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Abstract-This paper presents a three-phase claw pole permanent magnet soft magnetic composite motor, which was designed to take advantage of specific properties of the material. Parameter calculations by the finite element magnetic field analysis and performance prediction by the equivalent circuit are discussed. To verify the theory, a prototype motor was constructed and operated by a sensorless brushless dc drive scheme. The experiment results are reported and show good correlation with the theory. Keywords-Claw pole motor, finite element analysis, sensorless brushless dc drive, soft magnetic composite.
Sweden. It is characteriz.ed by a thin continuous surface insulation layer with little or no effect on the powder compressibility. This malerial was specially developed for soft magnetic applications with 3D magnetic fluxes, such as electrical machines. Although the motor prototype in this paper was manufactured by cold machining from available performs, the compression molding technique would be used for commercial mass production. 11. SMC PROPERTIES EXPLOITED IN MOTOR DESIGN The powdered nature of the SMC material yields isotropic magnetic propexties, which opens up the crucial design benefit of employing 3D flux paths. The 3D machine explored here is a claw pole structure, which is very difficult to manufacture by using laminated steels. Taking advantage of the isotropic magnetic property of SMC material, the magnet axial length in the prototype can be designed longer than the claw pole to obtain higher stator flux and then higher specific torque. Besides the radial direction, the flux can also flow into the SMC claw poles via the side surfaces. By contrast, laminated steels are effective in carrying varying magnetic flux only in the plane of laminations while maintaining low eddy current loss. The isotropic thermal property of SMC materials is also advantageous in increasing heat dissipation from the internal stator of the motor described here. For laminated steels, the thermal conductivity in the direction perpendicular to the lamination plane is much lower than that within the plane. This implies that in laminated cores the heat is transferredl almost uniquely at lamination edges. For the claw pole stator here, SMC use implies additional cooling from the teeth sides which would improve the heat dissipation. Because the iron particles are insulated by the surface coating and adhesive, which is used for composite bonding, the eddy current loss is much lower than that in laminated steels, especially at higher frequencies. The total loss is dominated by hysteresis loss, which is higher than that of laminaled steels due to the particle deformation during compaction. At the power frequency 50 Hz and 1.5 T, the total core loss in SomaloyTM 500 (with 0.5% Kenolube) is 14 W/kg [4], double that of even the low grade Kawasaki 65RM800 (0.65 mm thick, 28 x 10' Qm) [5]. When the excitation frequency increases, however, the increment of core loss in SMC is smaller
I. INTRODUCTION Soft magnetic composite (SMC) materials possess a number of advantages over traditional laminated steels commonly used in electromagnetic devices and have undergone a significant development in the past few years [l]. SMC material is made of iron powder of high purity and compressibility. The grains are coated with an organic material, which provides the bonding and produces a high electrical resistivity. The coated powder is then pressed in a die to form a solid part and finally heat treated to anneal and cure the bond. There is usually no further machining required, and product cost is much lower than punching, stacking and welding of laminations. The unique properties of SMC materials include three-dimensional (3D) isotropic ferromagnetic behavior, very low eddy current loss, relatively low total iron loss at medium and high frequencies, and higher thermal conductivity than across laminations (though lower than within laminations). To investigate the potential of SMC materials, a lot of work has been conducted and encouraging improvement has been achieved in both the material and its application in electrical machines [2,3]. In this paper, a small three-phase three-stack claw pole permanent magnet (PM) motor with SMC stator has been designed and constructed to take advantage of the properties of SMC materials. 3D finite element magnetic field analysis was conducted for major parameter calculation and dimension optimization. The design and performance analyses are validated by experimental tests on the prototype, which is driven by a sensorless brushless dc drive scheme. Both the method and results of the experiment are reported in detail below. The stator core material is SOMALOY" 500 [4], a new soft magnetic composite produced by Hoganas AB,
