Beruflich Dokumente
Kultur Dokumente
Advisor(s)
Chau, KT
Author(s)
Li, Wenlong;
Citation
Issued Date
URL
Rights
2012
http://hdl.handle.net/10722/173931
LI, Wenlong
B.Sc.(Eng), M.Sc.(Eng.)
at the
Department of Electrical and Electronic Engineering
The University of Hong Kong
in
September 2012
DECLARATION
I hereby declare that this thesis represents my own work, except where due
acknowledge is made, and that it has not been previously included in a thesis,
dissertation or report submitted to this University or to any other institution for a
degree, diploma or other qualifications.
Signed
LI, Wenlong
September 2012
To my parents
With the growing interests and high requirements in low-speed linear drives, the
linear machines possessing high force density, high power density and high efficiency
feature become in great demands for the linear direct-drive applications. There are
many available linear machine topologies, but their performances for exhibiting the
high-force density capability dissatisfy the industrial requirements. In order to solve
this problem, the new machine topologies emphasizing on high force density are
explored and studied. The objective of this thesis is to present the design, analysis,
and application of permanent magnet (PM) linear machines which can offer a higher
force density at the same magnetic loading and electric loading than the conventional
machines.
Although in recent years there are many emerging advanced PM rotational
machines for direct-drive rotational drives, the development of advanced PM linear
machines for direct-drive linear drives is sparse. In spite of the motion type of electric
machines, the inherent operating principle is the same. By studying and borrowing
concepts of the high torque density rotational electric machines, the linear machine
morphologies of the promising candidates are designed and analyzed. The problems
and side effects resulting from the linearization are discussed and suppressed.
Two main approaches for machine design and analysis are developed and applied,
namely the analytical calculation and the finite element method (FEM). By
analytically solving the magnetic field problem, the relationships between the field
quantities and the machine geometry are unveiled. With the use of analytical
calculation, the machine design and dimension optimization are conveniently
achieved. With the use of FEM, the machine design objective and its electromagnetic
performance are verified and evaluated.
Finally, the proposed low-speed PM linear machine is applied for direct-drive
wave power generation. By mathematically modeling the wave power, generation
system and the generator, the conditions for maximum power harvesting are
determined. By using the vector control, the generator output power is maximized
which is verified by the simulation results.
II
ACKNOWLEDGEMENTS
Firstly and foremost, I greatly appreciate and express my deepest gratitude to my
supervisor Professor K.T. Chau, for his generous support and guidance on my
academic and professional career. His profound knowledge and extensive
professional experience and invaluable discussion lead me into the science world and
make me understand what the in depth research is. He helps me grasp the research
skills and enrich my study in the academic ocean. His academic knowledge and life
attitude benefit me all my life.
I also would like to express my thanks to Prof. C.C. Chan, Prof. J.Z. Jiang and
Prof. M. Cheng. Prof. C.C. Chan is always full of energy in his career and is an
amiable person. Prof. J.Z Jiang is an extremely nice teacher. His experience and
knowledge are the treasure for me. Prof. M. Cheng provides me greatly convenience
in fabrications for machine prototype and its test-bed. Here, I am very grateful to
them again.
My sincere thanks also owns to Mr. Raymond S.C. Ho, who always give his
selfless help to me. Whatever my research or daily life, he always supports me
quickly.
Many thanks are also given to my research group, my teachers and my friends.
Their help, advice, guidance, encouragement and support are very helpful during my
study, most notably Dr. Y.B. Li, Dr. Y. Fan, Dr. S. Ye, Dr. Z. Wang, Dr. X.Y. Zhu,
III
Dr. W.X. Zhao, Dr. C. Liu, Dr. S. Niu, Dr. C. Yu, Dr. L. Jian, Dr. X. Zhang, Miss J.
Li, Miss. S. Gao, Miss. D. Wu, Mr. Z. Zhang, Mr. F. Li, Mr. M. Chen, Mr.
Christopher H.T. Lee, Mr. D. Yi, and Miss R.Y. Ma.
I would like to express my deepest appreciation to my parents and my sisters.
Their love gives me the power and strength. With their understanding and
encouragement, my life is always energized and full-hearted.
This work was supported in part by a grant (Project No. HKU 710711E) from the
Research Grants Council, Hong Kong Special Administrative Region, China.
IV
CONTENTS
DECLARATION
ABSTRACT
ACKNOWLEDGMENTS
III
CONTENTS
CHAPTER 1
INTRODUCTION
1.1
Background .........................................................................1
1.2
1.3
1.4
1.3.1
1.3.2
1.3.3
Thesis Outlines..................................................................15
CHAPTER 2
ANALYSIS
PERMANENT
APPROACHES
MAGNET
FOR
LINEAR
MACHINES
2.1
Introduction .......................................................................17
2.2
Maxwells Equations.........................................................18
2.2.1
2.2.2
2.3
Analytical Calculation.......................................................19
2.3.1
2.3.2
2.3.3
2.4
2.5
2.6
2.5.1
2.5.2
2.5.3
Force Calculation........................................................ 27
Summary ...........................................................................28
CHAPTER 3
TRANSVERSE-FLUX
PERMANENT
Introduction .......................................................................29
3.2
3.3
3.4
3.5
VI
3.4.1
3.4.2
3.4.3
Summary ...........................................................................46
CHAPTER 4
4.1
Introduction .......................................................................47
4.2
4.3
4.2.1
4.2.2
4.3.2
4.3.3
4.4
4.4.2
4.5
4.6
Summary ...........................................................................88
CHAPTER 5
5.1
Introduction .......................................................................89
VII
5.2
Configurations ............................................................ 91
5.2.2
5.3
5.4
5.5
Analysis...........................................................................105
5.6
5.7
CHAPTER 6
INDUSTRIAL
DIRECT-DRIVE
APPLICATION
WAVE
FOR
ENERGY
HARVESTING
VIII
6.1
6.2
6.2.2
6.3
6.4
6.5
6.6
6.7
Summary .........................................................................135
CHAPTER 7
CONCLUSIONS
AND
RECOMMENDATIONS
7.1
Conclusions .....................................................................136
7.2
Recommendations ...........................................................138
LIST OF FIGURES
140
LIST OF TABLES
147
REFERENCES
148
APPENDICES
162
PUBLICATIONS
167
IX
CHAPTER 1
INTRODUCTION
1.1 BACKGROUND
Linear motion is a fundamental motion type that an object travels in a straight
line. It is quite universal in industrial field, such as transportation and factory
automation system, etc. For conventional industrial application, the linear motion is
usually converted from the rotational motion by a rotational electric motor with the
intermediate mechanical components such as ball screw, lead screw and rack and
pinion, etc. As shown in Figure 1.1, the motion type conversion is commonly realized
by teeth of the different mechanical devices meshing with each other. The meshing
engagement of the mechanical devices for motion type conversion inevitably incurs
loss, noise, vibration, regular maintenance, and degrades the precious positioning
capability. Therefore, the direct-drive electric machines are highly expected.
The linear machine operation principle can described as the following model. As
show in Figure 1.2, when the switch is closed on, the DC current flows anticlockwise
in the circuit. Since the sliding bar is exposed into a magnetic field directed out of the
page, a Lorentz force is exerted on the sliding bar which drives the sliding bar
straightly forward to the left hand side. When the battery is short circuited, the sliding
bar is driven by man hand, a current can also be drawn in the circuit. At this situation,
the linear machine operates as a generator. The linear machine was firstly invented by
Sir Charles Wheatstone in 1840s [1]. This prototype has the same structure as modern
Introduction
linear machines which can be considered as slitting the rotational one longitudinally
and unrolling it into a flat one. Due to the low efficiency and difficulty in control, the
linear machine in its early ages was not applied widely. Since 1960s, with
advancement of the material industry, computer technology and control theory,
development and application of linear electric machines are in an accelerated pace.
Particularly with the widespread applications of the high energy product permanent
magnet (PM) material for providing the excitation magnetic field, the research and
development of PM machines attracts more and more attention. Compared to the
electrically excited machine, the PM machines possessing features of simple
structure, robust, high energy density, and high efficiency, etc., are widely used in
industrials and household appliances. As its rotational counterpart, the linear machine
topologies ranges in induction, synchronous, stepping, reluctance, etc. Its application
spreads in various fields, such as industrial automation, robotics, power generation,
and transportation, etc [2]-[6].
Low-speed drives attract more and more attention in recent years with the active
demands for renewable energy related industrials, such as wind power generation and
electric vehicle motor drives, etc [7]-[10]. For the conventional electric machine
which usually operates at a high speed compared to the speed of wind turbine or
vehicle wheels, the low-speed gearless drives usually render a large physical volume
and relative low efficiency at the same power rating. In order to solve these problems,
mechanical gearboxes for speed reduction and torque transmission are applied which
can improve the efficiency of the whole driving system. However, the mechanical
transmission units inevitably incur the system complexity, increased cost and further
Introduction
deteriorate the control performance and reliability. Therefore, direct and gearless
driven approaches are put on the agenda. In order to satisfy the above requirement,
the electric machine possessing high thrust density, high power density and high
efficiency features is high expected.
Introduction
Based on the two analysis methods, optimal design for machine structure can
be carried out. According to the analytical expressions of the machine
performance, the needed field quantities are optimized under several
limitations. Finally, the results are verified by the numerical methods.
