International Journal of Energy and Power Engineering Research 1 (2013) 24-31
PERFORMANCES COMPARISON OF 24S-10P AND 24S-14P FIELD EXCITATION FLUX SWITCHING MACHINE (FEFSM) WITH SINGLE DC-COIL POLARITY
E. Sulaiman 1 , M. F. M. Teridi 1 , Z. A. Husin 1 , M. Z. Ahmad 1 and T. Kosaka 2
1 Faculty of Electrical and Electronic Eng. Universiti Tun Hussein Onn Malaysia, Bt. Pahat, 86400, Johor, MALAYSIA 2 Dept. of Electrical and Computer Engineering, Nagoya Institute of Technology (NIT), Nagoya, JAPAN Email: erwan@uthm.edu.my, zarafi@uthm.edu.my and kosaka@nitech.ac.jp
ABSTRACT Flux switching machines (FSMs) that comprise of all flux sources in the stator have been developed in recent years due to their advantage of single robust rotor structure suitable for high speed applications. They can be classified into three groups that are permanent magnet (PM) FSM, field excitation (FE) FSM, and hybrid excitation (HE) FSM. Both PMFSM and FEFSM has only PM and field excitation coil (FEC), respectively as their primary flux sources, while HEFSM combines both PM and FECs. FEFSM offers advantages of low cost, simple construction and variable flux control capabilities suitable for various performances. In this paper, design study and flux interaction analysis of 24S-10P and 24S-14P FEFSM with one-way FEC winding are presented. Initially, design procedures of the FEFSM including parts drawing, materials and conditions settings, and properties settings are explained. Then, coil arrangement tests are examined to affirm the machine operating principle and position of each armature coil phase. Finally, the flux interaction between DC FEC and armature coil, FEC flux capabilities at various current conditionand initial torque are also investigated.
Keywords: Field excitation flux switching machine, DC field excitation coil, single FEC polarity
1. INTRODUCTION The original concept of flux switching machine (FSM) has been founded in the mid-1950s. A permanent magnet (PM) FSM that is permanent magnet single-phase limited angle actuator, having 4 stator slots and 4 rotor poles (4S-4P) has been improved (Laws, 1952), and it has been extended to a single phase generator with 4 stator slots, and 4or 6 rotor poles (4S-4/6P) (Rauch and Johnson, 1955). Over the last ten years, many new FSMs topologies have been developed for various applications, ranging from low cost domestic appliances, automotive, wind power and etc. (Hoang et al. 2007). Figure 1 illustrates the classifications of FSMs which can be categorized into three groups that are permanent magnet (PM) FSMs, field excitation (FE) FSMs, and hybrid excitation (HE) FSMs. Both PMFSMs and FEFSMs have only PM and field excitation coil (FEC), respectively as their main flux sources, while HEFSMs combines both PM and FECs (Sulaiman et al. 2011, Sulaiman et al. 2012). Among all FSMs, the FEFSM offers advantages of magnet-less machine, low cost, simple construction, and variable flux control capabilities suitable for various performances. Moreover, to form the FEFSMs, the PM excitation on the stator of conventional PMFSMs can be easily replaced by DC FEC as shown in Figures 2 to 5. In other words, the FEFSMs are a form of salient-rotor reluctance machine, combination of inductor generator principles and SRMs (Walker 1942, Miller 1993). The idea of the FEFSM relates changing the polarity of the flux linking with the armature coil windings, with respect to the rotor position. Early examples of single-phase 4S-2P FEFSM that applies with a DC FEC on the stator, a toothed- rotor structure and full-pitched windings on the stator is shown in Figure 2(Pollock and Wallance 1999, Fan et al. 2006). From the figure, it is clear that both armature coil and FEC windings are set in the stator which overlapped each other. The viability of this design has been demonstrated in assorted applications requiring high power densities with a good level of durability (Pollock et al. 2003).
Another example of single-phase FEFSM is shown in Figure 3 with eight stator slots and four rotor poles, 8S-4P FEFSM (Bangura 2006). From the figure, the FEC winding in four of the slots is supplied with direct current to establish four pole magnetic fields. The other four slots contain an armature winding that also pitched over two stator teeth. The direction of the current in the armature winding determines a set of four stator poles carries flux and also the position of the rotor. Since the FEC is excited by unipolar current, it can be directly connected in parallel or in series with the dc-supply of power converter which feeds the bipolar current into the armature winding. The design principle is explained in (Bangura 2006), and the single- phase 8S-4P FEFSM has achieved higher output power density and much higher efficiency when compared with the induction machine (IM). However, the 1-phase FEFSMs suffer with problems of low starting torque, large torque ripple, fixed rotating direction, and overlapped windings between armature coil and FEC.