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than that in electrical steels due to the smaller eddy currents. At 400 Hz and 1.5 T the total core loss in 500 is the same as the low-medium grade SomaloyTM Kawasaki 50RM700 (0.5 mm thick, 28 x lo-' Qm), namely 120 W/kg. High grade Kawasaki 35RM270 (0.35 mm thick, 54 x IO-* Qm) has one third the loss then, i.e. 40 Wikg at 400 Hz and 1.5 T. Thus, SMC materials are more likely to be better used for motors operating at higher excitation frequencies, but they are not yet as good as high grade laminations at low and medium frequencies and any superior performance must come from exploring 3D flux topologies or some other SMC feature. The permeability of SMC material is lower than that of electrical steels because it has less full density. Best figures are in the range of 500 for maximum relative permeability [4]. It is expected that this material would be appropriate for construction of PM motors for which the magnet reluctance dominates the magnetic circuit, making such motors less sensitive to the permeability of the core than armature magnetized machines, e.g. induction and reluctance machines. In spite of the lower value, the permeability of SMC is much more stable with respect to the frequency than that of electrical steels. SMC can maintain nearly a constant magnetic permeability up to a quite high frequency. This is a favorable property for motors operating at higher frequencies. The saturation flux density is reduced as compared to the base iron powder. Hoganb AB reports that SomaloyTM 500 has a flux density of 2.37 T at 340 kA/m [4], which is 1.94 T above that for air at that field strength, compared to 2.18 T for perfectly aligned iron. To help compensate for the reduced saturation flux density and increased core loss, the prototype is designed to have lower magnetic flux density in iron components, e.g. only about 1.0 T in the stator yoke. 111. PROTOTYPE MOTOR Fig. 1 illustrates the magnetically relevant parts of the rotor and the stator of the prototype. Table 1 lists the dimensions and major parameters. The three phases of the motor are stacked axially. Each stator phase has a single coil around an SMC core, which is molded in two halves. The outer rotor comprises a tube of mild steel with an array of magnets for each phase mounted on the inner surface. Mild steel is used for the rotor because the flux density in the yoke is almost constant. For the prototype, the motor size and core geometry were to a large extent determined by the dimensions of the available SomaloyTM 500 preforms. They were chosen the same as those .of a PM SMC transverse flux motor prototype [6], in order to simplify comparison between the two topologies. A pole number of 20 was chosen giving an operating frequency of 300 Hz at 1800 rpm. It is not an unrealistically high frequency to work at for SMC materials. Since a simple concentrated stator winding is used, the fill factor is higher and the manufacturing cost
(a) Rotor
(b) Three-stack stator cores Fig. 1. Magnetically relevant parts of the claw pole motor
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For continuous rotation, either the stator cores or the magnets should be shifted through an angle between phases. In the case of this three-phase three-stack claw pole motor, the shift between different stacks is 120' electrical, while the magnets with the same polarity are lined up.
Finite element analysis has been recognized as a suitable and accurate method of field computation to aid motor design, allowing material non-linearity . and structure details to be included. Because of the complex geometry, the magnetic field in a claw pole motor is truly three-dimensional. In 3D flux machines, the armature carries significant field in all three directions. This is only achievable using SMC material. Consequently, for the correct calculation of magnetic field and motor characteristics, a 3D numerical analysis is required. By taking the advantage of the periodical symmetry, only one pole pitch of the machine needs to be studied. At the two radial boundary planes, the magnetic scalar potential used to solve the magnetic field distribution obeys the so-called half-periodical boundary conditions:
The armature reaction at the rated current can also be computed by this field analysis to check whether the magnets would be demagnetized. An improved method is applied for predicting the core losses of this 3D-flux SMC motor [SI. Different formulations are used for core loss prediction with alternating, circular rotating, and elliptically rotating flux density vectors, respectively. A series of 3D finite element analyses are conducted to determine the flux density locus in each element when the rotor rotates. The calculated no load core loss, varied approximately linearly with frequency and was 58 W at 300 Hz. Under the rated load it will increase by about 20%.
v.
(1)
where cylindrical coordinates are used and de = 18" is the angle of one pole pitch. A number of key parameters of the motor can be determined from the numerical magnetic field analysis [7]. The no-load magnetic field distribution is calculated to find out the magnetic flux linking the stator winding. The motor structure and dimensions were adjusted such that the flux linkage was maximum. The induced electromotive force (emj) under rotation is inferred by differentiating the no-load flux with respect to e. For the claw pole motor the emf was found to be closely sinusoidal. Cogging torque arises from the reluctance variation of the magnetic circuit as the rotor rotates and exists even when there is no stator current. The cogging torque can be computed by the virtual work or Maxwell stress tensor methods after the magnetic field distribution is determined. The cogging torque has a period of 180" electrical and is anti-symmetric about zero, and hence has only even sine harmonics. As the stator stacks are shifted by 120" electrical, the torque harmonics of the three stacks sum to zero except for the 6'h order and its multiples. The self-inductance of each phase winding can be calculated by Ll=Nlq51111, where is the magnitude of the flux linking the stator winding due to a stator current I, in each of NI turns. It can be obtained from the results of a field analysis with a stator current I , while the permanent magnets are "switched off', i.e. remanence is set to zero.
