Analysis, design optimisation and experimental performance of synchronous reluctance and permanent magnet assisted synchronous reluctance machines

Abstract

The research studies, in detail, the synchronous reluctance machine (SynRM) and permanent magnet assisted synchronous reluctance machine (PMSynRM) to improve the machine performances. In this study, the SynRM analytical models are revisited, and functional characteristics are mathematically developed to improve the machine performance. The performance parameters such as torque density, power factor, and efficiency are investigated along with torque ripples. SynRM is known for its high torque density in a compact size. Its improvement is analytically studied further by optimising rotor properties. The power factor of these machines is rather low compared with its equivalent AC machines. Although the machine's power factor can be improved using control techniques, it is still not high enough. The machine has gone through significant development over the years since J.K Kostko published the first paper on reluctance machines back in 1923. The researchers have tested various types of anisotropies, such as axially laminated and transversally laminated. The machine torque and power factor depend on its saliency ratio. Although the axially laminated structure offers high saliency ratio due to the naturally distributed flux barrier structure, it has mechanical constraints. The axial rotor segments are fixed together by specially designed bolts that are conductive material in nature. This mechanical arrangement increases quadrature axis inductance, consequently reduces the saliency ratio of the machine. On the other hand, the transversally laminated structure is more mechanically feasible and offers comparatively high performance. One of the primary focus of this study is to improve the power factor. It has been comprehensively investigated. The SynRM machine is also known for high torque ripples. The non-linear structure and its reluctance path along the air-gap make the machine highly susceptible to torque pulsation. The cross induction due to the D and Q axis along the air-gap increases the machine's ripples. Besides, poor stator winding (both sinusoidal and step excitation) also increases the machine torque ripples. The existing ripple reduction practices are revisited in this study to further understand the torque ripples of this machine. The rotor of SynRM is redesigned and optimised to reduce the ripples effect. The causes of ripples are also analytically studied in detail, and mathematical models are developed and presented for understanding the phenomena. Two different ways of analysing the ripple effects are considered, and the pros and cons of both methods are discussed. The SynRM is simulated using an advanced finite element analysis (FEM) software to verify the analytical models as well as optimise the machine performance. Firstly, primitive rotor structures are developed so that they can be automatically varied during parameterisation and optimisation. Four flux barrier shapes are analysed to determine the optimum shape for high performance by investigating flux's natural path. From the results, a multi-barrier arrangement is studied with an advanced algorithm for three and four-layer designs, and an optimum rotor is proposed based on the simulations. Using a single-objective and multi-objective optimisation techniques, the SynRM is optimised from the simulated design. An advanced topology is developed for automated optimisation that can offer flexibility in varying optimisation variables as part of this research. The optimised design's performance is analysed in detail and compared with analytical models. The torque ripples are discussed in detail, and an advanced torque ripple minimisation topology is developed. Then the design is optimised for two types of barrier shapes. A number of designs are prototyped for experimental verification. Finally, the current trend in rare-earth magnets is investigated with its cost per volume ratio. The rare-earth neodymium magnets are focused on this study for improved performance with optimum volume. The analytical model of PM assisted design is studied in detail, and its performance parameters are compared with SynRM. A PMSynRM with a linear-barrier is simulated for a detailed analysis of the machine that discusses different PM volumes and the impact on machine performance due to the volume of PM and location. The performance parameters, discussed in the analytical model, are compared with the simulation results. The improvement in power factor and torque density is investigated using various designs. The optimisation is performed in two ways. The first one is adding PMs to the optimised SynRM. Single-objective and multi-objective optimisation are performed using an advanced optimisation algorithm. Secondly, the topology of SynRM is modified for PMSynRM in such a way the entire machine can be automated during optimisation by adding the PM's variables to the existing one. The performances of the two optimised designs have been compared. PMSynRM prototypes are developed to verify the simulation results. The eight SynRM designs are prototyped to report the practical results. Six of them are to verify various performance parameters of SynRM and two of them to test the ripples effect. Moreover, two PMSynRM prototypes are fabricated to verify the simulation results. The saliency of each SynRM is measured and compared with simulated results. Then, each design is tested experimentally in all possible scenarios and compared. Extensive testing is performed on all prototypes under various operating conditions and reported.

Date of Award	2019
Original language	English