Application for oceanic wave power generation is assessed. Wave energy has
an abundant storage with low-frequency and time-varying feature. In order to
Introduction
maximize the harvesting efficiency, the vector control of the PM linear
machine is applied and evaluated.
W co
1 2
Li PM i W PM
2
(1)
Fem
dWco 1 dL 2 dPM
i Fcog
i
2 dx
dx
dx
(2)
The thrust force consists of three force components: reluctance force component,
PM force component, and cogging force component. For non-saliency machines, the
synchronous inductance is space-invariant, and the reluctance force component can
Introduction
be ignored. The cogging force component is a parasitic component caused by sloteffect and end-effect.
The research and development of low-speed and direct-drive rotational machines
for renewable energy application becomes a hot topic in recent years. However, the
machine topologies of PM linear machines are not diversiform as that of PM
rotational machines. In order to fulfill the research objective research and
development of low-speed PM linear machines, it is necessary to draw on experience
from that of the PM rotational machines. Due to the booming development of wind
power generation and electric vehicles, advanced PM machine topologies emerge in
an endless stream. The following overview reviews representatives of these PM
machines.
Introduction
A. Doubly Salient PM (DSPM) Machines [13]-[15]
In DSPM machines, the PMs usually located in the stator yoke as shown in
Figure 1.3. Due to the doubly saliency of the stator and the rotor, the flux links the
armature winding in a variation mode along with the rotating of the rotor. Although it
has salient poles in the stator and rotor, the PM torque significantly dominates the
reluctance torque, hence exhibiting low cogging torque. Thus, the torque density of
DSPM machine is higher than that of the SR machine. Since the variation of flux
linkage with each coil as the rotor rotates is unipolar, it is very suitable for the BLDC
operation.
Introduction
The flux-linkage with each coil reverse polarity as the rotor rotates. Thus, the phase
flux-linkage variation is bipolar, while the phase back-EMF waveform is trapezoidal.
Such a machine topology exhibits a low winding inductance, while the magnets are
more vulnerable to partial irreversible demagnetization.
Introduction
Introduction
Introduction
order to avoid this loss, the AlNiCo PM alloy is adopted for flux control. The high
effectiveness is due to its direct magnetization of PMs by magnetizing windings,
whilst the high efficiency is due to the use of temporary current pulse for PM
magnetization. The memory machine can be designed with only AlNiCo PM for
excitation [9] or AlNiCo PM and NdFeB PM for hybrid excitation [10], as shown in
Figure 1.7.
11
Introduction
12
Introduction
Figure 1.9 PMV machine. (a) Rotational morphology. (b) Linear morphology.
Introduction
mechanical gear and the electric motor is often used. Due to the prominent
advantages, the integrated machines are very suitable for direct-drive application,
such as electric vehicle drive system and wind power generation.
The literature review covers the emerging PM machines of the near decades
which gives us enough knowledge of various machine topologies and their
performances. Three promising machine topologies fall into our research and
development candidates, namely transverse-flux permanent magnet (TFPM) machine,
magnetic-geared machine (MGM), permanent magnet vernier (PMV) machine. The
research will be carried out based on the above three machine topologies.
14
Introduction
15
Introduction
structure for field modulation is optimized. A prototype is also fabricated to testify
the analytical results which show good agreement.
The application of PM linear vernier machine for wave power generation is
discussed in Chapter 6. Firstly, the wave power generation techniques are reviewed.
Then, the direct-drive wave energy conversion is selected. In order to maximize the
harvesting power, vector control of PMLV machine is applied.
Chapter 7 is the last chapter and gives the conclusion of the whole thesis and
recommendations for future work.
16
CHAPTER 2
ANALYSIS
APPROACHES
FOR
PERMANENT
2.1 INTRODUCTION
Permanent magnet (PM) electric machines apply PMs for providing excitation
field without external excitation circuit, therefore the machine structure can be
simplified and efficiency can be improved.
The PM in the PM machines not only serves as a magnetomotive force (MMF)
source, but also composes part of the magnetic circuit. Due to special features of the
PMs, design and analysis approach of PM machines can not totally refer to that of the
electrically-excited machines. In general, there are two main approaches for PM
machine analysis [34]. One is based on the equivalent magnetic circuit method, and
the other is based on the magnetic field. The first approach simplifies the magnetic
field problem into magnetic circuit with PM considered as MMF source or flux
source. The computation complexity is low but accuracy is not high. Although the
magnetic circuit method can satisfy the industrials at some situation, it can not
preciously predict the flux distribution, some nonlinear characteristics and the
saturation problems which are common in the real cases. The magnetic field approach
can give preciously assessment of the PM machines, since the saturation of
ferromagnetic materials, motion of the mover, tooth-slot effect and the skin effect etc.
The magnetic field problems describe by a set of Maxwells equations. By solving
17
H dl I t
s
E dl t
c
dA
dA
(1)
(2)
B dA 0
(3)
E dA Q
(4)
where H is the magnetic field intensity, I s is the free current within the surface s,
D is the electric displacement, E is the electric field intensity, B is the magnetic
flux density, Q is the net electric charge within the surface s, and c is the closed
boundary of the surface s.
18
D
t
B
t
(5)
(6)
B 0
(7)
(8)
where J is the free current density and is the free charge density.
The above quantities obey following conditions:
J E
(9)
D E
(10)
B 0 H
(11)
B Br 0 H
(12)
In vector calculus, the curl of a gradient of a scalar field always gains the zero
vector. Therefore, in the irrotational field, the field vector can be expressed as a
gradient of a function in terms of the magnetic scalar potential :
H ( ) 0
H (
y
x
i
j z k)
y
x
z
(13)
(14)
2 M
(15)
2 0
(16)
In the solenoidal field, the field vector can be expressed as a curl of a function in
terms of the magnetic vector potential A [36]. In Cartesian coordinates, the magnetic
field density can be expressed as:
B A (
Ay Ax
A A
Az Ay
)i ( x z ) j (
)k
y
z
z
x
x
y
20
(17)
H (H ) ( A ) J
(18)
( A ) J (Br )
(19)
( A ) 0
(20)
In the PM region:
In other region:
The analytical calculation of the magnetic field can be conducted by the above
two approaches which are finally deduced into a set of partial differential equations.
To solve these equations, a set of expression called general solution can be achieved.
In order to gain the unique solution for the partial differential equations, the
conditions for describing the field boundaries and initial values can make the problem
solvable. In most cases, only the boundary conditions can be listed out. There are
three kinds of conditions which are elaborated as follows.
(1) First type boundary condition
It is also called the Dirichlet condition. For this situation, the potential u along
the boundary s can be expressed by a function.
u f1 ( s )
(21)
When the value is zero, the boundary condition is also called homogenous
Dirichlet condition.
(2) Second type boundary condition
It is also called the Neumann condition. For this situation, the normal derivative
of the potential u along the boundary s can be expressed by a function.
21
(22)
When the value is zero, the boundary condition is also called homogenous
Neumann condition.
(3) Third type boundary condition
It is also called the Robin condition which is the linear combination of the first
type and second type boundary conditions.
k1u k2
u
f 3 (u )
n
(23)
(24)
H1t H 2t
(25)
1
6
4
3
In each triangle, the potential can be expressed by its geometry and the potential
at the three vertexes.
n
u N i ( x, y )ui
(26)
i 1
where N i (x, y) is the shape function and u i is the potential at each vertex of the
triangle.
As shown in Figure 2.2, the shape function can be expressed as:
23
ai bi x ci y
2
a j bj x c j y
2
a b x cm y
Nm m m
2
(27)
N i 3
i
N i 3
dxdy Ni dxdy
v
N
A
N
A
j
j
j
j
x x j1
S
y y j 1
24
(28)
N i 3
A
N i 3
N j A j dxdy PM N i i dxdy
N
A
v
j j
x x
t
y y j 1
j 1
3
3
v Brx N j Bry N j dxdy
y j 1
x j 1
(29)
N i 3
N i 3
v
N
A
N j A j dxdy 0
j j
x x
y y j 1
j 1
(30)
In the iron core, if the eddy current effect is taken into account, it yields:
N i 3
N i 3
A
dxdy Fe N i i dxdy 0
v
N
A
N
A
j
j
j
j
x x j1
y y j 1
t
(31)
The above discretized equation in each region can be reformed into the following
matrix:
A
A
[C ] [ D] t [ P]
i
i
t
(32)
where [A] is the vector potential matrix, [i] is the current matrix, [C] and [D] are the
coefficient matrix, and [P] is the matrix related to the output voltage and PM material.
The variables in (32) all relate to time, thus time discretization of these variables
should be carried out for solving the matrix. By applying the implicit Euler method, ()
can be expressed as:
[C t t
t t
t t
D t t A D t t A
] t t [
] t t [ P t t ]
t i
t i
(33)
Due to the use of the ferromagnetic material, coefficients in (33) contain the
electric resistivity which depends on the electric field intensity. For solving the
25
According to (2), the induced voltage can be calculated by derivative of the flux
linkage in the coil. With the knowledge of magnetic vector potential, it is easy to find
out the flux linking one coil by the following equation:
A1 A2 lef
(34)
where A 1 and A 2 is the magnetic vector potential at the two sides of one coil and l ef is
the effective length of the coil. When the 2-D analysis is applied, the magnetic vector
potential is degraded to a scalar value.
