ELEC-E8404 Design of Electrical Machines

Aim: to learn the basic

principles and methods for
designing electromagnetic
devices.
 Plan

Feb March April

Course plan
25 28 4 7 11 14 18 21 25 31 4 14 14 18
Lectures
1 Basics, reluctance Network
2 Transformer
3 Slot Windings and resistive loss
4 Design and Thermal Modeling
5 Synchronous Machines

Homeworks
1 Magnetic Circuit
2 3-phase winding
3 Design of Induction Machine

Transformer Design work

1 Basic Design
2 Destailed design, construction
3 Testing
4 Related values, equivalent circuit
5 Report
Schedule

25 Principles of Design, Reluctance Model

Feb 28 Relcutance model (contd.) Homework 1 Introduction
4 Transformer
7 Transformer (contd.) Submission : Homework 1
Groups start preparing for transformer design
11
Three phase slot winding
March

14 Three phase slot winding (contd.) Homework 2 Introduction

18 Design and Thermal Modeling
21 Thermal Modeling (contd.) Submission : Homework 2
25 Synchronous Machines
31 Synchronous Machine (contd.) Homework 3 Introduction
4 Synchronous Machine (contd.)
April

14 Submission : Homework 3
12..15 Submit Report
 Assessment
• Three assignments (contributes to 1/3rd of final grade)

• Trasformer design task and report (contributes to 2/3rd of

final grade)

Course reading
• Lecture slides, course handouts

• ”Design of Electrical Machines” , Juha Pyrhonen, Tapani

Jokinen, Valeria Hrabovcova.
Specifications Design process
P, m

Mechanical
design

Electromagnetic
design

Thermal design

Bearings

Power supply
Electromagnetic and thermal modelling
Maxwell’s equations Material equations
 D =  D = E
B = 0 J =E
B B = H
E = −
t
D
 H = J +
t

Heat transfer
T
 cp −   ( T ) = ph q = −T
t

In addition, boundary conditions have to be specified.

Electrical losses of a prototype …
and thermal field
 Raw Materials

• Conductors
– Copper, aluminium, brass
– Insulation layers

• Insulators
– Foils, tapes, bars
– Supports and frames
– Castable compounds
Form-wound coils in a
low-voltage machine
 Raw Materials II

• Electrical steel sheets

– Standard dimensions
– Ready-made, punched sheets available
– Insulation coating
– Magnetic characteristics
• Oriented steel sheets
• Non-oriented steel sheets
 Magnetic characteristics of iron

1.50

1.00

0.50
B [T]

0.00

-0.50

-1.00

-1.50
-1500 -1000 -500 0 500 1000 1500
H [A/m]

Alternating field Fields in an electrical machine

 Raw Materials III Laminated,
Non-insulated non-oriented,
copper bar insulated steel
Form-wound coil sheets (0.5 mm)

Form-wound
coils

Laminated non-
insulated steel
sheets (2.5 mm) Non-magnetic
slot wedges
Solid steel shaft
 Tools for the design process

• Computer
• Design codes developed by experts
– A coupled electromagnetic, thermal and
mechanical problem has to be solved
– Typically, semi-analytical models for routine
design, FEA for designing new products
• Test results from previous products
– Provide verification and possible correction factors
between the theoretical models and real world
Magnetic circuits F3

 H  ds =  Fi = I F4
s i F2
bi
Fi =  H  ds
ai I F1
F1 + F2 + F3 + F4 = I

 B  dS = i = 0 3
S i

 i =  B  dS 2
Si 1 + 2 +  3 = 0
1
Analogy between electric and magnetic
circuits
Resistance Reluctance

l l
R= Rm =
A A

U1 Vm1

I 

R Rm

U2 Vm2
Radial Flux Permanent Magnet Machines

Radial direction

Axial direction
A

x out of page
Front view
o inside the page
Flux flows in the stator yoke.

16
 Radial Flux Permanent Magnet
Machines
A B C x out of page
o inside the page

ɸB
ɸA ɸC

ɸst

17
 Radial Flux Permanent Magnet
Machines
A B C x out of page
o inside the page

ɸC
ɸA

10
 Radial Flux Permanent Magnet
Machines
A B C x out of page
o inside the page

ɸst
ɸC
o
ɸA

11
 Radial Flux Permanent Magnet
Machines
A B C x out of page
o inside the page

ɸst
ɸA

ɸC
ɸB

• Rotating magnetic field is produced.

12
 Radial Flux Permanent Magnet
Machines
A B C ɸr
x

N
ɸst

• The interaction between these two rotating fields produces torque.

• AFPMSM principle of operation is similar to RFPMSM.

12
Flux distribution on d-axis
i a = i

ib = −i as ia + ib + ic = 0
i = 0
c

6
5
6
Rag
Rag 5 4
Rag 4
3
Rag
3
2
Rag
2
Rpm 1
Rrb
Rag2
1
0
 Flux distribution on d-axis II
0.009
0.008
0.007
0.006
Flux density [T]

0.005
0.004
0.003
0.002
0.001
0.000
-0.001
-0.002
0 30 60 90 120 150 180
Polar angle [el.deg.]

Calculated FEM
 Thermal resistance
A conductor having a constant cross-sectional area

P P = Power,
A
I  = Temperature
difference
l
 U

Equations for the heat flow and electric current (ph = 0)

     l
P =  q  dA =  − T  dA =  A = R=
A A l R A
   U U l
I =  J  dA =  −   dA =  A = Re =
A A l Re A
 1D thermal network

ph A

T1 x T2

  (T ) = − ph  = constant; ph = constant

d 2T ph ph 2
=− = T ( x ) = − x + c1 x + c2
dx 2
 2

T ( 0 ) = T 1 ph l−x x
 => T (x) = x(l − x ) + T1 + T2
T ( l ) = T 2 2 l l
 Average temperature of a conductor
Knowledge of the average temperature is often sufficient

ph A

T1 x T2

l−x
l
1  ph x  ph 2 1
Tave =   x (l − x ) + T + T2dx = l + 2 (T1 + T2 )
l 0  2 l  12
1
l

Task: Define a simple thermal network, which models

correctly the heat transfer and gives as a nodal value the
average temperature of the conductor.
 Thermal network for 1D heat flow

ph A

T1 l T2

The thermal network below fulfils the requirements

R1 R2
T1 T2
l
R1 = R2 =
R3 2A
l
Ta R3 = −
P
6A
Air outside Thermal network for a stator
Boundary layer
from yoke to air Heat source

Yoke Thermal resistor

The two end-regions combined

Tooth Winding End ring End-winding air

Air
outside
Boundary
layers to
and from
Boundary layer from end caps
teeth to air gap

Air in air gap