Figure 1.
Electric motor design procedure.
Figure 1.
Electric motor design procedure.
Figure 2.
Synchronous reluctance motor (SynRM) electromagnetic design parameters.
Figure 2.
Synchronous reluctance motor (SynRM) electromagnetic design parameters.
Figure 3.
SynRM design parameters.
Figure 3.
SynRM design parameters.
Figure 4.
(a) B-H curve of the M700 Si-steel; (b) The mesh discretization of 4 kW motor.
Figure 4.
(a) B-H curve of the M700 Si-steel; (b) The mesh discretization of 4 kW motor.
Figure 5.
The equi-flux lines and flux densities of (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW Induction motors.
Figure 5.
The equi-flux lines and flux densities of (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW Induction motors.
Figure 6.
The normal component of the flux density in the air gap (a) 2.2 kW, (c) 4 kW, and (e) 5.5 kW motors and torque variation of (b) 2.2 kW, (d) 4 kW, and (f) 5.5 kW motors.
Figure 6.
The normal component of the flux density in the air gap (a) 2.2 kW, (c) 4 kW, and (e) 5.5 kW motors and torque variation of (b) 2.2 kW, (d) 4 kW, and (f) 5.5 kW motors.
Figure 8.
SynRM design parameters (A The number of rotor barriers per pole: (a) one barrier, (b) two barriers, (c) three barriers, (d) four barriers, B Barrier Shape: (e) angular, (f) round, (g) angular-round, (h) cut-off).
Figure 8.
SynRM design parameters (A The number of rotor barriers per pole: (a) one barrier, (b) two barriers, (c) three barriers, (d) four barriers, B Barrier Shape: (e) angular, (f) round, (g) angular-round, (h) cut-off).
Figure 9.
Torque profiles of the 2.2 kW SynRM due to the number of rotor barriers (Data from [
22]).
Figure 9.
Torque profiles of the 2.2 kW SynRM due to the number of rotor barriers (Data from [
22]).
Figure 10.
Torque outputs of 2.2 kW SynRM due to different end thicknesses for three and four barriers (Data from [
22]).
Figure 10.
Torque outputs of 2.2 kW SynRM due to different end thicknesses for three and four barriers (Data from [
22]).
Figure 11.
Air gap flux density of 2.2 kW SynRM due to different end thicknesses (Data from [
22]).
Figure 11.
Air gap flux density of 2.2 kW SynRM due to different end thicknesses (Data from [
22]).
Figure 12.
Flux density and average torque of 2.2 kW SynRM for different number of barriers and air gap values.
Figure 12.
Flux density and average torque of 2.2 kW SynRM for different number of barriers and air gap values.
Figure 13.
Torque ripple of 2.2 kW SynRM for different number of barriers and air gap values.
Figure 13.
Torque ripple of 2.2 kW SynRM for different number of barriers and air gap values.
Figure 14.
The output torque variation for different power levels.
Figure 14.
The output torque variation for different power levels.
Figure 15.
Structural analysis of 2.2 kW motor with four-rotor barrier per pole (a) total deformation (axial view), (b) total deformation (radial view), (c) Equivalent Elastic Strain (axial view), (d) Equivalent Elastic Strain (radial view), (e) Equivalent Stress (axial view), (f) Equivalent Stress (radial view), (g) Safety Factor (axial view), (h) Safety Factor (radial view).
Figure 15.
Structural analysis of 2.2 kW motor with four-rotor barrier per pole (a) total deformation (axial view), (b) total deformation (radial view), (c) Equivalent Elastic Strain (axial view), (d) Equivalent Elastic Strain (radial view), (e) Equivalent Stress (axial view), (f) Equivalent Stress (radial view), (g) Safety Factor (axial view), (h) Safety Factor (radial view).
Figure 16.
Prototype motor sample lamination and the rotor [
22].
Figure 16.
Prototype motor sample lamination and the rotor [
22].
Figure 17.
(a) Prototype SynRM Motors at 5.5 kW, 4 kW, and 2.2 kW; (b) Prototype motor and its driver.
