Search Results (90)

This paper proposes a fault-tolerant optimal design method for quad-winding permanent magnet synchronous motors (PMSMs) considering irreversible demagnetization under fault conditions. In quad-winding motors, when one or more winding sets become unavailable, the remaining windings must carry higher current to maintain the required torque. This increases the external magnetomotive force acting on the permanent magnets and may cause irreversible demagnetization, particularly in spoke-type magnet structures. To address this issue, the demagnetization characteristics of the quad-winding motor were analyzed under healthy and faulty operating conditions. Based on this analysis, an optimization process using a Radial Basis Function–Multi-Layer Perceptron (RBF–MLP) surrogate model and a combination of grid-based search and local optimization was applied to obtain an optimal motor design. The optimization results show that the irreversible demagnetization ratio was reduced from 5.9% to 0.5% while maintaining a similar magnet volume. The proposed design approach effectively suppresses irreversible demagnetization in quad-winding PMSMs. Full article

Active suspensions in automotive applications are designed to improve vehicle stability and comfort and reduce vibration transmission from the road surface. Active systems often include a dedicated actuator, and, to reduce their mass and energy absorption, it is a typical choice to rely on brushless electric motors with permanent magnets containing Critical Raw Materials such as Neodymium, a Rare Earth Element (REE), offering favorable power density values. Although these systems offer clear advantages in terms of ride quality and performance, their direct and indirect energy requirements, combined with their dependence on resource-intensive materials, raise concerns about life cycle sustainability: in other words, there is a trade-off between production impact (relevant for REE) and use impact (reduced by REE adoption). To address this issue, the research proposes a method to estimate energy consumption during the use phase of a vehicle through a dedicated parametric modeling and simulation framework; the aim is to evaluate the energy performance of active suspension systems under different road and driving conditions. The analysis explores how design parameters and operational choices affect energy consumption and efficiency. The simulation results reveal a marked sensitivity of system performance to road profiles and driving scenarios, highlighting the importance of holistic assessments during the early stages of design. The proposed framework represents a first step toward integrating circular design principles into the development of active suspensions. By combining technical and environmental perspectives, it supports the development of next-generation automotive components that balance comfort, performance, and sustainability. Full article

Recently, unmanned aerial vehicles (UAVs) based on electric propulsion systems are being increasingly adopted in various fields, including industrial and military applications. Outer-rotor surface-mounted permanent magnet synchronous motors (SPMSMs) are predominantly applied in UAV propulsion systems. However, these motors are vulnerable to the price fluctuations of rare-earth materials and supply chain instability. In addition, the magnets in these motors are prone to detachment at high rotational speeds, and demagnetization under high-temperature conditions may reduce output performance. To address these limitations, research is being actively conducted on non-permanent magnet motors, among which, wound-rotor synchronous motors (WRSMs) offer the advantage of controllable field excitation at high speeds. Furthermore, WRSMs can use both magnetic and reluctance torques, thereby increasing power density relative to other non-permanent magnet motors. However, the adoption of an additional field winding increases copper loss, thus reducing motor efficiency. This study investigates the application of the toroidal winding structure, which is already widely applied in permanent magnet and brushless direct current machines, to WRSMs. The performance of these motors is compared with that of motors using conventional tooth-coil windings. The toroidal windings are circumferentially distributed along both the inner and outer stator yoke paths, effectively reducing the end-turn length relative to that of conventional tooth-coil windings. Two WRSMs, one with tooth-coil and another with toroidal windings, are designed using identical specifications to compare performances via finite element analysis. The armature copper loss in the proposed model decreased by approximately 28% because the toroidal winding structure reduced the end-turn length. As a result, the efficiency increased by about 1.9% due to the reductions in copper, core, and eddy current losses. Full article

This paper presents a magnetic-flux-based encoder for BLDC drives that maintains high accuracy under rotor eccentricity and dynamic transients. Conventional Hall-sensor-based angle estimators rely on ideal sinusoidal flux assumptions and degrade in the presence of air-gap distortion or misalignment. To overcome these limitations, a nonlinear autoregressive network with exogenous inputs (NARXNet) is proposed as a temporal neural observer that learns the nonlinear, time-dependent mapping between measured flux densities and the true electrical rotor angle. A physics-informed data augmentation framework combines experimentally measured magnetic flux maps with dynamic simulation to generate diverse training scenarios at low and variable speeds. Validation demonstrates mean angular errors below 2°, 95th-percentile errors under 5°, and negligible drift, with enhanced resilience to eccentric displacement and acceleration transients compared to classical methods. The proposed approach provides a compact, data-driven sensing solution for robust, encoderless electric drive control. Full article

