Search Results (1,425)

Outer rotor permanent magnet synchronous motors (ORPMSMs) are widely used in drone and aircraft propulsion due to their high power density. However, conventional arc-shaped designs involve an inherent trade-off between efficiency and torque ripple. Increasing the arc curvature improves the sinusoidal air gap flux density and reduces torque ripple, but it also increases rotor eddy current loss due to larger flux variations, thereby degrading efficiency. This paper investigates the effects of stator and rotor geometries on rotor eddy current loss and torque ripple in ORPMSMs. To address this trade-off, arc- and rectangular-shaped rotor and stator pole shoes are combined to form four design candidates. Their electromagnetic performance is evaluated using finite element analysis. Based on this comparison, a configuration with rectangular rotor and stator pole shoes is selected as the initial design and further optimized using a multi-objective genetic algorithm to simultaneously improve efficiency and torque ripple. The optimized design demonstrates significant improvements, achieving reductions of 56.67% in peak-to-peak torque ripple and 46.89% in rotor eddy current loss compared to the initial design. Full article

Against the backdrop of the global clean energy transition, this paper addresses the volatility of renewable energy like wind and PV power, focusing on magnetic suspended flywheel energy storage systems (FESS). It expounds FESS’s structure (flywheel body, magnetic suspension bearings, etc.) and working principles (charging, energy retention, discharging) and studies key technologies including rotor material selection, magnetic bearing classification/modeling, motor coordination, and heat dissipation. Challenges such as high material costs and magnetic bearing stability are pointed out, with prospects for developing FESS toward higher performance, lower cost, and multi-scenario integration to support the clean transformation of power systems. Full article

The Axial Flux Permanent Magnet Synchronous Motor (AFPMSM) has gained significant attention as a core power source for next-generation industrial sectors, including electric vehicles, wind turbines, robot joints, and drone propulsion motors, due to its high power density from a short axial length and large radial dimensions. Despite these structural advantages, cogging torque caused by magnetic interaction between the stator teeth and permanent magnets remains a critical drawback, inducing noise and vibration. While conventional Soft Magnetic Composite (SMC) core methods facilitate 3D flux paths, they suffer from low magnetic permeability, insufficient mechanical strength, and manufacturing complexity. To address these issues, this study proposes a stepped structure model utilizing electrical steel sheets to effectively reduce cogging torque. This structure features radial stacking of identical electrical steel sheets with varying widths, where each layer's center is incrementally shifted in the rotational direction. This configuration achieves an effect analogous to continuous skewing without specialized 3D machining. To validate the proposed design, 3D Finite Element Analysis (FEA) was conducted. Results demonstrate that the peak-to-peak cogging torque was reduced to approximately 86% of the conventional model’s value, while maintaining the back-EMF reduction rate within 5%. By presenting a novel skewing technique, this research provides a practical alternative for high-precision and high-power AFPMSM. Full article

This paper presents an analysis of the impact of sub-cycle voltage reductions (below 1 ms) on the operation of a slip-ring induction motor. Due to the specific design of the slip-ring induction motor and the presence of a separate rotor circuit, direct measurements of rotor currents and voltages are possible, enabling a more detailed analysis of the physical phenomena occurring in the machine. A series of experiments was conducted using the Profline 2100 device, which enables the generation of controlled sub-cycle voltage reductions. This made it possible to directly assess the influence of such disturbances on motor operation, particularly changes in stator and rotor currents, rotational speed, and electromagnetic torque pulsations. The electrical and mechanical parameters of the motor were also identified. The obtained data were used to develop a mathematical model and implement it in the MATLAB/Simulink environment, enabling qualitative reproduction of the observed phenomena. The main novelty of this work is the analysis of the electromagnetic response of a slip-ring induction motor to sub-cycle voltage reductions below 1 ms, supported by direct measurements in the rotor circuit. The resulting model, validated against measurement results, shows qualitative agreement with the experiments and enables a more detailed analysis of motor dynamics during sub-cycle voltage reductions, including phenomena that are difficult to capture experimentally. Full article