Figure 17.
(a) Prototype SynRM Motors at 5.5 kW, 4 kW, and 2.2 kW; (b) Prototype motor and its driver.
Figure 18.
Comparison of Torque vs. Current for (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW.
Figure 18.
Comparison of Torque vs. Current for (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW.
Figure 19.
Comparison of Input Power vs. Torque for (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW.
Figure 19.
Comparison of Input Power vs. Torque for (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW.
Figure 20.
Comparison of Total Losses vs. Torque for (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW.
Figure 20.
Comparison of Total Losses vs. Torque for (a) 2.2 kW, (b) 4 kW, and (c) 5.5 kW.
Figure 21.
Thermal analysis of 2.2 kW SynRM (a) radial, (b) axial, (c) nodal equivalent representation.
Figure 21.
Thermal analysis of 2.2 kW SynRM (a) radial, (b) axial, (c) nodal equivalent representation.
Table 1.
Reference Induction Motors’ Nameplate.
Table 1.
Reference Induction Motors’ Nameplate.
Power (kW) | 5.5 | 4 | 2.2 |
---|
Voltage (V) | 400/690 | 400/690 | 230/400 |
Current (A) | 11.1/6.4 | 8.3/4.8 | 8.5/4.9 |
Frequency (Hz) | 50 | 50 | 50 |
Number of Poles | 4 | 4 | 4 |
Speed (min−1) | 1465 | 1455 | 1450 |
Slip | 0.0233 | 0.03 | 0.033 |
Efficiency (%) | 89.6 | 88.6 | 86.7 |
Table 2.
Stator resistances per phase for the reference induction motors.
Table 2.
Stator resistances per phase for the reference induction motors.
Power | Initial Condition | Thermal Regime |
---|
Temperature (°C) | Resistance (Ohms) | Temperature (°C) | Resistance (Ohms) |
---|
2.2 kW | 22 | 1.91 | 64.1 | 2.196 |
4 kW | 22 | 2.35 | 72.8 | 3.159 |
5.5 kW | 22 | 1.32 | 67 | 1.603 |
Table 3.
No-Load Test results of 2.2 kW induction motor.
Table 3.
No-Load Test results of 2.2 kW induction motor.
V (V) | V2 | I (A) | P0 (W) | Pcu0 (W) | Pfe + Pfw0 (W) |
---|
120 | 14,400 | 0.86 | 43 | 4.9 | 38.1 |
160 | 25,600 | 1.13 | 55 | 8.5 | 46.5 |
200 | 40,000 | 1.43 | 70 | 13.5 | 56.5 |
240 | 57,600 | 1.73 | 88 | 19.6 | 68.4 |
305 | 93,025 | 2.28 | 124 | 34.1 | 89.9 |
370 | 136,900 | 3.02 | 178 | 60.2 | 117.8 |
400 | 160,000 | 3.49 | 210 | 80.1 | 129.9 |
435 | 189,225 | 4.22 | 271 | 117.5 | 153.5 |
Table 4.
No-Load Test results of 4 kW induction motor.
Table 4.
No-Load Test results of 4 kW induction motor.
V (V) | V2 | I (A) | P0 (W) | Pcu0 (W) | Pfe + Pfw0 (W) |
---|
120 | 14,400 | 0.95 | 36 | 8.6 | 27.4 |
160 | 25,600 | 1.49 | 48 | 21 | 27 |
200 | 40,000 | 1.81 | 68 | 31 | 36.9 |
240 | 57,600 | 2.24 | 93 | 47.5 | 45.4 |
305 | 93,025 | 3.01 | 140 | 85.8 | 54.2 |
370 | 136,900 | 4.1 | 210 | 159.3 | 50.69 |
400 | 160,000 | 4.7 | 263 | 209.3 | 53.7 |
435 | 189,225 | 5.4 | 366 | 276.3 | 89.7 |
Table 5.
No-Load Test results of 5.5 kW induction motor.