Synchronous motors with a field winding in the rotor, known as wound-rotor synchronous motors (WRSMs) or electrically excited synchronous motors (EESMs), are claimed to be a good alternative to induction motors and even permanent-magnet synchronous motors (PMSMs) in electric traction applications. WRSMs do not require expensive rare-earth magnets and potentially have high power and torque density, and lower inverter power and cost, especially in applications demanding a wide constant-power speed range. Designing WRSMs for electric traction imposes some challenges and requires careful analysis. This paper provides an overview of commercial WRSMs for ground electric transport over the past 40 years, a comparison of WRSMs with other types of electric motors suitable for electric traction, and an overview of optimization methods and brushless excitation technologies for such machines. The goals of this paper are to present and discuss design approaches for traction WRSMs, to benchmark WRSMs against other motor types used in ground electric transport, and to highlight the most promising WRSM topologies and design techniques. Full article

Railway barrier drives are key components of railway infrastructure and have a direct impact on traffic safety. Many of the commonly used drives are mechanical EEG-type barrier drives. EEG is a commercial designation of level-crossing gate drives produced by one of the Polish railway signalling equipment manufacturers, currently known as Alstom ZWUS Polska Sp. z o.o. (Katowice, Poland). These drives are characterized by their simple design and low cost, but limited efficiency and durability. Operational experience shows particular problems with the operation of this type of drive in winter conditions. This article presents an analysis of the impact of the selection of electric motors on the efficiency and reliability of level crossing drives. In addition to discussing the classic design with a PRMOa90-90 motor, commonly used in EEG drives, two proprietary solutions are presented: a commutator motor with rectangular neodymium magnets and a brushless DC motor (BLDC). Key operating parameters such as energy efficiency, starting torque, durability, maintenance requirements, and costs were compared. The results of the analyses indicate that the use of motors with neodymium magnets and BLDC solutions can significantly increase the efficiency and reliability of barrier drives, with each variant presenting a different profile of advantages and limitations. Full article

Demand for brushless alternatives to the series universal motors and induction motors in domestic applications and automotive applications is increasing. Among the available candidates, single-phase flux-switching permanent magnet (SP-FSPM) machines have gained attention due to a simpler magnetic structure and control system. However, their torque density remains limited. Therefore, a SP doubly-fed FSPM (SP-DF-FSPM) machine is developed in this paper which features an additional set of armature windings on the rotor. By effectively utilizing the rotor slot area, the proposed SP-DF-FSPM machine enhances electrical loading and torque density while providing inherent fault-tolerant capability, a critical addition compared with conventional SP-FSPM machines. A comprehensive parameter-sensitivity analysis is conducted for a 10-stator-pole/10-rotor-tooth configuration to optimize key geometric parameters for the maximum torque and reliable self-starting operation. The electromagnetic performance of an optimized design is evaluated and compared against a conventional SP-FSPM machine. The results show that the SP-DF-FSPM machine can achieve a 24.75% higher torque output, improved efficiency, and enhanced power factors under the healthy condition. Moreover, the machine can deliver 63.5% and 36.0% torque when operating with only stator and rotor windings, respectively, demonstrating the fault-tolerant capability. Experimental validation via an SP-DF-FSPM prototype shows close agreement with simulation results. Full article