The optimization of blanking technology using the novel double-layer configuration allows for increased production capacity, but it introduces certain drawbacks, which mainly affect the quality of the blanked parts. In this study, the effect of this blanking configuration was evaluated on two types of electrical steels intended for the production of rotor and stator cores. A numerical simulation of the blanking process was conducted using the Simufact Forming 2022 software. Analysis of the experimental results showed that blanks produced by the double-layer configuration exhibit significantly increased dishing deformation, more than 3.5 times for material B and more than nine times for material C when compared with the dishing increment in single-layer samples. Each layer of the configuration also produces different sheared edge shapes with different proportions of zones. Neither of the layers corresponds fully to the results produced by conventional blanking. Based on the results of the simulations of this process, it can be concluded that this simulation software can predict double-layer blanking with limited accuracy as most differences between measured parameters of the sheared edge relative to the nominal thickness are within 20%. Full article

Large-diameter axial ventilation fans are widely used in poultry houses to regulate ai flow, temperature, and air quality. However, conventional induction motors driving these fans typically operate at fixed speed and suffer efficiency degradation under low-speed, high-torque conditions due to slip-induced rotor copper losses. This study presents an experimental investigation of a manufacturing constrained conversion of a commercial induction motor platform into a direct-drive surface permanent magnet synchronous motor (PMSM). Instead of developing a completely new motor design, the proposed approach reuses the existing stator lamination, housing structure, and winding production process while redesigning the rotor electromagnetic structure to incorporate surface-mounted permanent magnets. Experimental testing was conducted using a dynamo meter-based measurement system to evaluate the performance of both the commercial induction motor and the converted PMSM prototype. The results show that the commercial induction motor exhibits significant efficiency degradation at high torque due to increased slip, whereas the PMSM eliminates slip-dependent rotor copper losses and maintains efficiencies above 88% within the typical ventilation operating range of 650–750 rpm. This study further relates airflow demand to rotational speed using fan affinity laws, highlighting the cubic relationship between speed and input power and demonstrating the energy-saving potential of variable-speed PMSM drives. The proposed conversion framework therefore provides a practical pathway for improving the energy efficiency of agricultural ventilation systems while maintaining compatibility with existing motor manufacturing infrastructure. Full article

This study addresses the premature failure of electric motor bearings caused by inverter-induced parasitic currents. We propose a novel segmented end shield design utilizing 24 carbon fiber-reinforced polymer (CFRP) lamellae to provide both structural support and galvanic isolation. The “main working” of the design relies on a segmented architecture where the lamellae are adhesively bonded between a central bearing housing and an outer mounting flange, creating a high-impedance path that interrupts circulating currents. Experimental validation focused on both mechanical stability and dielectric performance. Results indicate that the assembly maintains rotor positional integrity under nominal loads while providing an insulation resistance > 1 GΩ at 1 kV and a structural capacitance of 2.47 nF. These parameters effectively mitigate low-frequency circulating currents. Data analysis, derived from the mean values of repeated test cycles, confirms that the composite architecture serves as a viable, mechanically robust alternative to conventional metallic end shields. Full article

Dual three-phase interior permanent magnet synchronous motors (DT-IPMSMs) are widely used in high-power and high-reliability applications, and accurate rotor polarity identification at startup is a critical prerequisite for their stable and efficient operation. This study aims to address the problem of initial position acquisition during the startup of DT-IPMSMs by proposing a simple and fast rotor polarity identification method. The proposed method is based on the high-frequency square-wave voltage injection (HFSWVI) in the vector space decomposition (VSD) space, where both the current and voltage are injected into the d-axis. The single-pulse direct current (DC) injection is used to alter the magnetic saturation. Then, the change rates of the d-axis high-frequency response current are compared before and after DC injection to identify the rotor magnetic polarity. In addition, a moving average filter (MAF) is applied to suppress the fluctuations in the current change rate, which increases the accuracy of polarity identification. Moreover, a simple compensation technique is designed to make the estimated d-axis current change smoothly when the estimated angle changes from N-pole to S-pole. The effectiveness of the proposed method is proved by the experimental results in both standstill and free-running states for the prototyped DT-IPMSMs. This method provides a practical and efficient solution for initial position identification of DT-IPMSMs, contributing to the advancement of control technology for dual three-phase motor systems in related fields. Full article