Therefore, the induced voltage in one coil can be deduced by:
eN
d dx
dx dt
(35)
The phase inductance can also be determined by the flux linkage method. Due to
the PM excitation, the total flux linkage of the winding sum of the flux linkage
produced by current and PMs. The inductance of one winding is determined by:
26
i tot PM
i
i
(36)
where Y i and Y PM is the flux linkage produced by current i and PMs respectively, and
i
i
(37)
With the information of magnetic field, the thrust force of the linear machine can
be determined by Maxwell stress tensor which expresses the force pre unit area on a
surface produced by the magnetic field.
The tangential force of a point which is parallel to the surface can be calculated
by:
f t Bn H t
Bn Bt
(38)
where B n and B t is the normal and tangential component of flux density at one point
in the air-gap respectively, and H t is the field intensity at that point.
The normal force of a point which is perpendicular to the surface can be
calculated by:
f n Bn H n
Bn2
(39)
27
(40)
2.6 SUMMARY
In this chapter, the analysis approaches for PM linear machine are discussed. The
two approaches are focused, namely analytical calculation and the FEM analysis. The
first one deals with a set of partial differential equation derived from the Maxwells
equation. Since the analytical expression shows the relationship of field quantities
with the machine structure, it is helpful for machine design and parameter
optimization. The latter one is a numerical approach to find the approximate solution
of the partial differential equation using the discretization. The FEM method can
gives accurate solution of a particular machine structure with considering the
nonlinear characteristics. With the assist of the two approaches, the design and
analysis of PM linear machines are carried out in the following chapters.
28
CHAPTER 3
TRANSVERSE-FLUX PERMANENT MAGNET LINEAR
MACHINES
3.1 INTRODUCTION
In the conventional machines, the developed torque/thrust is determined by the
magnetic loading and the electrical loading. Thus, the average thrust force developed
in a linear electrical machine can be estimated in terms of Lorentz force equation:
Fem IlBag p
bt
Bt Il p
bt
Bt JS s l
(1)
where l is the stack length of the flat linear machines and the circumferential length
of the tubular linear machines, B ag is the air-gap flux density, p is the mmf pole-pair
numbers of the field excitation, b t is the tooth width, t is the tooth pitch, B t is the
flux density in stator tooth, J is the current density in one slot, and S s is the slot area.
The thrust density per unit area can be obtained by:
Fd
Fem
b
b
p t Bt JS s l t Bt JS s
S ag
t
m t
(2)
where S ag is the total area of the air-gap and m is the mmf pole-pitch of the field
excitation.
According to (2), for improving the thrust density, the flux density in the tooth,
current density, slot area and tooth width should be increased. The flux density in the
tooth and the current density depends on the ferromagnetic permeability and the
cooling method respectively. Therefore, it is quite straightforward to increase thrust
29
3.2
LINEAR
MORPHOLOGY
OF
TRANSVERSE-FLUX
MACHINES
Figure 3.1 TFPM machine arrangements. (a) U-shaped core stator. (b) C-shaped core
stator.
Figure 3.1 (a) shows the principle model of a typical TFPM motor [40]. It adopts
the double-stator arrangement with the rotor/mover sandwiched between the two
stators. Its stator consists of U-shaped cores and windings on both sides of the
30
31
32
Figure 3.4 Performance analyses. (a) Back-EMF waveforms. (b) Cogging force. (c)
Normal force.
33
34
Figure 3.6 Performance analyses. (a) Back-EMF waveforms. (b) Cogging force
waveform.
Firstly, the cogging force of the proposed TFPM linear machine due to the
interaction between stator teeth and PM segments can be reduced by using the
36
FLx Fx 0 Fk sin k0 x
(3)
k 1
FRx Fx 0 Fk sin(k 0 x )
(4)
k 1
(5)
It can be found that F x will become zero if q= (2n1) , where n is an integer. Since q
is governed by the magnetic length of the stator L sm and , the condition for F x = 0
can be rewritten as:
Lsm (2n 1) , n is the natural number
(6)
37
Figure 3.8 Variation of cogging force with respect to physical stator length.
3.4
PROPOSED
TFPM
LINEAR
MACHINE
AND
ITS
IMPROVEMENT
Figure 3.9 shows the detailed structure of the proposed motor. The stator consists
of 12 C-shaped iron cores with a stack length of 10 mm. The cores alternate with
phases A, B and C, while every four of them are grouped together to form a phase.
38
Rated power
300 W
Phase number
30 V
3.3 A
Rated speed
1 m/s
50
Stator length
231 mm
Air-gap length
1 mm
Stack length
52 mm
PM dimension
4 mm 12 mm 30 mm
PM material
NdFeB
PM coercivity
940 kA/m
PM remanence
1.05 T
39
The principle of thrust force generation of the proposed motor can be illustrated
by Figure 3.10. There are two stator teeth and an effective air-gap (including two
actual air-gaps and the PM) between them. The magnetic flux generated by the
armature winding flows through the air-gap from one stator tooth to another. Because
of the fringing effect, there is a portion of flux passing through the air-gap beside the
stator teeth. So, the thrust force F exerted on the PM can be expressed as [30]:
F F1 F2 ( B1 B2 ) I pm l pm
(7)
where F 1 and F 2 are the magnetic forces developed at the left and right hand sides of
the PM, respectively, B 1 is the magnetic flux density under the stator teeth, B 2 is the
magnetic flux in the fringing areas, I pm is the equivalent current sheet of the PM, and
l pm is the length of the PM. Also, I pm can be written as:
I pm H c hpm
(8)
where H c and h pm are the coercive force and thickness of the PM, respectively. From
(7), it is obvious that the thrust force can be maximized by increasing the difference
between B 1 and B 2 . In order to achieve this goal, HTS bulks are inserted into the slot
between the stator teeth so as to provide magnetic shielding of the fringing flux.
Thus, B 2 is suppressed to almost zero while B 1 is improved, hence maximizing the
difference between them.
In order to enlarge the difference of B 1 and B 2 , the high temperature
superconductor (HTS) bulks are placed between two teeth for field shielding. Due to
the Meissner effect of HTS materials, the use of HTS bulks can force all PM flux
passing through the stator teeth [54], thus significantly decreasing the flux leakage in
40
Figure 3.10
As the proposed motor has a simple magnetic circuit in which the yoke of each
stator core is equivalent to the tooth with periodic boundary, the two-dimensional (241
42
Figure 3.12 Magnetic flux distributions with and without HTS bulks under
armature winding excitation.
43
Figure 3.13 Air-gap flux density waveforms with and without HTS bulks under
armature winding excitation.
Figure 3.14 Air-gap flux density waveforms with and without HTS bulks under
PM excitation.
Figure 3.15
44
Figure 3.16 Thrust force waveforms with and without HTS bulks under different
armature winding excitations.
Figure 3.17
Figure 3.18 Comparison of thrust force waveforms with HTS bulks using 2-D
FEM and 3-D FEM.
45
3.5 SUMMARY
In this chapter, a novel linear TFPM machine has been designed and analyzed.
Firstly, with the introduction of C-shaped stator cores, the motor possesses a simple
structure which is easy to fabricate. Secondly, by properly selecting the numbers of
stator slots and PM poles as well as tuning the physical stator length, the cogging
force can be significantly suppressed to less than 6%. Thirdly, by using the HTS
bulks to perform magnetic shielding, the rated thrust force can be significantly
improved by 183%. Therefore, the proposed motor is very promising for those
applications desiring high thrust force, low cogging force and easy to manufacture
such as industrial linear actuators and vehicular linear drives.
46
CHAPTER 4
LINEAR MAGNETIC GEARS AND THE INTEGRATED
MACHINES
4.1 INTRODUCTION
Mechanical gears are widely used in industry as the tools for transmission of
torque/thrust, speed scaling up/down and direction conversion. Especially for lowspeed applications, such as wind power generation, electrical vehicle power train
system, the electrical machines can operate at a high efficiency working condition via
mechanical gear transmission system. However, the drawbacks of mechanical gears,
namely noise, vibration, regular maintenance, mechanical loss and wear and tear,
may degrade the performance and efficiency of the whole system accordingly.
In order to solve the above problems, the magnetic gears which imitate the
operation of mechanical ones were proposed and developed. These magnetic gears
employ magnetic field interaction for torque transmission without physical contact,
hence eliminating the transmission loss and wear-and-tear problem [55]. In the early
stage, the magnetic gear adopts the topology resembles the mechanical gears [56]. As
shown in Figure 4.1, only parts of PMs are engaged for torque transmission, thus it
exhibits a low torque density. In order to fully utilize PMs, the coaxial magnetic gear
was proposed. Coaxial magnetic gears consist of three main parts: the outer-rotor, the
stationary ferromagnetic segments and the inner-rotor, as shown in Figure 4.2. The
key of coaxial magnetic gears is the ferromagnetic segments which locate between
47
Figure 4.1 Gears. (a) Mechanical spur gear. (b) Magnetic spur gear.