Figure 3: 1-phase 8S-4P FEFSM
To improve the performances, a 3-phase 12S-8P with segmental rotor and 12S-10P FEFSMs have been developed as shown in Figures 4 and 5, respectively. For 12S-8P FEFSM, segmental rotor is used to supply a clear magnetic path for conveying the field flux to adjacent stator armature coil following the rotor rotation. This design gives shorter end windings than the toothed-rotor structure which is associated with overlapping coils. This arrangement uses less conductor materials give significant gains and also can improve the overall machine efficiency (Zulu et al. 2010) Furthermore, the 24S-10P FEFSM is redesigned from the 24S-10P PMFSM in which the PM is removed from the stator and half of the armature coil slots in the upper layer are placed with the FEC windings (Chen et al. 2010). In contrast with alternate flux polarities from adjacent PM of 24S-10P PMFSM, the FEC in this machine is set up with a sole polarity of DC current source. Since the adjacent DC FECs are isolated as shown in red circle in Figure 5, the total flux generation is limited and thus decreasing the performances.
2. METHODOLOGY/EXPERIMENTAL SETUP In this paper, design study and flux interaction between FEC and armature coil of the 24S-10P FEFSM and 24S-14P FEFSM are investigated. The machines configurations and dimensions are illustrated in Figure 6, Figure 7 and Table 1, respectively. From both structures, it is clear that the FEFSMs are having 24 stator teeth including 12alternate FEC slots and 12 armature coil slots around the stator. The only difference is at the number of rotor pole. 24S-10P FEFSM possesses 10 rotor poles while 24S-14P FEFSM possesses 14 rotor poles. The DC FEC is wound in counter-clockwise polarity and the three phase armature coils are arranged in clockwise polarity and both are arranged in between. The advantages of this machine over dual FEC adjacent windings are easy manufacturing, low copper loss, less flux leakage and have high degree of design freedom of FEC. Commercial FEA package, JMAG-Designer ver.11.0, released by Japan Research Institute (JRI) is used as 2D- FEA solver for this designs.Firstly, the rotor, stator, armature coil and FEC of the proposed FEFSMs model are drawn by using JMAG Editor. Then, the materials, conditions, circuits and properties of the machines are set in JMAG Designer. The design process of both parts is demonstrated in Figure 8. Furthermore, coil arrangement tests are examined to
Figure 4: 3-phase 12S-8P segmental rotors
Figure 5: 3-phase 24S-10P FEFSM
A1 C1 B1 FE-1 FE-2 FE-1 A1 C1 B1 FE-2 FE-1 FE-2 A1 C1 B1 A1 C1 B1 A1 C1 B1 A1 C1 B1 FE FE FE FE FE FE 26
validate the operating principle and to set the position of each armature coil phase. Finally, the flux interaction between DC FEC and armature coil, FEC flux capabilities at various current condition and initial torque of both design are also investigated.
Figure 6: 24S-10P FEFSM
Figure 7: 24S-14P FEFSM
3. RESULTS AND DISSCUSSION 3.1 Coil Arrangement Test Coil arrangement tests are examined in each armature coil separately to validate the operating principle and to set the position of each armature coil phase. The resulting flux linkages are compared and the armature coil phases are defined according to the conventional three- phase system. Figures 9 to 13 illustrate FEFSMs flux linkage of all coils at separate phase and this proof that both machines successfully achieved the principles to get 3-phase flux linkage. The three-phase flux linkage is defined as U, V, and W, respectively.
(a) (b) Figure 8: Design methodology of the proposed FEFSM (a) Parts drawing (b) Conditions setting
Table 1: 24S-10P and 24S-14P FEFSM Parameters
Parameters 24S-10P 24S-14P Number of phase 3 3 Number of stator poles 24 24 Number of rotor poles 10 14 Outer radius of stator (mm) 132 132 Stack length (mm) 70 70 Air gap length (mm) 0.8 0.8 Inner radius of stator (mm) 97.2 97.2 Stator tooth top width (mm) 14 14 Stator tooth bottom width (mm) 14 14 Stator yoke thickness (mm) 8 8 Rotor tooth width (mm) 20 20 Number of phase turns 8 8 Number of DC winding turns 60 60
3.2 FEC Flux Linkage at Various FEC Current Densities The FEC flux linkage at various FEC current densities is also investigated to verify the flux characteristics. The FEC flux linkage for both FEFSM at U phase versus electric cycle is plotted as demonstrates in the Figure 11 and Figure 12 for 24S-10P and 24S-14P FEFSM respectively. From the JE characteristic, 24S-10P and 24S-14P FEFSM have same pattern but they have slightly different values. Both flux increases to some values then constant and slightly decrease in the end. Start Rotor Stator Armature coil FEC End Start Set materials Set the condition Set the circuits Set the study properties Simulate End 27
Figure 9: Flux linkage of 24S-10P phase U, V and W Figure 10: Flux linkage of 24S-14P phase U, V and W This is because the material used for FEC, copper, has reached its limit to produce flux. Furthermore, inside the machines, there are some fluxes that flow in opposite direction and result in cancelling each other. Apart from that when the FEC current density is higher more heat will be generated in the copper hence create more loss.