Table 5.
No-Load Test results of 5.5 kW induction motor.
V (V) | V2 | I (A) | P0 (W) | Pcu0 (W) | Pfe + Pfw0 (W) |
---|
120 | 14,400 | 1.6 | 68 | 12.3 | 55.7 |
160 | 25,600 | 2.1 | 88 | 21 | 67 |
200 | 40,000 | 2.63 | 120 | 33.3 | 86.7 |
240 | 57,600 | 3.22 | 151 | 49.8 | 101.2 |
305 | 93,025 | 4.26 | 213 | 87 | 126 |
370 | 136,900 | 5.62 | 298 | 151.8 | 146.2 |
400 | 160,000 | 6.47 | 349 | 201.3 | 147.7 |
435 | 189,225 | 8.07 | 434 | 312.9 | 121.1 |
Table 6.
Load Test results of 2.2 kW IM.
Table 6.
Load Test results of 2.2 kW IM.
Parameters | 25% | 50% | 75% | 100% | 115% | 125% |
---|
Voltage V (V) | 402 | 401 | 401 | 401 | 400 | 401 |
Phase Current I1 (A) | 3.5 | 3.82 | 4.37 | 4.92 | 5.83 | 6.72 |
Input Power Pin (W) | 771 | 1336 | 1943 | 2560 | 3187 | 3822 |
Torque T (Nm) | 3.6 | 7.3 | 10.9 | 14.6 | 18.2 | 21.9 |
Speed n (min−1) | 1487 | 1473 | 1458 | 1445 | 1427 | 1410 |
Output Power Pout (W) | 560 | 1126 | 1663 | 2208 | 2718 | 3232 |
Efficiency | 72.7 | 84.2 | 85.6 | 86.3 | 85.3 | 84.6 |
Table 7.
Load Test results of 4 kW IM.
Table 7.
Load Test results of 4 kW IM.
Parameters | 25% | 50% | 75% | 100% | 115% | 125% |
---|
Voltage V (V) | 402 | 400 | 401 | 401 | 400 | 401 |
Phase Current I1 (A) | 5.19 | 5.88 | 6.91 | 8.22 | 9.73 | 11.41 |
Input Power Pin (W) | 1264 | 2327 | 3415 | 4500 | 5655 | 6819 |
Torque T (Nm) | 6.6 | 13.2 | 19.8 | 26.3 | 32.9 | 39.5 |
Speed n (min−1) | 1491 | 1480 | 1466 | 1457 | 1439 | 1426 |
Output Power Pout (W) | 1030 | 2045 | 3038 | 4011 | 4955 | 5896 |
Efficiency | 81.5 | 88 | 89 | 89.1 | 87.6 | 86.5 |
Table 8.
Load Test results of 5.5 kW IM.
Table 8.
Load Test results of 5.5 kW IM.
Parameters | 25% | 50% | 75% | 100% | 115% | 125% |
---|
Voltage V (V) | 402 | 400 | 399 | 400 | 401 | 400 |
Phase Current I1 (A) | 6.74 | 7.77 | 9.27 | 11.1 | 13.11 | 15.24 |
Input Power Pin (W) | 1701 | 3161 | 4632 | 6122 | 7652 | 9188 |
Torque T (Nm) | 9.1 | 18.1 | 27.2 | 36.2 | 45.3 | 54.3 |
Speed n (min−1) | 1491 | 1484 | 1476 | 1467 | 1455 | 1445 |
Output Power Pout (W) | 1420 | 2814 | 4202 | 5558 | 6899 | 8213 |
Efficiency | 83.5 | 89 | 90.7 | 90.8 | 90.2 | 89.4 |
Table 9.
Induction Motors’ FEM and TEST results.
Table 9.
Induction Motors’ FEM and TEST results.