48
49
(1)
where hpm = 0 /h hpm , oag = 0 /h oag , iag = 0 /h iag , and lpm = 0 /h lpm are the
magnetic permeances in the longitudinal direction of the PMs on the high-speed
mover, outer air-gap, inner air-gap and PMs on the low-speed mover, respectively;
fm (z) is the magnetic permeance in the longitudinal direction of the field modulation
segment area which is a function of the axial position z; and h hpm , h oag , h iag , h lpm and
h fm are the longitudinal lengths of PMs on the high-speed mover, outer air-gap, inner
air-gap, PMs on the low-speed mover and ferromagnetic ring, respectively. When the
segment area is the ferromagnetic ring, the corresponding fm (z) is infinite. On the
contrary, when the segment area is air space, fm (z) = 0 /h fm ; and when it is the HTS
bulk, fm (z) = 0.
51
( z ) 0 m cos(mN s
m 1
2
z)
L
(2)
n ,odd
52
n H
hc hpm
cos(nN hpm
2
4
2
z1 )
H hc hhpm cos[nN hpm
( z z 0 )]
L
n
L
n ,odd
(3)
4
2
2
2
L
L
L
2
2
2
L
L
1
2
3
Bhpm
Bhpm
Bhpm
(4)
where B1 hpm has the same pole-pair number with that of PMs on the high-speed
mover, and B3 hpm has the same pole-pair number with that of PMs on the low-speed
mover. Thus, a thrust force can be produced by B3 hpm and PMs on the low-speed
mover.
In order to obtain the expression of the thrust force, an equivalent current sheet is
used to substitute the MMF of PMs on the low-speed mover. The fundamental MMF
component of PMs on the low-speed mover is given by:
Flpm1 ( z )
2
( z z2 )]
L
(5)
where H lc , h lpm and N lpm are the coercive force, thickness and pole-pair number of
PMs on the low-speed mover, and z 2 is its initial position as shown in Figure 4.4.
Thus, the corresponding equivalent current sheet is given by:
I lpm ( z )
2
( z z2 )]
L
(6)
53
L/2
D B
l
3
hpm lpm
dz
L / 2
where
is
the
angular
displacement
(7)
between
the
centers
of
PMs
of the two movers, hence written as = 2N hpm z 0 /L+2N lpm z 2 /L, and D l is the
diameter of the low-speed mover. The maximum thrust force occurs at equal to
zero:
Flm _ Max
(8)
By using the same derivation, the magnetic flux density due to PMs on the lowspeed mover can be expressed as:
3
Blpm
2
2
z N hpm
z2 )
L
L
(9)
Then, the thrust force exerted on the high-speed mover can be obtained as:
Flm ( )
L/2
D B
h
3
lpm hpm
dz
L / 2
(10)
54
2(h l )
sin
h
fm
(11)
where h = 0 /(h hpm + h oag + h iag + h lpm ), l = 0 /(h fm + h hpm + h oag + h iag + h lpm ), h
is the length of ferromagnetic ring in z direction, and fm is the pole-pitch of
ferromagnetic ring. When h equals one half of fm , 1 achieves the peak value which
is 2( h - l )/.
56
(a)
(b)
Figure 4.7 Comparison of inner air-gap flux densities excited by PMs on high-speed
mover. (a) Waveforms. (b) Spectra.
57
(a)
(b)
Figure 4.8 Comparison of outer air-gap flux densities excited by PMs on low-speed
mover. (a) Waveforms. (b) Spectra.
58
fm _ r 0 (1
fm _ z
bt
) ic
bt
0 ic t
ic t bt ( 0 ic )
(12)
(13)
where 0 is the airspace permeability, ic is the iron core permeability, b t is the width
of the field-modulation rings, and t is the pole-pitch of the field-modulation ring.
In order to ease the modeling, PMs on the high-speed mover and the low-speed
mover are handled individually. Then, by using the superposition law, the resultant
magnetic field distribution can be obtained. Firstly, PMs on the high-speed mover are
considered while PMs on the low-speed mover are considered as airspace. Taking the
abovementioned assumptions, the calculation areas can be divided into four regions,
namely the high-speed mover PM region I, the inner air-gap region II, the fieldmodulation region III, and the outer airspace region IV, as shown in Figure 4.11. The
field density B and field intensity H in each region can be deduced accordingly.
In region I, where PMs are involved, it yields:
B 0 ( rm H M )
(14)
60
(15)
(16)
B 0 H
(17)
Due to the symmetry of the tubular structure, the 3-D problem can be reduced to
a 2-D problem in which only the radial and axial components exist. The governing
field equations in the four regions can be derived by using the Laplaces and
Poissons equations accordingly.
In region I, the governing equation can be expressed as:
2 I 1 I 2 I
1
(rM r )
2
2
r
z
r r
r rm r
(18)
0
r r
r 2
z 2
(19)
fm _ r (
2 III 1 III
2 III
)
0
fm _ z
r 2
r r
z 2
(20)
H zI (ri , z ) 0
(21)
(22)
(23)
(24)
(25)
(26)
(27)
H zIV (ro , z ) 0
(28)
When r = r m , it yields:
When r = r fi , it yields:
When r = r fo , it yields:
When r = r o , it yields:
It should be noted that since the axial length of the linear tubular magnetic gear is
assumed to be infinite, all the boundary conditions are only radially dependent.
(a)
62
(b)
(c)
Figure 4.10 Linear tubular magnetic gear model. (a) Schematic diagram. (b)
Equivalent magnetic circuit of field-modulation region along r-direction. (c)
Equivalent magnetic circuit of field-modulation region along z-direction.
63
By using the separation of variables, the magnetic field equations in regions II,
III and IV governed by the Laplaces equation can be decomposed into a Helmholtz
equation and a Bessel equation. Then, by solving the two equations, a general
solution can be obtained.
(29)
n 1
where I 0 () and K 0 () are the modified Bessel functions of the first kind and the
second kind of order zero, respectively.
In region III, the solution of can be written as:
(30)
n 1
where
pn
fm _ z
fm _ r
kn
(31)
64
(32)
(33)
n 1
R1 ( R2 r 2 )
M n sin( n z )
r
n 1
(34)
where
R1
1
ri rm
(35)
R2 ri rm
n
Mn
2n 1
4 Bres
(36)
(37)
1
(2n 1)
(38)
where r i and r m are the radii of the high-speed mover and the PMs on the high-speed
mover respectively, and B res is the residual flux density of PMs. Thus, by using the
separation of variables, the particular solution can be deduced as:
pI
2 R1
rm
Mn
n 1
2
n
sin( n z ) 2 R0
n 1
Mn
n2
sin( n z )
(39)
65
Based on the boundary conditions of each region, the coefficients of the above
equations can be determined accordingly.
Firstly, on the surface of the high-speed mover back iron, from (21), it yields:
[ AnI I 0 (kn ri ) BnI K 0 (kn ri )] cos(k n z ) 2 R0
Mn
n2
cos(n z ) 0
(40)
(41)
2 R0 M n
F (n , n , ri ,0) BnI
2
I 0 (n ri )n
(42)
Secondly, on the surface of the low-speed mover back iron, from (28), it yields:
AnIV I 0 (n ro ) BnIV K 0 (n ro ) 0
(43)
Thirdly, on the surface of the PMs on the high-speed mover, from (22) and (23),
it yields:
66
AnI I 0 (n rm ) BnI K 0 (n rm ) 2 R0
Mn
rm [ AnI I1 (n rm ) BnI K1 (n rm )]
Mn
2
n
AnII I 0 (n rm ) BnII K 0 (n rm )
(44)
AnII I1 (n rm ) BnII K1 (n rm )
(45)
(46)
(47)
Finally, on the outer surface of the field-modulation region, from (26) and (27), it
yields:
AnIII I 0 ( pn rfo ) BnIII K 0 ( pn rfo ) AnIV I 0 (n rfo ) BnIV K 0 (n rfo )
(48)
(49)
(50)
n 1
(51)
n 1
67
16 mm
12 mm
6 mm
PM height
4 mm
Air-gap length
1 mm
6 mm
4 mm
8 mm
4000
PM relative permeability
1.09
PM remanence
1.23 T
PM coercivity
890 kA/m
68
(52)
n 1
(53)
n 1
Similarly, the magnetic flux density distributions in the outer air-gap are given by:
(54)
n 1
(55)
n 1
(a)
(b)
Figure 4.13 Magnetic scalar potentials at inner and outer air-gaps. (a) Due to PMs on
high-speed mover. (b) Due to PMs on low-speed mover.
70
(a)
(c)
(b)
(d)
Figure 4.14 Magnetic flux density distributions due to PMs on high-speed mover. (a)
Radial component in inner air-gap. (b) Tangential component in inner air-gap. (c)
Radial component in outer air-gap. (d) Tangential component in outer air-gap.
71
(a)
(b)
(c)
(d)
Figure 4.15 Magnetic flux density distributions due to PMs on low-speed mover. (a)
Radial component in inner air-gap. (b) Tangential component in inner air-gap. (c)
Radial component in outer air-gap. (d) Tangential component in outer air-gap.
72
(a)
(b)
Analytical
FEM
0.8
0.4
0
-0.4
-0.8
(c)
60
120
180
240
Electrical angle (degree)
300
360
(d)
Figure 4.16 Magnetic flux density distributions due to PMs on both movers. (a)
Radial component in inner air-gap. (b) Tangential component in inner air-gap. (c)
Radial component in outer air-gap. (d) Tangential component in outer air-gap.
73
2-D schematic
3-D schematic
(a)
74
2-D schematic
3-D schematic
(b)
Figure 4.17 Linear magnetic-geared machine. (a) Series integration. (b) Parallel
integration.