Accurate modeling of Brushless DC (BLDC) motors is crucial for the multi-domain simulation of complex electromechanical systems like electric torque tools, especially when high fidelity is required for Model-Based Design (MBD) and controller validation. Standard BLDC models often employ simplifications that may not capture critical operational details. This paper presents a comparative analysis of four distinct BLDC motor simulation models: two based on ready-to-use MATLAB/Simulink/Simscape Electrical library blocks (Specialized Power Systems/Electrical Machines/Permanent Magnet Synchronous Machine and Electromechanical/Permanent Magnet/BLDC) and two custom models developed by the authors at AGH University. The models are evaluated based on their structure, underlying equations, and performance in simulating typical operational scenarios of an electric torque tool. Key assessment criteria include the ability to implement realistic (e.g., tabulated, non-ideal) back-EMF (electromotive force) profiles, incorporate cogging torque, model commutation effects, and flexibility for modification. Simulation results indicate that while all models can be suitable for basic control design, the custom-developed models offer greater flexibility and fidelity in representing detailed motor phenomena such as irregular back-EMF waveforms and cogging torque, making them better suited for advanced, high-precision applications. Conversely, standard library models, particularly the one underlying the PMSM block, exhibit limitations in custom back-EMF implementation. This study concludes by recommending models based on specific application requirements and outlines directions for future enhancements, including thermal modeling and iron loss representation. Full article

As electric scooters (e-scooters) continue to populate city streets and gain popularity as a key mode of micro-mobility, issues such as their energy consumption and demand from the power grid, as well as optimizing their electrical systems, become increasingly important. Improving performance requires a deep understanding of their electrical behavior and the design of smart control strategies. This paper presents a detailed analysis of the entire electrical system of commercial electric scooters, with a particular focus on the performance of key components such as the permanent magnet brushless direct current motor and the lithium-ion battery system. The study involves modeling and simulation of motor control, battery management, and DC-link voltage stabilization using MATLAB/Simulink. The simulations are complemented by laboratory measurements of the motor performance in an SXT Scooters MAX unit under various operating conditions. Additionally, a complete battery charging cycle is analyzed to evaluate charging characteristics and usable energy storage capacity. This paper presents a first step for researchers interested in studying the electrical systems of e-scooters. Additionally, it can serve as educational material for electrical engineers in the field of e-scooters. Full article

Electric vehicles are playing an important role in transport, aided by rapid advances in battery technology. The Faculty of Engineering at the University of Debrecen is also engaged research and development in the field of electric vehicles. To support the development of electric vehicle prototypes, a vehicle dynamics simulation program has been designed. The study presents the modeling and simulation of a permanent magnet synchronous motor (PMSM) in MATLAB/Simulink, which has been integrated into the existing vehicle dynamics simulation framework. The methods used to determine the motor characteristics required for the simulation are described in detail. In addition, the performance of the PMSM is compared with that of a brushless DC (BLDC) motor within the vehicle dynamics simulation program. The developed method allows the selection of the appropriate motor type for the given competition tasks. Full article

This paper proposes a model identification method based on the auxiliary variable closed-loop subspace identification algorithm to address the problem of modeling difficulties caused by various complex factors affecting permanent magnet brushless DC motors in practical working conditions. This method breaks through the limitations caused by the correlation between input signals and noise in traditional subspace identification algorithms. By introducing auxiliary variables, it effectively avoids the projection process, simplifies the complex calculations of principal component analysis, and improves the practicality and efficiency of the algorithm. When constructing a data-driven identification model, the actual situation of measurement data being contaminated by noise has to be fully considered. Orthogonal compensation matrices and auxiliary variables were used to construct uncorrelated terms for noise, thereby eliminating the negative impact of noise on the model’s identification accuracy. The effectiveness of the proposed identification algorithm was verified by collecting data through a chassis dynamometer simulation test of a vehicle-mounted permanent magnet brushless DC motor. The results show that compared with the traditional N4SID algorithm, the proposed closed-loop subspace identification algorithm based on auxiliary variable principal component analysis exhibits higher model identification accuracy, stronger anti-interference ability, and better stability in both noise-free and noise-contaminated conditions, providing a more reliable model basis for motor performance evaluation and control strategy design. Full article