Figure 11: U phase flux linkage at various FEC current for 24S-10P FEFSM
Figure 12: U phase flux linkage at various FEC current for 24S-14P FEFSM
Figure 13: Combination of maximum U phase flux at various FEC current for 24S-10P and 24S-14P FEFSM
Figure 13 shows a combination of maximum U phase flux for both FEFSM at various FEC current. From the graph, 24S-14P flux is higher than 24S-10P because the volume of 14 pole rotor is larger than 10 pole rotor. The 14 pole rotor feature generates less flux in consequence of longer flux linkage and loss of flux to surrounding.
3.3 Armature Flux Linkage at Various Armature Current Densities The armature coil flux linkage at various armature current densities is investigated as well in order to verify the flux characteristics. The armature flux linkage at U phase versus electric cycle for both models are depicted in Figures 14 to 15, while Figure 16 shows maximum U phase flux at various armatures current densities for combination of 24S-10P and 24S-10P FEFSM. It is clear that both armature coil flux linkage are increased with the increase of armature current density. In addition, increment of the armature flux linkage -0.05 -0.04 -0.03 -0.02 -0.01 0 0.01 0.02 0.03 0.04 0.05 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] U Flux V Flux W Flux -0.04 -0.03 -0.02 -0.01 0 0.01 0.02 0.03 0.04 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] U Flux V Flux W Flux -0.06 -0.04 -0.02 0 0.02 0.04 0.06 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] JE=5 JE=10 JE=15 JE=20 JE=25 JE=30 -0.06 -0.04 -0.02 0.00 0.02 0.04 0.06 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] JE=5 JE=10 JE=15 JE=20 JE=25 JE=30 0 0.01 0.02 0.03 0.04 0.05 0 5 10 15 20 25 30 Flux [Wb] JE [A/mm 2 ] Maximum U Flux, 24S-10P Maximum U Flux, 24S-14P 28
with increasing armature current makes the machine possible to be applied for high current density condition, without reducing the performances. This is a great advantage of the FEFSM with variable flux capabilities suitable for wide range applications.
Figure 14: U phase armature coil flux for 24S-10P FEFSM
Figure 15: U phase armature coil flux for 24S-14P FEFSM
3.4 Flux I nteraction of FEC and Armature Coil at J E of 30A/mm 2 and J A of 30A/mm 2
Interaction between FEC and armature flux characteristic at JE equal 30A/mm 2 and JA equal 30A/mm 2 is investigated to observe the resulting flux between them. Figure 20 and Figure 21 show the resulting flux for 24S- 10P FEFSM and 24S-14P FEFSM respectively. The resultant flux proved the principle of rotor rotation and the interaction between them also create angle shifting. The resulting flux follows armature flux phase but with 15 shift of angle for 24S-10P FEFSM and 20 for 24S- 14P FEFSM.
Figure 16 Maximum U phase flux at various armatures for 24S-10P and 24S-10P FEFSM
Figure 17: Resultant flux for 24Slot-10Pole FEFSM
Figure 18: Resultant flux for 24Slot-14Pole FEFSM
3.5 I nstantaneous Torque Characteristic The instantaneous torque versus electric cycle characteristic of the proposed FEFSMs is depicted in Figure 22 for 24S- 10P and Figure 23 for 24S-14P. Cogging torque is -0.10 -0.06 -0.02 0.02 0.06 0.10 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] JA=5 JA=10 JA=15 JA=20 JA=25 JA=30 -0.10 -0.06 -0.02 0.02 0.06 0.10 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] JA=5 JA=10 JA=15 JA=20 JA=25 JA=30 0 0.02 0.04 0.06 0.08 0.1 0 5 10 15 20 25 30 Flux [Wb] JA [A/mm 2 ] Maximum Armature U Flux, 24S-14P Maximum Armature U Flux, 24S-10P -0.12 -0.08 -0.04 0 0.04 0.08 0.12 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] JE=30,JA=0 JE=0,JA=30 JE=30,JA=30 -0.10 -0.06 -0.02 0.02 0.06 0.10 0 30 60 90 120 150 180 210 240 270 300 330 360 Flux [Wb] Electric Cycle [] JE=30, JA=0 JE=0, JA=30 JE=30, JA=30 29
undesirable because the larger value of cogging torque is lead to larger jerkiness. Peak to peak value of cogging torque at JE equal to 30 A/mm 2 and JA equal 30A/mm 2 for 24S-10P is 15.4Nm while for 24S-14P FEFSM is 7.5Nm. Thus, 24S-14P FEFSM has lower torque ripple and low jerks when compared to 24S- 10P FEFSM. Cogging torque for 24S-14P is less than the 24S-10P FEFSM due to the shorter distance interaction between FEC and rotor pole. The torque profile and average instantaneous torque at both JE and JA equal to 30 A/mm 2 for 24S-10P is represented in Figure 19 while 24S-14P FEFSM represented in Figure 20. The average torque for 24S-10P is 204 Nm but 24S-14P FEFSM gives 201 Nm average. The average torque for 24S- 10P is slightly greater than 24S-14P.