This study presents a systematic topological progression and multi-objective optimization of a Permanent Magnet-assisted Non-overlapping Winding Line-Start Synchronous Reluctance Motor (PMaNWLS-SynRM) for industrial applications. To explicitly highlight the core contribution, the research establishes a rigorous comparative framework evaluating the transition from a conventional 4-pole/36-slot distributed winding (DW) to a 2 × 12-slot non-overlapping winding (NW) architecture. Baseline results demonstrate that the NW configuration shortens end-turns, successfully reducing total electromagnetic losses from 417 W to 349 W and improving steady-state efficiency from 93.7% to 95.1%. To overcome the inherent starting limitations of pure synchronous reluctance machines, an aluminum squirrel-cage is integrated to enable robust direct-on-line (DOL) synchronization, while NdFeB permanent magnets are embedded within the rotor flux barriers to mitigate asynchronous spatial harmonics and elevate torque density. Finite element analysis (FEA) confirms this magnetic assistance raises the average synchronous torque to 65.8 Nm while suppressing absolute torque ripple to 1.37 Nm. Finally, an evolutionary genetic algorithm is deployed across 440 iterative configurations to resolve geometric multi-physics conflicts. The finalized optimized design achieves a 13.2 kW output power at 1800 rpm, maximizing average torque to 70.12 Nm and strictly dampening absolute torque ripple to an industry-acceptable 1.04 Nm. Operating with an aggregated total loss of 1382 W, the optimized PMaNWLS-SynRM yields a 90.5% operational efficiency, definitively validating its suitability as an ultra-premium IE4/IE5 alternative to conventional induction motors. Full article

To mitigate low-speed speed oscillations in permanent magnet synchronous motors (PMSMs) arising from the combined effects of rotor-position-related periodic disturbances and external perturbations, this paper develops a composite robust speed regulation scheme that integrates non-singular terminal sliding mode control (NTSMC) with angle-domain iterative learning control (ILC). First, a non-singular terminal sliding mode speed controller is established to remove the singularity inherent in conventional terminal sliding mode formulations while preserving finite-time error convergence. To further improve robustness and reduce chattering, an enhanced generalized super-twisting reaching law incorporating a continuous saturation function is introduced. Second, to compensate for periodic disturbances associated with rotor position, an angle-domain ILC law is constructed to iteratively learn the periodic speed-tracking error, thereby suppressing low-speed speed ripple. Meanwhile, an extended state observer (ESO) is incorporated to estimate aperiodic disturbances online, enabling coordinated rejection of disturbances with different temporal characteristics. Experimental results demonstrate that the proposed composite strategy effectively weakens the dominant harmonic components in speed fluctuation and enhances low-speed operational smoothness, confirming the effectiveness of the developed method. Full article

To solve the problems of rotor position estimation error caused by the installation deviation of Hall sensors and the increase in yarn amount detection error in complex environments, resulting in speed fluctuations and unstable yarn feeding in the traditional permanent magnet synchronous motor (PMSM) drive system for yarn feeder, a control method for yarn amount in yarn feeder PMSMs based on an improved dual second-order generalized integrator (DSOGI) and Kalman filter is proposed. Firstly, in order to reduce the influence of installation deviation of Hall sensors, the three-phase Hall signals are converted into two-phase orthogonal Hall vector signals. An improved DSOGI is used to filter out high-order harmonic components and specific harmonic components in the Hall vector signals, and a cross-coupled structure is constructed to further enhance the fundamental component and suppress high-order harmonic components of negative coefficients. Then, accurate motor rotor position information is extracted by a quadrature phase-locked loop; secondly, in order to obtain accurate information on yarn amount, a system state model based on yarn amount and its rate of change is established, and Kalman filtering is used for optimal estimation of the yarn amount; finally, the above methods are integrated into the PMSM control system of the yarn feeder. Experimental results show that, compared with traditional methods, the PMSM control system of the yarn feeder using the method proposed in this paper has a shorter startup time and smaller steady-state error in motor speed and yarn amount when conveying yarn at a constant speed; when transporting yarn at variable speed, the motor speed and yarn amount settling time are shorter, and the peak deviation is smaller. Full article

