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fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2703662, IEEE
Transactions on Magnetics
INTERMAG 2017, Paper BH-09 1
The integration of a magnetic gear and a brushless permanent magnet machine to realise a pseudo direct drive (PDD) with
alternative winding configurations is investigated. It is shown topologies which facilitate the winding process and achieve a more
robust stator construction exist. Comparisons with conventional PDD topologies which are essentially equipped with concentric
windings have shown that similar efficiencies can be achieved, albeit at the expense of reduced torque densities. Furthermore, analysis
of the magnetic forces exhibited by a pole-piece has shown that both the average and dynamic forces are significantly affected by the
rated load condition, exacerbating the radial forces.
I. INTRODUCTION
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Transactions on Magnetics
INTERMAG 2017, Paper BH-09 2
Fig. 2 Harmonic spectra of the flux density waveforms in the air gap adjacent
to the stator due to the HSR PMs.
stationary PM array via an essentially constant flux, negligible
EMF is induced as a result.
The realisation of the magnetic gear component should yield
high airgap shear stress whilst maintaining low cogging
torque. In turn the stator should strongly couple the fluxes
from the HSR and those arising from the winding. Selecting a
single tooth per stator magnet pole couples the pole number to
the winding configuration and the number of stator teeth.
Intrinsic to this is the selected number of electrical phases and Fig. 3 Proposed realisation of PM magnet array and alternative winding with
in order to achieve a viable machine, the following conditions a) kcon = 1 and b) kcon = 2
must be satisfied: factor for the fundamental component k w is given by:
Q nq (1) k w kd k p (6)
where n 1,2,3,... Where, k d is the distribution factor is given:
sinq ph . ph / 4
Q (2)
pl kd for even q ph (7)
k con q ph / 2sin ph / 2
ns ph pl sinq ph . ph / 4
(3)
for odd q ph (8)
kd
Gr
ns (4) q ph sin ph / 4
ph
where,
Cf
2 ph ns
1
(5) ph s t (9)
LCM 2 ph , ns
where q is the number of phases, Q is the number of stator q ph
Q (10)
qt
slots, kcon is the number of consecutive stator magnets per where s is the slot pitch and t is the greatest common divisor
pole, ph and pl are the number of pole pairs on the HSR and (GCD) of Q and ph . The pitch factor k p is given by:
stationary magnet arrays, respectively, ns is the number of
modulating pole-pieces, Gr is the gear ratio and C f is the k p sin w (11)
2
Cogging Torque Factor [6]. where the coil span w is given:
Fig. 3(a) shows an example of a PDD, where each stator 2 ph yq (12)
magnet pole is mounted on a stator tooth. However, the use of w
Q
multiple teeth per stator pole is made possible by selecting the
where yq is the number of whole slots per pole. An example
appropriate number of consecutive magnets of the same
polarity ( kcon 1 ). This can result in a different winding of such a dual layer distributed winding, for the machine in
Fig. 3(a), is shown in Fig. 4.
configuration as shown in Fig. 3(b).
B. Winding Configurations III. SIMULATION STUDIES
To analyse key electrical characteristics of the proposed Finite element analysis enabled the determination of the key
machine configuration, parameters including winding factor parameters, including the fundamental airgap flux density,
are required. The winding configuration, where the armature transmitted torque and flux linkage, used to investigate various
pole pair number equals ph , is determined using the method topologies. The parameters of machines under investigation
outlined in [7]. For no rotor or stator skewing the winding are given in Table I. As it is the case for other machine
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2703662, IEEE
Transactions on Magnetics
INTERMAG 2017, Paper BH-09 3
0018-9464 (c) 2016 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2703662, IEEE
Transactions on Magnetics
INTERMAG 2017, Paper BH-09 4
Fig. 8 Variation of shear stress at pull-out torque with the ratio of angular slot Fig. 11 Variation of Required active length with the ratio of angular slot
opening to slot pitch (Conventional concentric winding shear stress at pull-out opening to slot pitch when kcon >1
torque, ~100kPa [1] )
Fig. 12 Variation of Efficiency with the ratio of angular slot opening to slot
Fig. 9 Variation of shear stress at pull-out torque with the ratio of angular slot pitch when kcon =1 at rated power
opening to slot pitch for kcon > 1 (Conventional concentric winding shear stress
at pull-out torque, ~100kPa [1] )
Fig. 13 Variation of Efficiency with the ratio of angular slot opening to slot
pitch when kcon >1 at rated power
Fig. 10 Variation of Required active length with the ratio of angular slot
opening to slot pitch when kcon =1
in Fig. 15 and Fig. 16, which show the variations of the
efficiency with .