(a)
75
(b)
Figure 4.18 Flux distributions. (a) Series integration. (b) Parallel integration.
In the series integration, the gear and the machine share the same shaft, and their
magnetic circuits can be designed independently as shown in Figure 4.18 In the
parallel integration, the magnetic gear and the machine share the high-speed mover,
thus a smaller volume can be achieved. However, the parallel integration usually
involves three air-gaps so that the configuration becomes very complicated.
Therefore, the series integration is adopted in this design.
76
Bg Br
hm
khm r kc hag
sin(
m
)
2
(56)
(57)
where S f is the slot fill factor, A s is the slot area, J is the current density, and l is the
stack length. Under natural cooling, the current density is limited to 10 A/mm2. When
the slot fill factor is set to 0.7 and the PM remanence is selected at 1.1 T, the force
density can be calculated by using (57) which gives the value of 0.5 MN/m3.
Figure 4.19 shows the structure of the proposed machine, which consists of a
linear magnetic gear cascaded with a linear PM generator, thus artfully sharing with
the same shaft (the high-speed mover of the gear and the translator of the generator).
The integrated machine consists of two moving parts separated by two air-gaps. For
mechanical realization, two sets of linear bearing are engaged for supporting the two
moving parts. One set of linear bearings is implemented between the gear stator and
the low-speed mover; the other one is implemented between the machine stator and
the high-speed mover. The detailed design data of the linear magnetic gear is listed in
Table 4. 2, and the key design data of the linear integrated machine is listed in Table
4.3.
77
120 mm
100 mm
127.3 mm
98 mm
86 mm
150 mm
84 mm
40 mm
100 mm
Air-gap length
1.0 mm
11
15
PM remanence
1.2 T
78
Because of its linear tubular structure, the 2D-FEM analysis can give satisfactory
results for the performance analysis, since the transverse end-effect can be neglected.
Firstly, Figure 4.21 and Figure 4.22 show the flux density waveforms and their
spectra in the inner air-gap and the outer air-gap of the linear magnetic gear,
respectively. It can be observed that the dominant harmonic components in the inner
and outer air-gaps match with the corresponding numbers of active PM pole-pairs,
namely 4 pole-pairs in the high-speed mover and 11 pole-pairs in the stator. The high
flux density in these air-gaps confirms a high developed force density. Figure 4.23
depicts the waveform of static thrust force over one pole pitch of the low-speed
mover when the high-speed mover is fixed. It can be observed that a thrust force up
to 2020 N can be developed. Thus, a continuous thrust force of 1800 N is selected as
the operating force so as to avoid losing synchronism. When the low-speed mover is
driven by the wave motion with 1800 N at 1 m/s, the speed of the high-speed mover
is amplified while the force is scaled down accordingly. Figure 4.24 shows its force
transmission characteristics. It can be seen that the thrust force of the high-speed
mover is about 3.9 times lower than that of the low-speed mover, which is slightly
79
(a)
80
(b)
Figure 4.21 Gear inner air-gap flux density waveform and spectrum.
(a)
(b)
Figure 4.22 Gear outer air-gap flux density waveform and spectrum.
81
Figure 4.23 Static thrust force waveform of linear magnetic gear part.
82
-4
0
10
15
Position (mm)
20
25
B. Dynamic analysis
To assess the dynamic performance of the proposed machine, the dynamic model
is built as shown in Figure 4.28. The equation of the system can be given as:
Fe Fs Fem F f mg m
d 2x
dt 2
(58)
where F e is the force of the buoy, F s is the force of the spring, F em is the generator
electromagnetic force, F f is the viscous friction force, g is the gravitational
acceleration, m is the mass of the translator, and x is the displacement of the
translator.
When a time-varying sinusoidal buoy force is exerted on the low-speed mover as
shown in Fig 4.29(a), the machine terminals are connected to a resistance load of
20 W. As shown in Figure 4.29(b), the speeds of the two movers vary accordingly.
Due to the magnetic gearing effect, the speed of the high-speed mover is 3.75 times
that of the low-speed mover, thus a low-speed force is converted to a high-speed
force. As shown in Figure 4.29(c), the instantaneous EMF is proportional to the speed
of the high-speed mover. Figure 4.29(d) shows the total power losses in which the
core loss is higher than the copper loss. On the other hand, a conventional low-speed
linear PM synchronous machine, which has the same power rating as the proposed
one, is analyzed and simulated under the same condition. The conventional machine
has about 4 times volume as the proposed one. The required volumes of PMs, iron
cores and copper windings are respectively 167%, 214% and 271% of the proposed
one, resulting in a much higher cost. The corresponding power losses are shown in
Figure 4.30. It can be found that its core loss is similar to that of the proposed
84
Force (N)
(a)
(b)
(c)
85
(d)
Figure 4.29 Dynamic responses of proposed machine. (a) Buoy force. (b) Mover
speeds. (c) Induced EMF. (d) Power losses.
Low-speed generator
Rated power
1.8 kW
1.8 kW
Rated voltage
110 V
110 V
Rated speed
1 m/s
1 m/s
120 mm
302 mm
68 mm
250 mm
181.5 mm
181.5 mm
66 mm
248 mm
40 mm
222 mm
250 mm
250 mm
350 mm
250 mm
Total PM volume
461.6 cm3
766.6 cm3
2007.0 cm3
4299.5 cm3
236.87 cm3
641.26 cm3
3958.4 cm3
16310 cm3
87
4.6 SUMMARY
In this chapter, design and analysis of the linear magnetic gear and its integrated
machine are discussed and studied in details. Firstly, using the magnetic circuit
modeling, the operating principle, field modulation characteristic, force production
and transmission are presented. Then, using the analytical calculation method, the
detailed information of the magnetic field distribution in the linear magnetic gears is
deduced by solving Maxwells equations with corresponding boundary condition.
With these analysis tools, topologies of the linear magnetic-geared machine are
proposed and designed. Finally, FEM analysis is applied for its performance
evaluation. Both static and dynamic characteristics are given to testify the design
objectives and its feasibility.
88
CHAPTER 5
PERMANENT
MAGNET
LINEAR
VERNIER
MACHINES
5.1 INTRODUCTION
The magnetic-geared machine exhibits a high efficiency and high performance
for the low-speed applications in virtue of the force transmission and speed reduction
capability from the magnetic gear. The magnetic gear, either rotational or linear,
consists of two moving parts and one stationary part. One moving part operates at a
low speed and other at a high speed. Thus, the low-speed drives can be transmitted to
the high-speed drives via the so-called magnetic gear effect. Figure 5.1 shows the
linear tubular morphology of the coaxial rotational magnetic gear [57]. The two
movers have surface-mounted permanent magnets (PMs) with different pole-pair
numbers. The stationary part locating between the two movers consists of iron rings
and airspaces interpolating each other. By integration of the magnetic gear with the
conventional high-speed machine, the integrated machine can enable low-speed
operation but with high efficiency. Thus, the magnetic-geared machine becomes a hot
research topic in recent several years. However, the magnetic-geared machine suffers
the penalty of high material cost and manufacturing cost due to the integration
structure. In order to retain its merits and improve its deficiency, a novel machine
topology was proposed. By borrowing the magnetic gear operation principle, the
novel machine named as PM vernier machine was proposed which uses a toothed-
89
Air-gaps
Low-speed mover
Field modulation
rings
High-speed mover
PMs
90
Figure 5.3 Vernier machine. (a) Vernier structure. (b) Air-gap permeance waveform.
5.2
VERNIER STRCTURE
5.2.1 CONFIGUATIONS
The electric machine with vernier structure was proposed in 1960s [72]. The
vernier structure is composed by the tooted-pole stator and moving part. Along with
91
92
Figure 5.4 PM vernier machine. (a) Active mover type. (b) Passive mover type.
93
l
l
2
2 ( Z 1 P ) x 2Pvt
1
Fm 1 cos
2
l
Bag ( x, t ) F ( x) ( x, t ) Fm sin
(1)
where F(x) is the MMF of PMs, (x,t) permeance function of the air-gap, Z 1 is the
teeth number of the stator, Z 2 and P is the pole-pair number PMs of the mover and
MMFs of the armature winding respectively. The first item of the equation has the
same pole-pair number as that of the PMs. The second and third items have much
more pole-pair numbers than that of the PMs.
According to (1), the pole-pair number of MMFs and the stator teeth number
should satisfy the following relationship for developing a steady thrust force:
Z 2 Z1 P
(2)
when ac current with an angular frequency w is fed into the armature winding, the
resultant magnetic field of armature excitation rotates at a speed of w/P, and the rotor
94
As shown in Figure 5.6, the toothed-pole structure of the vernier machine takes
the function of flux modulation which inherently governs the machine operation.