The electrification of the automotive industry and the lightweighting of aerospace equipment demand high-efficiency centrifugal pumps for compact spaces. A novel centrifugal pump incorporates an integrated impeller-motor rotor design, achieving a more compact footprint and higher power density. However, research is scarce on the radial clearance between the rotor and casing. This study presents a comprehensive investigation of the internal flow dynamics, combining numerical simulations with experimental validation. A significant reduction in fluctuation amplitude for pump efficiency, head coefficient, and frictional loss rate occurs when the clearance ranges from 1.0 to 1.5 mm. Within clearances of 0.75 to 1.5 mm, complex vortex systems emerge in the radial clearance, inducing diverse circumferential high-speed zones. Pressure fluctuations within the radial clearance are predominantly governed by the blade passing frequency. At a clearance of 1.5 mm, the rotational harmonic amplitude at monitoring points exceeds the blade passing frequency amplitude by a factor of 1.9, while the average pressure fluctuation intensity at other points increases significantly by 36.9%. An optimal clearance of 1.25 mm achieves a balance between flow characteristics and energy consumption. This research provides practical insights for optimizing pump energy performance and operational stability. Full article

This study focuses on improving the electromagnetic performance of flux-switching permanent magnet (FSPM) machines as a high-efficiency alternative aligned with the “green industry” concept. FSPM machines offer high torque density and mechanical robustness due to their stator-mounted magnet design; however, they suffer from cogging torque and torque ripple caused by magnet–stator tooth interactions. Three structural optimization methods were applied to a 12-slot, 10-pole reference FSPM machine: rotor notching, unequal rotor slot arc (URSA), and a hybrid approach combining both techniques. Eight models (D0–D7) were analyzed using genetic algorithms and the two-dimensional finite element method (FEM). Results demonstrate significant performance improvements while maintaining power density. The D1 design reduced torque ripple from 9.2% to 1.59%, achieving approximately a sixfold improvement. The D3 design yielded the lowest cogging torque at 0.4 Nm. Hybrid configurations (D5–D7) exhibited consistent performance with high back-EMF amplitude and uniform torque distribution. Physical manufacturability was validated through laser-cut prototype production of the optimized models. These findings highlight the strategic potential of FSPM machines for electric vehicle and industrial automation applications requiring precise positioning and high efficiency. Full article

This study investigates the primary electromagnetic sources of acoustic noise in single-phase induction motors and proposes design-oriented strategies for noise reduction. A 370 W, four-pole, 80-frame single-phase induction motor was designed, analyzed, and experimentally validated. Finite Element Method (FEM) simulations were conducted using Ansys Maxwell 2D to examine the effects of magnetic field distortion, magnetic saturation, and rotor eccentricity on torque ripple and inductance variation. The results demonstrate that these factors significantly increase electromagnetic force harmonics acting on the stator teeth and frame, leading to vibration and acoustic noise generation. In addition, inductance fluctuations caused by interphase magnetic coupling and air-gap harmonics were found to increase current harmonic content and potentially excite structural resonances. The influence of capacitor selection and winding configuration on magnetic saturation, phase displacement, and torque ripple was systematically evaluated. Prototype motors were manufactured and acoustic noise measurements were performed to experimentally validate the simulation results. Unlike previous studies that often investigate these parameters separately, this work presents a coupled analysis that explicitly links capacitor selection, winding configuration, and rotor eccentricity to inductance variation, torque ripple, and acoustic noise generation. The findings provide practical design guidelines for the development of low-noise single-phase induction motors and contribute to reducing electromagnetic vibration and acoustic emissions in electric machine design. Full article

Active magnetic levitation bearings incorporate backup bearings that support the rotor during a breakdown, allowing it to maintain its circular movement despite the loss of magnetic force. This safeguards both the stator of the magnetic levitation bearing and the motor stator from harm. Research reveals that ball bearings are susceptible to failure mechanisms, including raceway wear and scoring. The principal cause is the unregulated motion of the rolling parts, which are divided by the cage, once wear manifests, resulting in raceway lag. This leads to significant contact deformation between the rolling elements and the raceway, along with prolonged cumulative impacts between the rolling elements and the cage. Cage-free bearings prevent collisions between the cage and rolling elements; yet, the orbital motion of the rolling elements in these bearings demonstrates a level of independence and randomness relative to traditional caged ball bearings. This presents considerable obstacles to attaining standard orbital motion in cage-free ball bearings. Despite advancements in technology that have largely elucidated the non-linear motion dynamics of ball bearings, several critical hurdles in behavioral characterization persist. This work presents a thorough review of the non-linear motion behavior of ball bearings and the methodologies for their multi-body dynamic characterization. This report proposes future research topics to improve the design of high-performance bearings and augment their reliability. Full article