Parameter | 2.2 kW FEM | 2.2 kW Test | 4 kW FEM | 4 kW Test | 5.5 kW FEM | 5.5 kW Test |
---|
Torque (Nm) | 14.6 | 14.5 | 26.26 | 26.3 | 36.1 | 36.2 |
Current (Arms) | 4.8 | 4.95 | 8 | 8.22 | 11.1 | 11.7 |
Output Power (W) | 2215 | 2203 | 3957 | 3984 | 5535 | 5482 |
Efficiency (%) | 86 | 86.3 | 89.53 | 89.1 | 89.8 | 90.8 |
Table 10.
Output Torques and their ripples due to the rotor barriers’ number for 2.2 kW SynRM motor.
Table 10.
Output Torques and their ripples due to the rotor barriers’ number for 2.2 kW SynRM motor.
Parameter | 1 Barrier | 2 Barriers | 3 Barriers | 4 Barriers |
---|
Torque (Nm) | 15.1 | 17.9 | 19.1 | 24.4 |
Torque Ripple (%) | 77 | 46 | 41 | 27 |
Table 11.
Air Gap Flux Densities and average output torque of 2.2 kW SynRM due to different end thicknesses for three and four barriers.
Table 11.
Air Gap Flux Densities and average output torque of 2.2 kW SynRM due to different end thicknesses for three and four barriers.
Parameter | 3 Barriers | 4 Barriers |
---|
Thickness (mm) | 0.5 | 1 | 1.5 | 0.5 | 1 | 1.5 |
Flux Density (T) | 0.78 | 0.78 | 0.78 | 0.79 | 0.78 | 0.78 |
Torque (Nm) | 28.9 | 23.9 | 19 | 29.9 | 24.7 | 19.8 |
Table 12.
Average Output Torques and their torque ripples for SynRM at different power ratings.
Table 12.
Average Output Torques and their torque ripples for SynRM at different power ratings.
Parameter | 4 Barriers |
---|
2.2 kW | 4 kW | 5.5 kW |
---|
Torque (Nm) | 14.1 | 25.2 | 35.03 |
Torque Ripple (%) | 18 | 17 | 22 |
Table 13.
Mechanical Characteristics of Rotor Si-Steel.
Table 13.
Mechanical Characteristics of Rotor Si-Steel.
Parameters | M700 |
---|
Mass Density (kg/m3) | 7800 |
Young Modulus (GPa) | 210 |
Poisson Coefficient | 0.31 |
Tensile Yield Strength (MPa) | 300 |
Tensile Ultimate Strength (MPa) | 410 |
Table 14.
Structural analysis results of 2.2 kW motor.
Table 14.
Structural analysis results of 2.2 kW motor.
Parameter | 1 Barrier | 4 Barriers |
---|
Maximum Total Deformation (µm) | 29.296 | 16.755 |
Maximum Elastic Strain (mm/mm) | 1.942 × 10−4 | 1.1719 × 10−4 |
Maximum Stress (MPa) | 25,424 | 24,555 |
Minimum Safety Factor | 64.525 | 12.217 |
Maximum Safety Factor | 15 | 15 |
Table 15.
Load Test results of 2.2 kW SynRM.
Table 15.
Load Test results of 2.2 kW SynRM.
Parameters | 25% | 50% | 75% | 100% | 115% | 125% |
---|
Voltage V (V) | 396.6 | 436.5 | 455.5 | 452.1 | 453.8 | 450.3 |
Phase Current I1 (A) | 2.34 | 3.25 | 4.03 | 4.91 | 5.95 | 7.16 |
Input Power Pin (W) | 651 | 1275 | 1887 | 2490 | 3159 | 3843 |
Torque T (Nm) | 3.52 | 7.04 | 10.56 | 14.1 | 17.6 | 21.1 |
Speed n (min−1) | 1500 | 1500 | 1500 | 1500 | 1500 | 1500 |
Output Power Pout (W) | 553.1 | 1106 | 1659 | 2212 | 2765 | 3318 |
Efficiency | 85 | 86.8 | 87.9 | 88.9 | 87.6 | 86.4 |
Table 16.
Load Test results of 4 kW SynRM.
Table 16.
Load Test results of 4 kW SynRM.