Figure 19: Cogging torque for 24S-10P FEFSM at JE of 30 A/mm 2 and JA of 30A/mm 2
Figure 20: Cogging torque for 24S-14P FEFSM Figure 21: Torque profile and average torque for 24S- 10P FEFSM
Figure 22: Torque profile and average torque for 24S- 14P FEFSM
3.6 Torque Vs J A at Various J E Torque versus JA is analyzed to observe the torque characteristic at various JE. Figure 23 and Figure 24 show torque versus JA for 24S-10P and 24S-14P FEFSM respectively. The figures proved that the higher the values of JE and JA, simultaneously, the higher the values of torque produced. However the value of torque is maintained after some values because of limitation of flux production due to many factors that have discussed before. Figure 25 displayed combination of FEC and armature flux for 24S-10P and 24S-14P FEFSM. The value of torque is closely associated with generation of flux. From the graph, although, 24S-14P has more poles than 24S-10P FEFSM the torque produced is about the same. This is because the resultant flux produced by flux interaction of 24S-14P FEFSM is approximately equal to resultant flux produced by 24S-10P FEFSM. -10 -8 -6 -4 -2 0 2 4 6 8 0 30 60 90 120 150 180 210 240 270 300 330 360 Torque [Nm] Electric Cycle [] -4 -3 -2 -1 0 1 2 3 4 0 30 60 90 120 150 180 210 240 270 300 330 360 Torque [Nm] Electric Cycle [] 180 190 200 210 220 230 240 0 30 60 90 120 150 180 210 240 270 300 330 360 Torque [Nm] Electric Cycle [] Torque Profile Average Torque 185 190 195 200 205 210 215 0 30 60 90 120 150 180 210 240 270 300 330 360 Torque [Nm] Electric Cycle [] Torque Profile Average Torque 30
Figure 23: Torque vs. JA at various JE for 12S-10P FEFSM
Figure 24: Torque vs. JA at various JE for 12S-14P FEFSM
3.7: Power versus J A at Various J E Power versus JA at various JE is observed as illustrated in Figure 26 and Figure 27 for 24S-10P and 24S-14P FEFSM respectively. The highest power generated is 27.7 kW for 24S-10P and 25.3 kW for 24S-14P FEFSM. The graph of power is identical to torque graph because value of power is proportional to value of torque. The increasing of torque leads to increasing power.
Figure 25: Combination of maximum U flux for both FEC and armature flux for 26S-10P and 24S-14P FEFSM
Figure 26: Power for 24S-10P FEFSM
Figure 27: Power for 24S-14P FEFSM
0 50 100 150 200 250 0 5 10 15 20 25 30 Torque [Nm] JE [A/mm 2 ] JA 5 10 15 20 25 30 0 50 100 150 200 250 0 5 10 15 20 25 30 Torque [Nm] JE [A/mm 2 ] JA 5 10 15 20 25 30 0 0.02 0.04 0.06 0.08 0.1 0 5 10 15 20 25 30 Flux [Wb] Current Density [ A/mm 2 ] JA (24S-14P) JA (24S-10P) JE (24S-10P) JE (24S-14P) 0 5 10 15 20 25 30 0 5 10 15 20 25 30 Power [kW] JE [A/mm 2 ] JA 5 10 15 20 25 30 0 5 10 15 20 25 30 0 5 10 15 20 25 30 Power [kW] JE [A/mm 2 ] JA 5 10 15 20 25 30 31
4. CONCLUSION In this paper, design study of 24S-10P FEFSM and 24S-14P with single DC FEC polarity has been investigated. The procedure to design the FEFSMs has been clearly explained. The coil arrangement test for both models have been examined to validate each armature coil phase and to proof the operating principle of the machines. The performances of the FEFSM such as flux capability, initial and final torque and power have been investigated. The machine has very simple configuration yet no permanent magnet and thus, it can be expected as very low cost machine. Both proposed models have their each distinctive performance. However there is no significant difference between both 24S-10P and 24S-14P FEFSM in performance aspect. Only the design configuration, 24S-10P FEFSM is used less rotor pole number results in less volume of rotor and making it less weight compared to 24S-14P FEFSM.
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