The claw pole SMC PM motor prototype has been driven by a six-step 120" rotor position sensorless brushless DC motor controller. Fig.2 sketches the inverter power circuit, featuring it 3-phase MOSFET bridge. The DC rail voltage:; are assumed to be +VD& and V D & . For six-step 120" switching a half cycle of any phase voltage is as follows: connection to one of the DC rails for two of the six steps, i.e. for 120"; followed by one step of 60" comprising two parts, a commutation period when the phase current decays to zero while connected via the freewheeling diode to the other DC rail, and a floating period, when the phase is disconnected and the phase current is zero. 'Note that it is assumed that the current at the start of the commutation period has the same sign as the DC rail to which it has been connected. If it has the opposite sign then the other diode would keep it connected to the same DC rail during commutation.
When the motor is operated in brushless DC mode, the three phase voltages are controlled according to the rotor position such that fundamental components of the phase current I1 and the induced emJ El are in phase, to achieve a maximum electromagnetic power P,,, at a given speed, i.e.
e,,, = 3E,I,
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The induced rms line-neutral stator emf can be determined by (3) where w1=2@, is the angular rotor speed in electrical the frequency of the induced stator radians per second, 1; emfin Hertz, N I the number of turns of the stator winding, , the magnitude of the magnetic flux linking the and $ stator winding due to the permanent magnets. From the no-load magnetic field analysis, the curves of the stator flux and the induced emjversus rotor angle or time are almost sinusoidal. The back emf's for three phase windings are taken as
(300Hz), El= 48.7 V, and for the rated rms current of 4 A, which is limited by the temperature rise of the stator winding, P,,=585 W and V,=63.7 V. The corresponding DC input voltage of the inverter can be approximately estimated by
V,, = 2.34V,
(13)
though this is only accurate for neload [IO]. The output power, output torque, input power, and efficiency are calculated by
where the switching is assumed to occur at 0 = wlt =' 0, and 0, is the advance of the switching angle ahead of the back emf: Bidirectional motors with a single set of position sensors must have 0, = 0, but a slight advance is needed for alignment of back-emf and current as required for minimum copper loss [9]. To obtain the currents in three phases the following equations are to be solved.
where PF, is the core loss, P,,, is the mechanical loss, P,,, is the copper loss, which is assumed here to be dominated by the fundamental component of current, and &I is the angular speed.
Fig.3 is a photo which shows the setup for testing the 3-phase 3-stack claw pole PM SMC motor (on the right). A DC machine (on the left) is connected to the prototype motor via a torque transducer (in the middle). It functions as the load when the prototype is operated as a motor, or the driver when the prototype is operated as a generator.
A. Resistance Measzrrement
dl
For measurement of the phase winding resistance, a fixed DC current of 1 A was fed into two of the terminals of the 3-phase winding. The measured voltage across these terminals was 0.450 V, and therefore the phase resistance is 0.225 R at the room temperature. The
The voltage V, at the neutral point can be obtained by addition of (7)- (9):
The line-to-neutral rms voltage and phase rms current have the following relationship when the motor is with the optimum brushless DC control:
where RI is the resistance of one phase winding and X I is the reactance. For the prototype motor, at 1800 rpm
Fig. 3. Set-up of a claw pole PM motor with SMC stator
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resistance at the rated operating temperature rise can be calculated by 234.5 + t2 234.5 + t,
R2 =
where tl is the room temperature, which is 22"C, and tz is the rated operation temperature 115"C.