efficiency increased with increased , albeit at the expense of
In the proposed machine topology a single stator magnet is
increased size. However, the PDDs with lower gear ratios can
bonded to a single tooth. This leads to a stator tooth carrying
potentially be operated at higher speeds, as the mechanical
the flux from a stator magnet, the magnets on the HSR and
constraints which restrict the maximum speed of the HSR are
flux produced by the stator winding. This can lead to increased
similar for all machines.
flux densities in the teeth and the back-iron. The resulting
The resulting achievable power of those machines is shown
potential saturation can be alleviated by increasing the
in Fig. 14. The machines with lower gear ratios show
thickness of the back-iron and the teeth without increasing the
increased efficiencies when operated at higher speed, as seen
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2703662, IEEE
Transactions on Magnetics
INTERMAG 2017, Paper BH-09 5
Physt kh Bm f (15)
d 2 T dB(t )
2 (16)
Peddy .dt
12T 0 dt
k T dB(t )
1.5 (17)
Pex e .dt
T 0 dt
where Bm is the peak magnetic flux density, f is the
electrical frequency, d is the lamination thickness, is the
electrical conductivity and k h , and ke are constants
determined from iron loss tests under sinusoidal flux density
waveforms and covering a range of frequencies and flux
densities. For the pole-pieces the frequency is different from
that of the stator and is given by:
G 1 (18)
Fig. 14 Variation of potential output power with gear at the same HSR speed
f PP r f
as in [1] Gr
Table II summarises the parameters and performance of the
selected designs. It can be seen that PDD designs with
alternative windings can be achieved with high equivalent
airgap shear stresses as well as high efficiencies and power
factors.
TABLE II
PARAMETERS OF OPTIMISED ALTERNATIVE WINDING PDDS
Fig. 15 Variation of Efficiency with the ratio of angular slot opening to slot PPR speed (rpm) 500 500 500
pitch when kcon = 1 at the same HSR speed as in [1] Rated Torque (Nm) 120 120 120
Active diameter (mm) 178 178 178
Machine Axial Length (mm) 75 111 99
Copper losses (W) 175 102 165
Iron losses (W) 102 124 172
Efficiency 0.958 0.965 0.949
Power factor 0.95 0.99 0.98
Magnet Mass (kg) 3.27 4.46 3.74
Current Density (Armsmm ) -2 1.5 1.3 1.7
Equivalent Airgap Shear
101.4 73.2 71.0
Stress (kPa)
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2703662, IEEE
Transactions on Magnetics
INTERMAG 2017, Paper BH-09 6
Fig. 17 Variation of the radial force (per pole piece) with PPR angular Fig. 20 Harmonic spectra of the circumferential force profile (per pole-piece)
position at rated load at rated load
Fig. 18 Variation of the circumferential force (per pole piece) with PPR
angular position at rated load Fig. 21 Variation of total PPR forces at rated load
Fig. 19 Harmonic spectra of the radial force profile (per pole-piece) at rated Fig. 22 Variation of the radial force (per pole piece) with PPR angular
load position at no load
period for the forces depends on the gear ratio. If the gear ratio and circumferential forces exhibited by a pole-piece. It can be
is non-integer the period is ph rotations of the PPR and ns seen that for the 3 machines the first largest harmonic order is
rotations of HSR. If the gear ratio is integer, the period is one 2 ph pl . The corresponding frequencies of the harmonics are
rotation of the PPR and Gr rotations of the high-rotor. given by:
Therefore, for machines A and B, the period is 720 rotation of n (19)
the PPR, while for machine C the period is 1440 rotation of n pp
ph
the PPR. The average radial forces for machines are A, B and
where n is the harmonic order and pp is the speed of the
C are 36N, -70N and -59N, respectively.
Fig. 19 and Fig. 20, show the harmonic spectra of the radial PPR. Fig. 21 shows the contour of the total force on the PPR
0018-9464 (c) 2016 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TMAG.2017.2703662, IEEE
Transactions on Magnetics
INTERMAG 2017, Paper BH-09 7
Fig. 23 Variation of the circumferential force (per pole piece) with PPR Fig. 26 Variation of total PPR forces at no load
angular position at no load 360o rotation of the PPR. It can be seen that the average
unbalanced magnetic pull is similar to the rated condition.
V. CONCLUSION
A technique for the selection of PDDs equipped alternative
windings is presented. Simulation studies and comparisons
with an existing PDD equipped concentric winding are
undertaken. It is shown that PDDs with alternative windings
can be realised, albeit with reduced torque density.
Nevertheless, shear stresses and power factors in excess of
70kPa and 0.98, respectively, can still be achieved. Special
attention was given to the forces exhibited by a pole-piece,
and it was shown that both the average and dynamic forces are
affected by the load condition.
Fig. 24 Harmonic spectra of the radial force profile (per pole-piece) at no load
ACKNOWLEDGMENT
This work was supported by the European Project
INNWIND.EU and Magnomatics Ltd.
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