95
2 I (r , z )
( M res )
(3)
2 II ( r , z ) 0
(4)
tp _ r
96
2 III (r , z ) tp _ r III (r , z )
2 III (r , z )
0
tp _ z
r 2
r
r
z 2
(5)
where tp _ z
0 fe t
b
and tp _ r 0 t ( fe 0 ) .
fe t bt ( 0 fe )
t
The unique solutions of the above partial differential equations are restricted by
the boundary conditions. There are four boundaries formed by three regions and its
conditions are listed as following:
BIz (r0 , z ) 0
(6)
(7)
(8)
(9)
(10)
BIIIz (r3 , z ) 0
(11)
Using separation of variables, the general solution of the Laplaces equations can
be easily obtained. By ignoring the right term of (12), the Poissons equation can be
reduced to the Laplaces equation. The general solution can be simplified as:
(12)
n 1
I p (r , z )
2
n
(13)
(14)
n 1
By using the same approach, the general solution of region III is described as:
97
III (r , z ) [a nIII I 0 (
k n tp _ z
n 1
tp _ r
r ) bnIII K 0 (
k n tp _ z
tp _ r
r )] sin( k n z )
(15)
[a nI I 0 ( k n r0 ) b nI K 0 ( k n r0 )] cos( k n z )
2K 0 M n
cos( n z ) 0
n2
(16)
On the boundary of region I and II, from (7) and (8), it yields:
anI I1 (n r1 ) bnI K1 ( n r1 )
Mn
a nI I 0 ( n r1 ) bnI K 0 ( n r1 )
anII I1 ( n r1 ) BnII K1 ( n r1 )
2K 0 M n
2
n
(17)
a nII I 0 ( n r1 ) bnII K 0 ( n r1 )
(18)
On the boundary of region II and III, from (9) and (10), it yields:
0 n [a nII I 1 ( n r2 ) bnII K 1 ( n r2 )] tp _ r n [a nIII I 1 (
k n tp _ z
tp _ r
r2 ) bnIII K 1 (
k n tp _ z
tp _ r
r2 )]
(19)
k n tp _ z
tp _ r
r2 ) bnIII K 0 (
k n tp _ z
tp _ r
r2 )
(20)
a nIII I 0 ( mn r3 ) bnIII K 0 ( mn r3 ) 0
(21)
Then, the Fourier coefficients aI n , bI n , aII n , bII n , aIII n , and bIII n can be easily
obtained from (16)-(21). For assessing the flux modulation of the toothed-pole
structure, the pth order harmonic component flux density in the stator back-iron is
investigated which is given by:
98
[ a
n 1
III
n
1
I (
k n tp _ z
tp _ r
r ) bnIII K1 (
k n tp _ z
tp _ r
r )] sin(k n z )
(22)
Figure 5.8 shows the Pth harmonic component flux density versus the PM
remanence according to the variation of the tooth width b t and slot depth h t over the
tooth pitch t . It can be observed that when the tooth width equals to one half of the
tooth pitch and the slot depth equals about 0.55 of the tooth pitch, the flux modulation
efficiency is optimal.
Bsp/Br
(a)
(b)
Figure 5.8 Pth harmonic component of flux density versus tooth width and slot depth.
(a) 3-D view. (b) 2-D view.
99
Figure 5.9 PM Vernier machines with active mover. (a) Stator morphologies. (b)
Mover morphologies.
Figure 5.9 shows the existing vernier machine topologies, only non-homopolar
structures considered here. There are two main morphologies of stator: namely
conventional tooth-slot type and auxiliary-tooth type. The auxiliary teeth are split
from the main teeth at the end, which can be made in a tapered or rectangular shape
for field modulation. Morphologies of the mover can be divided into 2 classes
according to the magnets location: namely surface-mounted and consequent-pole In
this design, the auxiliary-tooth type stator and surface-mounted magnet mover are
adopted. At the end of each main tooth, three auxiliary teeth were split. The
advantages of the proposed generator configuration can be listed as below:
The mover with surface-mounted magnets can be easily manufactured.
By using auxiliary teeth for field modulation, the main slots for housing
armature coils can be decreased, thus ease the space dispute for slots and teeth.
By using concentrated armature winding, the end-winding can be reduced,
100
Mover Design
The mover configuration with PMs can be classified into 3 categories, namely
Z2
p
(23)
where v s is the synchronous speed, is the pole-pitch of PMs on the mover. For a
given operation speed and current frequency, the PM pole-pitch can be easily
determined.
According to the analytical results, the fundamental component of air-gap flux
density B ag1 can be expressed as:
Bag1
B.
II
II
a n I 1 ( r ) bn K 1 ( r ) sin( z )
m
m
m
m
(24)
Stator Design
According to (1), the stator tooth pitch t can be calculated by the following
2Z 2
m
Z1
(25)
The linear machine developed thrust force is determined by the electrical loading
which limits by the cooling method. Most of the heat is caused by the copper loss
101
lef
Ac
(26)
where m is the phase number, N is the turns of coil of each phase, I is the phase
current, is the copper resistivity, l ef is the conductor effective length, and A c is the
area of he conductor cross section.
The heat produced by armature winding dissipates to the air space via the stator
yoke. The relationship of the total copper loss with the coil temperature rise T and the
heat transfer coefficient h can be expressed as [25]:
pCu 2 phTlef
(27)
According to (5) and (6), the machine electrical loading can be determined
depends on the cooling method and its temperature limit.
B.
Thrust Estimation
With the information of air-gap flux density and the electrical loading in the
windings, the pull-out developed thrust force can be easily estimated from the
magnetic field view point:
Fem
4m
NI
Bag1 hm sin 2 ( z )dz
1
m
(28)
102
Figure 5.10 PMLV machine model. (a) Phasor diagram. (b) Equivalent circuit.
s m Ls is
(29)
where L s is the synchronous inductance, i s is the phase current, and m is the effective
harmonic component of flux linkage produced by magnets. The effective harmonic
component means P 2 pole-pair number of MMFs produced by P 1 pole-pair number
of PMs via the field modulation of N s auxiliary teeth.
Therefore, the electromotive force (EMF) can be generated due to flux linkage
variation in the armature winding:
di
dL
d
[ Es ] s E0 s vt is Ls [ s ]
dt
dt
dx
(30)
where E 0 is the no-load EMF due to the magnets, x is the mover displacement, and v t
is the mover velocity.
The voltage equation can be expressed below, when the generator is on-load.
v Ra is dLs vt is Ls [ dis ] E0
dx
dt
(31)
where v is the terminal voltage, R a is the phase resistance and the phase leakage
inductance is ignored.
Figure 5.10 shows the phasor diagram and its equivalent circuit of the proposed
generator. m , a and s are the effective harmonic component flux due to magnets,
flux due to the armature reaction and its resultant flux respectively. The power
delivered to the load can be calculated by:
(32)
where V and I are terminal voltage and phase current in RMS value, and is the
power factor angle.
For determining the developed electromagnetic force, the magnetic co-energy
104
1 T
is Ls is is T m Wm
2
(33)
where W m is the magnetic field energy due to the magnets stored in the air-gap.
Thus, the electromagnetic force of the generator can be determined by:
Fem
1 T dLs
is is is T dm dWm
2
dx
dx dx
(34)
It should be noted that the third item in (8) is the cogging force component. Due
to the non-saliency nature, the first item in (8) can be ignored. The wave power
absorbed by generator can be expressed:
dWm dx
T d dx
Pin Fem vt is m
dx dt
dx dt
(35)
3VI cos
Fem vt
(36)
5.5 ANALYSIS
In order to preciously assess the proposed generator, the finite element method
(FEM) is applied for its key parameter calculation. Then, using modeling of section
II, its performances can be evaluated. Table I gives the key design data of the
proposed generator. The prototype assembly schematics are given in Appendix B.
105
106
Rated power
200 W
Phase number
15 V
4.3 A
Rated speed
1 m/s
50
Stator length
318 mm
Air-gap length
1 mm
200 mm2
Stack length
100 mm
6 mm 6mm
27
PM pole-pair number
24
PM dimension
6.625 mm 4 mm
PM material
NdFeB
PM coercivity
940 kA/m
PM remanence
1.2 T
Figure 5.11 shows the flux distributions at no-load condition. Due to limited
space, only a third model is shown here. It can be seen that there are multiply polepairs MMFs at the mover side, but at the stator side, seldom pole-pairs are left which
confirms the field modulation function of the toothed-pole structure. The flux
distributions show that the flux links phase A and phase B, respectively when the
mover at different positions. As shown the arrow pointer in Figure 5.11, even with a
tiny movement of the mover, the flux linkage in the armature winding is changed
dramatically. The whole model air-gap flux density waveform is shown in Figure
5.12 whose peak value is about 0.85 T. When phase A is applied a DC current of the
rated value, the flux linkage waveforms of 3 phases are shown in Figure 5.13. Thus,
the phase inductance can be calculated by its definition. When no current is fed to
armature winding, and the mover travels at the rated speed, the no-load EMF can be
obtained and its waveform is shown in Figure 5.14. The cogging force due to
variation of magnets stored energy can be obtained as shown in Figure 5.16. When
DC currents is applied to 3 phases under the rated condition, viz. i b = 8A, i a = i c =
-4A, the static thrust characteristic can be obtained via (34) and its waveform is
107
108
Figure 5.13 Flux linkage in three phases due to PMs and excitation of Phase A.
109
110
Coil
Stator
lamination
Air-gap
PM
Auxiliary teeth
111
Items
FEM
Measured
Self-inductance (mH)
7.35
7.21
Mutual-inductance (mH)
3.28
3.15
5.6 DISCUSSION
The power factor of the low-speed machine such as TFPM, PM vernier machine
is claimed not very high. In this section, the problem of low power factor is discussed.
The machine power factor can be expressed as [79]:
IX
cos cos tan 1
E
(37)
where I is the phase current, X is the stator reactance, E is the back-EMF. The ratio of
IX and E represents the ratio of flux produced by stator winding and PMs.