the input power, output power and efficiency are shown in Fig.7. Fig.8 shows the waveforms of the stator line voltages with respect to the average DC rail voltage at the rated torque and speed. It can be seen that three voltage waveforms have the similar shape but shifted by 120 electrical degrees. Since the motor speed is 1800 rev/min, the corresponding frequency and period of the applied AC voltages are 300 Hz and 3.333 ms, respectively. Fig.9
TABLE 11 NO LOAD FLUX AND EMF CONSTANT
Speed (rpd 301 597 905 1198 1503 1805
90
B. Inductance Measurement
For measurement of the phase winding inductance, an AC current of power frequency was fed into two of the terminals of the 3-phase winding with the rotor locked and the voltage across the two terminals, 2V1, and the current flowing through the windings, I,, are measured. The inductance of each phase winding can be calculated by
Voltage, L-N
Frequency
(Vl
8.3 16.1 24.5 32.3
40.5
(Hd
50.2 99.5 150.8 19!3.7 250.5 300.8
48.9
where f , is the power frequency, viz. 50 Hz. The measured average inductance for each phase winding is 5.79 mH.
-90I
The stator flux (averaged over three phases) has peak 0.488 mwb and the emf constant is 0.259 Vslrad.
I500
1000
500
Torque (Nm)
0 0.0
0.5
.o
I .5
2.0
2.5
3.0
4.0
r- lnvertcr
-
3.5 2.5
2.0
1.5
3.0 -
A:
0.0
1
0.0
,
0.5
,
1.o
Torque (Nm]
I
I .5
2.0
2.5
3.0
708
plots the waveform of a phase current and its relationship with the voltage. The rated performance of 500 W output at 1800 rpm at 80% efficency, from a motor OD 94 mm and total length (excluding shaft) 137 mm compare favourably with other laminated motors. For example, an aluminum TEFV induction motor rated 370 W at 1380 rpm, which is about the same torque (3% lower), has efficiency only 73% from frame size D71G, with OD 126 mm including fins and total length 220 mm (including fan but excluding shaft) [l I]. Or as a second comparison - a lower torque but higher power (610 W) brushless DC servo motor,
rated 2.2 Nm locked rotor and 1.95 Nm at 300 rpm (when mounted to a cooled 25C flange), hss square crosssection 100 mm and length 173 mm [12]. The claw pole SMC motor has similar performance from a smaller volume compared to these commercial motors.
700
600
500
To investigate the potential of SMC materials in manufacturing small motors of complex structures, a 3phase PM claw pole motor with SMC core has been designed and manufactured. The prototype is operated with a sensorless brushless DC drive and its performance is comparable to that of similar motors with electrical steel cores at potentially reduced manufacturing cost. The method for the motor design and performance analysis has been validated by experiment.
ACKNOWLEDGMENT
400
50
40
300
Pout
200
100
30
0 1 0.0
0.5
1.0
1.5
2.0
2.5
0 3.0
The authors wish to thank Hoganas AB, Sweden, for supplying preforms of SOMALOFM500.
Output torquc (Nm) Fig. 7. Curves of inverter input power, motor output power and system efficiency versus output torque
REFERENCES [I] A.G. Jack, Experience with the use of soft magnetic composites in electrical machines, in Pruc. Inr. Con6 on Electrical Machines, Istanbul, Turkey, 1998, pp. 1441-1448. [2] P. Jansson and A. Jack, Magmetic assessment of SMC materials, in Proc. 21 Annual Conf: on Properries and Applications of Magnetic Materials, Chicago, May 2002, pp. 1-9. [3] T.J. Hammons, H.B. Ertan, J.A. Tegopoulos, W. Drury, M. Ehsani, T. Nakata, and A.G. Jack, 1998 ICEM review, IEEE Power EngineeringReview, Feb. 1999, pp. 12-17. [4] Soft magnetic composites from Hiiganls metal powders SOMALOYTM500, Catalogp SMC 01, Hoganas AB, Sweden. [5] RM-core non-oriented magnetic steel sheet and strip, Catalogue, Kawasaki Steel, Mar. 1999. [6] Y. G. Guo, J. G . Zhu, P. A. Watterson, and W., Wu, Design and analysis of a transverse flux machine with sot\ magnetic composite core, The 6 Int. Cont on Electrical Machines andSysrems, Beijing, China, Nov. 2003. [7] Y.G . Guo, J. G . Zhu, P. A. Watterson, and W. Wu, Design and analysis of a three-phase three-stack claw pole permanent magnet motor with SMC stator, Aiistralusian Universities Power Eng. Cont. Christchurch, New Zealand, 28 Sept. - 3 Oct. 2003. [8] Y.G. Guo, J. G. Zhu, J. J. Zhong, and W. Wu, Core losses in claw pole permanent magnet machines with soft magnetic composite stators, IEEE Trans. M a p . , vol. 39, no. 5, Sept. 2003. [9] P.A. Watterson, Phasor analysis of six-step 120 conduction permanent magnet motor drives, 2 Int. Con$ on Power E1ectronic.s Drives and Energy systems, Perth, Australia, 30 Nov. - 3 Dec. 1998. [IO] P. A. Watterson, Analysis of six-step 120 conduction permanent magnet drives, Acc.stmlasian Universities Power Eng. ConJ. Sydney, 28 Sept. - 1 Oct. 1997, pp. 13-18. [I I] Aluminum IP54 motors, Brook Crompton Catalogue lX1800, July 1991. [ 121 FAS T series brushless servomotors, Vickers Catalogue EPC-GB-B-4030, Motor FAS TI M2 030,1991.
