fm =3 Hz), diode voltage drop VD = 1.1 (V).

Several simulations have been performed by Simulink (SimPower System Toolbox) in order to validate the model in section VI: the power P0 is predicted without any noticeable error. Moreover, even if the model of the diode rectifier neglects the machine inductance, it still predicts quite accurate results with a small ac inductance (error in P0 less than 5% if the reactance related to L is less than 0.33R). Fig. 12 shows the waveforms of the EMF e1, of the ac current i1 and of the dc current i0 as obtained from a simulation with Simulink . The simulation setup is settled according to the data given in Table III and with VD = 0.42 (V). The simulation confirms that the rectifier is operating in the mode 2/3 and predicts a dc transferred power P0 (sim) =6.12 W. Thus the percentage error between the values of the transferred power obtained by simulation and by the analytical model is |P0 (sim) P0 |/P0 (sim) = 1.1%.
6 4 2 0 -2 -4

e1 (V) i0 (A) i1 (A)

time (ms)
-6 0 5 10 15 20
Fig. 12. Simulation results (Simulink - SimPower System Toolbox) of the rectifier operation with the data in table III. As predicted by the analytical model the rectifier is working in the mode 2/3 and the transferred power is 6.12 W.

A simulation with the same data except for VD = 1.1 gives P0 (sim) = 3.71 (W) which is still very close to the analytical value P0 = 3.72 (W). The preliminary design discussed in this work has been based on the maximization of the extracted power at the minimum speed. Of course, the complete design also requires the evaluation of the performances of the machine in the operation above the minimum speed. Since the internal EMF linearly increases with the speed, the dc-dc

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[13] M. Hancock, Rectifier action with constant load voltage: Infinite capacitance condition, Proc. Inst. Elect. Eng., London 1973, vol. 120, no. 12, pp. 1529-1530. [14] K. L. Lian, B. K. Perkins, P.W. Lehn, Harmonic analysis of a threephase diode rectifier based on sampled-data model, IEEE Trans. Power Del., Vol. 23, No 2, Apr. 2008, pp. 1088-1096. [15] V. Caliskan, D. J. Perreault, T. M. Jahns, J. G. Kassakian, Analysis of three-phase rectifiers with constant-voltage loads, IEEE Trans. Circuits Syst. I, Vol. 50, No 9, Sep. 2003, pp. 1220, 1226. [16] J. A. M. Bleijs, Continuous conduction mode operation of threephase diode bridge rectifier with constant load voltage,, IEE Proc. Electr. Power Appl., vol. 152, no. 2, Mar. 2005, pp. 359-368.

Francesco Castelli-Dezza (M94) received the M.Sc. and Ph.D. degrees in electrical engineering from the Politecnico di Milano, Milan, Italy, in 1986 and 1990, respectively. Currently, he is an Associate Professor with the Department of Mechanical Engineering, Politecnico di Milano. His actual fields of interest are studies on dynamic behavior of electrical machines, on electrical drive control design, and on power electronics for energy flow management. Matteo Felice Iacchetti (M10), received the Ph.D. degree in electrical engineering from the Politecnico di Milano, Milano, Italy, in 2008. Currently he occupies a Post-Doc position at the Department of Electrical Engineering - Politecnico di Milano. His interests are design, modeling and control of electrical machines. Matteo M. Maglio (S11), received the M.S. degree from the Politecnico di Milano, Milan, Italy, in 2009. He is currently working towards the Ph.D. degree with Politecnico di Milano, Milan, Italy. During his thesis work for the M.S. degree, he cooperate with the University of South Carolina, Columbia, USA and with RWTH Aachen University, Aachen, Germany. His research activity mainly concerns the electrical machines design and the diagnostic tools for mechanical systems.

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BIOGRAPHIES

Marco Bassetti received the M.S. degree in electrical engineering from the Politecnico di Milano, Milano, Italy, in 2006. Currently he is an assistant professor at the Department of Mechanical Engineering Politecnico di Milano. His interests are wireless technology, embedded data acquisition systems and energy harvesting. Francesco Braghin received the M.S. in Mechanical Engineering in 1997 and the Ph.D. in Applied Mechanics at Politecnico di Milano, Milan, Italy in 2001. Currently he is an Associate Professor with the Department of Mechanical Engineering, Politecnico di Milano. His research work mainly focuses on tire-road and wheel-rail interaction, on road and rail vehicles' dynamics. Moreover his research activity deals with MEMS both with the dynamics of microcomponents and with their control. In these research fields prof. Braghin has published more than 150 papers, mainly on international journals and proceedings.

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