112
m 6 P A1 A2 A2 A3 A3 A4 A4 A5 A51 A6
Z1
A7 A8
(38)
where m is the main flux produced by PMs, is the active flux linking the stator
winding, and A n (n=1, ,8) represents the vector potential at certain points
respectively as shown in Figure 5.23.
According to (38), the no-load flux leakage coefficient is 7.65 which indicates
that only less than 20% of the main flux is utilized. The major problem of the severe
flux leakage owes to the multi-pole PM configuration which leads to a large flux
113
5.7 SUMMARY
In this chapter, a PMLV machine is proposed, analyzed, prototyped and verified.
By adopting the auxiliary-tooth stator and surface-mounted PM mover, the machine
can be easily fabricated but attain the low-speed and high-force operation feature. By
mathematically modeling the proposed generator, relationships between the generator
parameter and its performance are established. Using FEM, the proposed generator
performances are evaluated according to its modeling. Then, experimental
verification is engaged to confirm the analytical results. Finally, the power factor
problem of low-speed machine is discussed.
114
CHAPTER 6
INDUSTRIAL APPLICATION FOR DIRECT-DRIVE
WAVE ENERGY HARVESTING
6.1 INTRODUCTION
In recent years, the global issues such as environment deterioration and fossil
fuel crisis have forced people to develop a clean and sustainable energy source.
Renewable energy sources such as wind, solar, hydropower, tidal, wave, geothermal
and biomass, possessing features of green, environment-friendly, tremendous and free
of charge, are becoming attractive [80], [81]. Among those renewable sources, wave
energy from ocean is paid little attention. The ocean is a potential treasure trove for
renewable energy. A NASA study estimated that more than 91 trillion kilowatt-hours
of accessible energy worldwide from the oceans can be harnessed annually [82].
According to the report of the Electrical and Mechanical Services Department,
Government of Hong Kong SAR, an annual wave power density is 374 MJ/m2 [83].
As Hong Kong has about 1,600 km2 area of coastal water [84], the whole wave
energy per year can be estimated as 598,400 TJ which is about 4 times of the total
electricity consumption in Hong Kong in 2006 [85]. As a clean and sustainable
alternative resource, wave energy is becoming attractive when fossil energy crises
rise and the negative side effects of the traditional resources. Therefore, the
development of wave power generation has a very bright future for the ever
increasing demand for electricity.
115
6.2
OVERVIEW
OF
WAVE
ENERGY
HARVESTING
TECHNIQUES
From the origin where the wave energy comes from, it can be categorized as a
special form of solar energy. The earth is heated by the sun unevenly, and the unequal
quantity of heat energy causes air pressures differ from here and there. The different
air pressures produce the winds and the winds flowing through the water surface
invite the waves. In order to absorb the wave energy, it is necessary to harness the
mechanical energy of wave motion to drive the electric machines for electricity
generation. Thus the proper mechanical devices for mechanical energy conversion
and suitable and efficient electric machines are the key aspects in this research field.
Along with development of wave power generation technology in about several
decades, many kinds of wave energy converter topologies are presented and testified,
and some of those have already been put into commercial operation. Basically, there
are two types of wave power generation system: the rotational generator type which
converts the reciprocating wave motion into rotational motion by using mechanical
system and then adopts a conventional generator to produce electricity, and the linear
generator type which directly utilizes the wave motion to drive a linear generator for
electricity generation.
116
Figure 6.1 Oscillating wave column. (a) A wave crest comes into the air chamber.
(b) A wave crest flows out of the air chamber.
117
4) Pelamis [89]
As shown in Figure 8.4, the Pelamis consists of several cylinder sections linked
118
119
120
121
122
Items
TFPM
MGM
PMLV
Power density
0.16 W/cm3
0.45 W/cm3
0.21 W/cm3
Efficiency
71.3%
97.2%
84.9%
Power factor
0.35
0.92
0.44
Pd
C
w gH 2
8
w gA2
(1)
Ed w gH 2
T
8T
(2)
L
T
Pwf C Ed
(3)
w gH 2 L
8T
w g 2 H 2T w g 2 A2T
32
8
(4)
where E d is the wave energy density (J/m2), P d is the wave power density (W/m2),
P wf is the wave power per meter of wave front (W/m), w is the water density(1025
kg/m3), C is the velocity of the waves (m/s), g is the gravitational constant (9.81m/s2),
H is the wave height (m), A is the wave amplitude (m), L is the wave length (m), and
T is the wave period (s).
123
Power density
(kW/m2)
Figure 6.10 and Figure 6.11 show the relationship of wave height and wave
period with wave power density and wave power per meter wave front. It can be seen
that the larger the wave height, the larger wave energy power, but the wave period
has a totally different influence on the wave power density and the wave power per
meter of wave front.
124
As shown in Figure 6.12, the AWS based wave energy converter operates based
on the water pressure difference above its air chamber. For easing the problem, the
force exerted on the mover by the incident wave is only in vertical direction.
According to the Newtons second law of motion, the generator mover motion
equation is governed by:
Fe Fr F f Fem m
d 2x
dt 2
(5)
where F e is the incident wave force on the buoy, F r is the radiated force of buoy
acting on the water, F f is the force due to friction between mechanical parts and the
water, F em is the electromagnetic force of the linear generator, m is the mass of the
total moving part, and x is the displacement of the moving part.
By multiplying the velocity to (5), the power equation of the system can be
expressed as below:
125
Pe Pr Pf Pem m
dx d 2 x
dt dt 2
(6)
(7)
where v t is the velocity of the linear generator translator, and ~ denotes the variable
is a complex variable.
According to (7), the generator force F em should be controlled in phase with the
speed of the translator v t , thus the absorbed power P em can be maximized [97], [98].
It means that the current should be injected from the load part to satisfy the above
condition.
126
u q Ra iq
d d
t q 0
dt
dq
dt
t d 0
(8)
(9)
d Ld id pm
(10)
q Lq i q
(11)
Fem
3
[id iq ( Ld Lq ) pm iq ]
2 pm
(12)
where u d , u q , i d , i q , d and q are the terminal voltage, current, flux linkage of the
direct-axis and quadrature-axis, respectively, R a is the armature winding resistance,
w t is the translator velocity in radian per second, pm is the flux linkage due to
permanent magnet, pm is the pole-pitch of permanent magnets on the translator.
In order to control the generator force, the vector control for PMLV machine is
adopted which is also called field-oriented control (FOC), since the torque and flux
control can be achieved by controlling the direct-axis I d and quadrature-axis I q
current. According to (12), the generator force is only a function of the quadratureaxis current I q , thus the direct-axis current I d = 0 strategy is adpoted. The phasor
diagram is shown as Figure 6.13. The quadrature-axis current I q reference signal can
be determined based on (7) and (12):
iq*
cv~t 2 pm
pm 3
(13)
127
PM
128
A
B
A
B
C
129
Bi-directional
AC/DC converter
Linear vernier
generator
DC link
energy buffer
Current
sensor
Firing signals
ia,b,c
Encoder
Pulse
generator
Current
regulator
ia,b,c*
dq0/abc
transformation
Position
Velocity
estimation
vt
iq*
Current reference
signal calculation
130
id*=0
Items
60 V
5.6 A
Rated power
1 kVA
Phase number
PM remanence
1.2 T
PM coercivity
940 kA/m
Air-gap length
1 mm
Pole pitch
6.5 mm
Phase resistance
2.8 W
Direct-axis inductance
54.2 mH
Quadrature inductance
54.2 mH
Translator mass
3.2 kg
In order to testify the proposed control method to maximize the harvested wave
power, a simulated program is built based on Matlab/Simulink environment. A
PMLV machine prototype with 1 kVA is dimensioned as listed in Table 6.2. The
mathematical model of the generator is built according to (8)-(12). Figure 6.17 shows
the translator velocity waveform when a sinusoidal external force acts on the system.
Figure 6.18 depicts the 3-phase induced voltage waveforms with variable peak values
due to non-constant speed of the mover. With the speed information, the current
reference signals can be obtained. Thus, the actual current can be controlled by
current controller. Figure 6.19 and Figure 6.20 show the controlled direct-axis i d and
quadrature-axis current i q waveforms which both coincide with the reference signals.
131
132
Force (kN)
134
6.7 SUMMARY
In this chapter, the low-speed linear machine, PMLV machine, is applied for
harvesting the oceanic wave energy. Firstly, the various wave energy converter
techniques are overviewed. By comparing the complexity, the AWS based wave
energy converter is selected for the application. Then, the wave energy and AWS
based wave energy converter and the PMLV machine are discussed and
mathematically modeled. For maximizing the absorbed wave power, conditions for
the generator operation are discussed. Finally, performances of the generator and its
control strategy are assessed by simulations. The simulation results verify the
feasibility of the PMLV generator and the proposed control strategy for harvesting
the maximized wave energy.