-100
I
Timc (ins)
Fig. 8. Three phase waveforms of the line AC voltage with respect to the average DC rail voltage at 1800 rpm
709
PEDS2003
~
PEDS
Organised by
Industry Applications / Power Electronics Joint Chapter of IEEE Singapore Section
+IEEE
In Technical Co-sponsorship with
IEEE Industry Applications Society
--..
IAS~e
Society
2003 IEEE. Personal use of this material is permitted. However, permission to print/republish this material for advertising or promotional purposes or for creating new collective works for resale or redistribution to servers or lists, or to reuse any copyrighted component of this work must be obtained from the IEEE. IEEE Catalog Number ISBN
03TH8688C 0-7803-7886-5
Singapore and the first PEDS conference was held in Singapore in 1995. The aim of the PEDS Conference is to provide a forum for participants from the industry and academia in the area of power conference collaboration electronics and drives to exchange ideas and have interactions. Committee, Singapore The in
is biennial
and since
(PEDS-95 Singapore, PEDS-97 Singapore, PEDS-99 Hong Kong and PEDS-01 Bali). All the PEDS conferences are being held in technical co-sponsorship with the IEEE Power
After a gap of nearly six years, PEDS has now comeback to Singapore. The conference includes a half-day tutorial type of four technical seminars to be provided researchers in the afternoon of 17
th
by eminent
November 2003, followed by three days of technical 2003. The Technical Program Committee has
assembled a program that is outstanding in quality and diversity. There will be 322 technical papers presented during the conference, involving authors from 36 different countries.
Besides the technical program spreading over four days, there are many exciting tourist attractions within Singapore as well as in the South East Asian region for the delegates to explore. I hope the conference delegates would bring their families along to enjoy these period. We have appointed a travel agent who
would be located at the conference site to provide help to conference participants and their families.
Finally, I would like to thank everybody involved in the organization of this event for having brought together an outstanding technical program and wish all the participants a very
conference proceedings, which is another record. These papers coming from a record of 36 countries will be presented in 25 oral sessions and 4 poster sessions over the 3-day in this
conference.
PEDS conference.
In keeping with tradition, the conference would be preceded by professional seminars on 17 Nov 2003. There will be a keynote address by Prof Akagi on "Trends in Power Electronics and Motor Drives" during the opening ceremony on the morning of 18 Nov 2003, followed by a plenary session of 4 very interesting papers. Another new feature in this PEDS conference is the Rap Session in the evening of 18 Nov 2003, where a panel of distinguished electronic experts will lead a light-hearted discussion with the audience power
on a thought
provoking topic.
As power electronics and drives technologies mature, there is increasing focus on application issues. Hence the Technical Program Committee has adopted the theme of "Emerging
Opportunities for Power Communities" for PEDS 2003. This is reflected in the applicationsoriented arrangement in the technical sessions. I hope our delegates can depart from this
PEDS conference with new application ideas and new friendships to seek new opportunities in their areas of specialization.
Finally, I would like to express my sincere appreciation to all the members of the Technical Program Committee for their timely and outstanding efforts in reviewing the large number of extended digests. I wish all delegates an enjoyable time in this conference.
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