Parameters | 25% | 50% | 75% | 100% | 115% | 125% |
---|
Voltage V (V) | 461 | 469 | 485 | 478 | 457 | 473 |
Phase Current I1 (A) | 3.84 | 5.59 | 7.14 | 8.8 | 10.9 | 13.38 |
Input Power Pin (W) | 1147 | 2240 | 3326 | 4413 | 5540 | 6745 |
Torque T (Nm) | 6.38 | 12.75 | 19.13 | 25.5 | 31.88 | 38.26 |
Speed n (min−1) | 1500 | 1500 | 1500 | 1500 | 1500 | 1500 |
Output Power Pout (W) | 1001.5 | 2003 | 3004.6 | 4006.1 | 5007.7 | 6009.2 |
Efficiency | 87.3 | 89.4 | 90.3 | 90.8 | 90.4 | 89.1 |
Table 17.
Load Test results of 5.5 kW SynRM.
Table 17.
Load Test results of 5.5 kW SynRM.
Parameters | 25% | 50% | 75% | 100% | 115% |
---|
Voltage V (V) | 485 | 457 | 469 | 469.4 | 462 |
Phase Current I1 (A) | 5.34 | 7.61 | 9.59 | 11.8 | 13.79 |
Input Power Pin (W) | 1580 | 3052 | 4571 | 6013 | 7067 |
Torque T (Nm) | 8.83 | 17.64 | 26.46 | 35.3 | 42.56 |
Speed n (min−1) | 1500 | 1500 | 1500 | 1500 | 1459 |
Output Power Pout (W) | 1387 | 2770 | 4156 | 5550 | 6501 |
Efficiency | 87.8 | 90.8 | 90.9 | 92.3 | 92 |
Table 18.
Comparative Measured Performance Results (Frame-Size-Power Range).
Table 18.
Comparative Measured Performance Results (Frame-Size-Power Range).
Parameter | 2.2 kW (4 Pole) 100 Frame | 4 kW (4 Pole) 112 Frame | 5.5 kW (4 Pole) 132 Frame |
---|
IM | SynRM | IM | SynRM | IM | SynRM |
---|
Voltage (V) | 400 | 452.1 | 400 | 478 | 400 | 469.4 |
Current (A) | 4.95 | 4.91 | 8.3 | 8.8 | 11.1 | 11.8 |
Speed (min−1) | 1450 | 1500 | 1455 | 1500 | 1465 | 1500 |
Torque (Nm) | 14.48 | 14 | 26.25 | 25.46 | 35.85 | 35.01 |
cos θ | 0.78 | 0.647 | 0.79 | 0.6 | 0.79 | 0.6 |
Table 19.
Rotor Materials of IM & SynRM (in pu).
Table 19.
Rotor Materials of IM & SynRM (in pu).
Material | 2.2 kW | 4 kW | 5.5 kW |
---|
IM | SynRM | IM | SynRM | IM | SynRM |
---|
Magnetic steel | 0.79 | 0.79 | 0.79 | 0.79 | 0.88 | 0.88 |
Aluminum conductor | 0.21 | - | 0.21 | - | 0.11 | - |
Total active material at rotor | 1 | 0.79 | 1 | 0.79 | 1 | 0.88 |
Table 20.
Winding Temperatures of 2.2 kW motors.
Table 20.
Winding Temperatures of 2.2 kW motors.
SynRM | IM |
---|
Parameter | MOTORCAD | Test | Test |
---|
Temperature (°C) | 56.1 | 55 | 64.1 |
Table 21.
Vibration and Torque Ripple Comparison.
Table 21.
Vibration and Torque Ripple Comparison.
Power | Vibration (m/s2) | Torque Ripple (%) |
---|
IM | SynRM | IM | SynRM |
---|
2.2 kW | 0.267 | 1.43 | 13.5 | 18 |
4 kW | 0.273 | 1.67 | 15.2 | 17 |
5.5 kW | 0.316 | 1.82 | 20 | 22 |