135
CHAPTER 7
CONCLUSIONS AND RECOMMENDATIONS
7.1 CONCLUSIONS
This thesis deals with design, analysis and application of the PM linear machines
which exhibit high force density and low-speed operation features. Although three
topologies are studied, namely transverse-flux permanent magnet (TFPM) machine,
magnetic-geared machine (MGM) and permanent magnet vernier (PMV) machine,
the underlying operating principle of the three topologies is identical: the TFPM
machine and PMV machine belongs to the variable reluctance permanent magnet
(VRPM) machine family in which the flux-linkage to the armature windings changes
along with the interaction between a set of magnets and a set of teeth; the magnetic
gear and PMV machine use the so-called magnetic gear effect for converting the lowspeed mechanical speed into high-speed traveling magnetic field. The research
objectives have been achieved and concluded as following:
Discuss and study the problems caused by machine morphology conversion.
In the linear machines, the longitudinal end-effect which is incurred by the finite
length of the stator and mover is alleviated by multi-pole design and special
tuning the stator length. The phenomena such as large cogging force and
unsymmetrical magnetic circuit are greatly relieved. Thus, performances of the
PM linear machine can be improved and the control complexity is reduced.
136
in terms of magnetic scalar potential is developed. By considering the fieldmodulation area as a material with anisotropic permeability, the expressions of
the magnetic field can be concise and unified. Based on the analytical expression,
the machine structure parameters can be optimized for a better performance.
The electromagnetic performances of all the designed linear machines are
verified by finite element method (FEM). For TFPM machine, the high
temperature superconductor (HTS) bulk materials are ideally invited to shield the
leakage flux between teeth for maximizing the developed thrust. For linear MGM,
the two possible integration approaches are presented, and the static and dynamic
behaviors of the series integration machine are intensively studied. The
comparison with a gearless machine shows the MGM as the promising candidate
for low-speed application. For permanent magnet linear vernier (PMLV)
machine, the mathematical modeling is built for verifying the performance with
FEM. A 200W prototype is fabricated and experimentally evaluated on the test
bed. Its static electromagnetic effects agree well with the analytical results. In
addition, the problems for the low power factor are discussed and several
methods for improvement are proposed.
A PMLV machine of 1 kW for direct-drive wave power generation is
designed and dimensioned. The oceanic wave model, the system dynamic model
and the PMLV machine model are built and analyzed. In order to control the
generator thrust for harvesting a maximal power, a bidirectional AC/DC
converter is placed between the generator and the DC link. By using the field-
137
7.2 RECOMMENDATIONS
For future research, some suggestions are given as following:
The minimization of the tooth-tip flux leakage needs to be further investigated.
Because of the low-speed design, multi-pole PMs design is usually adopted. The
adjacent PMs are partially short-circuited by the stator teeth which result in a low
utilization of the PM materials and a large leakage inductance.
Since all the mover design adopts a surface-mounted PMs, the direct-axis
inductance and quadrature-axis inductance is the same. The flux weakening
capability is limited by the non-salient structure.
138
139
List of Figures
LIST OF FIGURES
Figure 1.1 Rack and pinion for linear-rotational motion conversion............................3
Figure 1.2 Idealized linear DC model...........................................................................3
Figure 1.3 DSPM machine............................................................................................7
Figure 1.4 FRPM machine ............................................................................................8
Figure 1.5 FSPM machine ............................................................................................9
Figure 1.6 PMHB machine .........................................................................................10
Figure
1.7
FRPM
Memory
machines.
(a)
Single-magnet
arrangement.
List of Figures
Figure 3.6 Performance analysis. (a) Back-EMF waveforms. (b) Cogging force
waveform.................................................................................................36
Figure 3.7 Cogging force component due to end-effect of stator core .......................38
Figure 3.8 Variation of cogging force with respect to physical stator length .............38
Figure 3.9 Proposed machine structure.......................................................................39
Figure 3.10 Principle of thrust force generation .........................................................41
Figure 3.11 Improved machine structure with HTS bulks ..........................................41
Figure 3.12 Magnetic flux distributions with and without HTS bulks under armature
winding excitation ...................................................................................43
Figure 3.13 Air-gap flux density waveforms with and without HTS bulks under
armature winding excitation....................................................................44
Figure 3.14 Air-gap flux density waveforms with and without HTS bulks under PM
excitation .................................................................................................44
Figure 3.15 No-load EMF waveforms ........................................................................44
Figure 3.16 Thrust force waveforms with and without HTS bulks under different
armature winding excitations ..................................................................45
Figure 3.17 Normalized cogging force waveform with HTS bulks............................45
Figure 3.18 Comparison of thrust force waveforms with HTS bulks using 2-D FEM
and 3-D FEM...........................................................................................45
Figure 4.1 Gears. (a) Mechanical spur gear. (b) Magnetic spur gear..........................48
Figure 4.2 Coaxial magnetic gear ...............................................................................48
141
List of Figures
List of Figures
List of Figures
List of Figures
List of Figures
146
List of Tables
LIST OF TABLES
Table 3.1 Specifications of Proposed Machine ...........................................................39
Table 4.1 Key Data of Linear Tubular Magnetic Gear................................................68
Table 4.2 Design Data of Linear Magnetic Gear.........................................................78
Table 4.3 Quantitative Comparison.............................................................................87
Table 5.1 Key Design Data .......................................................................................106
Table 5.2 Phase Inductance .......................................................................................112
Table 6.1 Performance Comparisons of Generators in 3 Topologies........................122
Table 6.2 PMLV Machine Parameters.......................................................................131
147
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Appendices
APPENDIX A
DETERMINATION OF THE COEFFICIENTS
Let
E ( f1 , f 2 , r , n)
I n ( f1r )
I n ( f 2r )
F ( f1 , f 2 , r , n)
K n ( f1r )
I n ( f 2r )
G ( f1 , f 2 , r , n)
K n ( f1r )
K n ( f2r )
H ( f1 , f 2 , r , n)
I n ( f1r )
K n ( f 2r )
0
fm _ r fm _ z
c0
G (n , pn , rfo ,0) c0G (n , pn , rfo ,1) F (n , n , ro ,0) H (n , pn , rfo ,0) c0 H (n , pn , rfo ,1)
U rm H (n , n , rm ,0) H (n , n , rm ,1) V rm 1
rm H (n , n , rm ,0) H (n , n , rm ,1)
U rm 1 V rm F (n , n , rm ,0) F (n , n , rm ,1)
rm F (n , n , rm ,0) F (n , n , rm ,1)
162
Appendices
anIV F (n , n , ro ,0)
Then, it yields:
2 R0 M n
W XF (n , n , ri ,0)I 0 (n ri ) n2
BnIV
2 R0 M n
K 0 ( n rm )H ( n , n , rm ,0) H ( n , n , rm ,1)W XF ( n , n , ri ,0)
Mn
rm n K1 ( n rm )H ( n , n , rm ,0) H ( n , n , rm ,1)W XF ( n , n , ri ,0)
2 R0 M n F ( n , n , ri ,0)
I ( n rm )F ( n , n , rm ,0) F ( n , n , rm ,1)W XF ( n , n , ri ,0)
M n F ( n , n , ri ,0)
rm n I1 ( n rm )F ( n , n , rm ,0) F ( n , n , rm ,1)W XF ( n , n , ri ,0)
2
n
2
n 0
Mn
rmn K1 (n rm )H (n , n , rm ,0) H (n , n , rm ,1)
BnI XBnIV
163
2 R0 M n
K 0 (n rm )H (n , n , rm ,0) H (n , n , rm ,1)
2
n
2 R0 M n
I (n rm )F (n , n , rm ,0) F (n , n , rm ,1)
2
n 0
Mn
rmn I1 (n rm )F (n , n , rm ,0) F (n , n , rm ,1)
Appendices
APPENDIX B
ASSEMBLY SCHEMATICS FOR PERMANENT MAGNET LINEAR
VERNIER MACHINE
164
Appendices
2. stator
Wiring terminals
Coils
Back-iron
165
Appendices
3. Machine assembly
166
Publications
PUBLICATIONS
Journal papers
[1] Wenlong Li and K.T. Chau, Analytical field calculation for linear tubular
magnetic gears using equivalent anisotropic magnetic permeability, Progress In
Electromagnetics Research, vol. 127, April 2012, pp. 155-171.
[2] Wenlong Li, K.T. Chau, and J.Z. Jiang, Application of linear magnetic gears for
Pseudo-direct-drive oceanic wave energy harvesting, IEEE Transactions on
Magnetics, vol.47, no.10, 2011, pp.2624-2627.
[3] Wenlong Li, K.T. Chau, and Jiangui Li, Simulation of a tubular linear magnetic
gear using HTS bulks for field modulation, IEEE Transactions on Applied
Superconductivity, vol.21, no.3, 2010, pp.1167-1170.
[4] Wenlong Li and K.T. Chau, Design and analysis of a novel linear transverse flux
permanent magnet motor using HTS magnetic shielding, IEEE Transactions on
Applied Superconductivity, vol. 20, no. 3, June 2010, pp. 1106-1109.
[5] Wenlong Li and K.T. Chau, A linear magnetic-geared free-piston generator for
range-extended electric vehicles, Journal of Asian Electric vehicles, vol. 8, no.1,
2010, pp. 1345-1349.
Conference papers
[6] Wenlong Li, K.T. Chau, Christopher Lee, Optimal design and implementation
of a permanent magnet linear vernier machine for direct-drive wave energy
167
Publications
Publications
[13] Wenlong Li, K.T. Chau, Yu Gong, and J.Z. Jiang, A new linear transverse flux
permanent magnet generator for wave energy conversion, Proceeding of IEEE
International Magnetics Conference, 2009, Paper No.BU-04.
169