This study investigates the electromagnetic analysis and optimal design of outer rotor type brushless DC (BLDC) motors for fan filter applications. The primary objective is to develop a method that integrates three-dimensional (3D) structural effects with efficient two-dimensional (2D) equivalent analysis. This study proposes a 2D equivalent analysis method that addresses the unique features of outer rotor type BLDC motors, particularly the permanent magnet (PM) overhang structure. This approach transforms the operating point on the B–H curve to facilitate accurate modeling in a 2D framework, overcoming traditional analysis limitations. An analytical method using spatial harmonics is introduced to derive essential electromagnetic quantities, namely flux linkage and back electromotive force (EMF). The method compensates for slot effects using the Carter coefficient, ensuring precise evaluation of circuit parameters and electromagnetic losses. To optimize motor performance, a multi-objective optimization technique is implemented using the Non-dominated Sorting Genetic Algorithm-II (NSGA-II), aiming to maximize both efficiency and power density. The research validates the proposed analytical approach against the finite element analysis method (FEM) results to confirm its accuracy. Full article

In hub-motor electric vehicles (HMEVs), performance is adversely affected by the mechanical-electromagnetic coupling effect arising from deformations of the air gap in the Permanent Magnet Brushless Direct Current Motor (PM BLDC), which are exacerbated by varying road conditions. In this paper, a Model Predictive Control (MPC) strategy for HMEVs equipped with air suspension (AS) is introduced to enhance ride comfort. Firstly, an 18-degree of freedom (DOF) full-vehicle model incorporating unbalanced electromagnetic forces (UEMFs) induced by motor eccentricities is developed and experimentally validated. Additionally, a Minimum Model Error Extended Kalman Filter (MME-EKF) observer is designed to estimate unmeasurable state variables and account for errors resulting from sprung mass variations. To further improve vehicle performance, the MPC optimization objective is formulated by considering the suspension damping force and dynamic displacement constraints, solving for the optimal suspension force within a rolling time domain. Simulation results demonstrate that the proposed MPC approach significantly improves ride comfort, effectively mitigates coupling effects in hub driving motors, and ensures that suspension dynamic stroke adheres to safety criteria. Comparative analyses indicate that the MPC controller outperforms conventional PID control, achieving substantial reductions of approximately 41.59% in sprung mass vertical acceleration, 14.29% in motor eccentricity, 1.78% in tire dynamic load, 17.65% in roll angular acceleration, and 16.67% in pitch angular acceleration. Full article

Additive manufacturing (AM) has the potential to produce novel high-performance electrical machines, enabling the direct printing of complex shapes and the simultaneous processing of multiple feedstocks in a single build. We examined the properties and functional performance of Fe-3 wt.% Si materials that were printed via selective laser melting, machined down to thin laminates, and stacked to form a stator core of a prototype brushless permanent-magnet electrical motor. Big Area Additive Manufacturing of Nd₂Fe₁₄B (NdFeB)–polyphenylene sulfide (PPS) bonded magnets was performed, with them then being magnetized and used for the rotor. The magnetic, mechanical, and electrical properties of the as-printed and various heat-treated thin laminates and the back electromotive force (EMF) of the electrical motors at different rotational speeds were measured. The thin laminates exhibit a maximum relative permeability of 7494 at an applied field of 0.8 Oe and a core loss of about 20 W/lb at 60 Hz with the maximum induction of 15 kg. In addition to the demonstration of AM printing, motor assembly, and complete characterization of printed Fe-3 wt.% Si, this report highlights the areas of improvement needed in printing technologies to achieve AM built electrical motors and the need for isotropic microstructure refinements to make the laminates appropriate for high-mechanical-strength and low-loss rotational electrical devices. Full article

Using the low-voltage and low-current platform (220 VAC-10 A), this paper selected the Mayr arc theoretical model and the improved control theory model as a theoretical basis and built a single-phase low-voltage AC series arc model based on Simulink. The simulation results showed that arc dissipation power directly determined arc voltage amplitude, arc time constant influenced arc voltage waveform, and arc current was mainly determined by load resistance. Because the arc length parameter can be set by the improved control arc theory model, the arc can be drawn only at the micro-distance of two electrodes, which is more suitable for describing the arc characteristics of low voltage and low current. A scheme of large ratio reducer for permanent magnet brushless DC motor was developed, which was combined with the stepless governor controlled by PWM and the positive and negative switch to realize the adjustment of the two-electrode micro-distance. The collection and analysis of arc voltage and arc current under pure resistance, resistive load, and multi-branch load were completed. The experimental results also verified that the Mayr arc and improved control theory arc have good accuracy in describing low voltage and low current characteristics, which improves data support for later fault identification and removal. Full article