Electromagnetic-Thermal Integrated Design Optimization for Hypersonic Vehicle Short-Time Duty PM Brushless DC Motor

High reliability is required for the permanent magnet brushless DC motor (PM-BLDCM) in an electrical pump of hypersonic vehicle. The PM-BLDCM is a short-time duty motor with high-power-density. Since thermal equilibrium is not reached for the PM-BLDCM, the temperature distribution is not uniform and there is a risk of local overheating. The winding is a main heat source and its insulation is thermally sensitive, so reducing the winding temperature rise is the key to the improvement of the reliability. In order to reduce the winding temperature rise, an electromagnetic-thermal integrated design optimization method is proposed. The method is based on electromagnetic analysis and thermal transient analysis. The requirements and constraints of electromagnetic and thermal design are considered in this method. The split ratio and the maximum flux density in stator lamination, which are highly relevant to the windings temperature rise, are optimized analytically. The analytical results are verified by finite element analysis (FEA) and experiments. The maximum error between the analytical and the FEA results is 4%. The errors between the analytical and measured windings temperature rise are less than 8%. It can be proved that the method can obtain the optimal design accurately to reduce the winding temperature rise.

[1]  Peter A. Jacobs,et al.  Production of high-Mach-number scramjet flow conditions in an expansion tube , 2014 .

[2]  Bangcheng Han,et al.  Loss Calculation and Thermal Analysis of Rotors Supported by Active Magnetic Bearings for High-Speed Permanent-Magnet Electrical Machines , 2016, IEEE Transactions on Industrial Electronics.

[3]  Weiguo Liu,et al.  Design and Control of a Two-Phase Brushless Exciter for Aircraft Wound-Rotor Synchronous Starter/Generator in the Starting Mode , 2016, IEEE Transactions on Power Electronics.

[4]  Yang Shen,et al.  Analytical Prediction of Optimal Split Ratio for Fractional-Slot External Rotor PM Brushless Machines , 2011, IEEE Transactions on Magnetics.

[5]  Marco Villani,et al.  High Reliability Permanent Magnet Brushless Motor Drive for Aircraft Application , 2012, IEEE Transactions on Industrial Electronics.

[6]  Wenxing Fu,et al.  Neural adaptive control of hypersonic aircraft with actuator fault using randomly assigned nodes , 2016, Neurocomputing.

[7]  Z. Zhu,et al.  Optimal split ratio for high-speed permanent magnet brushless DC motors , 2001, ICEMS'2001. Proceedings of the Fifth International Conference on Electrical Machines and Systems (IEEE Cat. No.01EX501).

[8]  Yang Guang.  Study on Electromagnetic Losses in High-speed Permanent Magnet Brushless Machines-the State of the Art , 2013 .

[9]  Yongxiang Xu,et al.  Optimization of split ratio to design the PM brushless DC motor , 2009, 2009 International Conference on Electrical Machines and Systems.

[10]  Annette Muetze,et al.  Design Constraints of Small Single-Phase Permanent Magnet Brushless DC Drives for Fan Applications , 2015, IEEE Transactions on Industry Applications.

[11]  Johann W. Kolar,et al.  Split Ratio Optimization for High-Torque PM Motors Considering Global and Local Thermal Limitations , 2013, IEEE Transactions on Energy Conversion.

[12]  Keith J. Burnham,et al.  The Impact of Thermal Degradation on Properties of Electrical Machine Winding Insulation Material , 2016, IEEE Transactions on Industry Applications.

[13]  Z.Q. Zhu,et al.  Optimal split ratio in fractional-slot interior permanent magnet machines with non-overlapping windings , 2009, 2009 IEEE International Electric Machines and Drives Conference.

[14]  Xianyu Wu,et al.  System design and analysis of hydrocarbon scramjet with regeneration cooling and expansion cycle , 2015 .

[15]  Z Kolondzovski,et al.  Power Limits of High-Speed Permanent-Magnet Electrical Machines for Compressor Applications , 2011, IEEE Transactions on Energy Conversion.

[16]  M. A. Valenzuela,et al.  Thermal evaluation for applying TEFC induction motors on short-time and intermittent duty cycles , 2002 .

[17]  Abdeslam Mebarki,et al.  Design Aspects of High-Speed High-Power-Density Laminated-Rotor Induction Machines , 2011, IEEE Transactions on Industrial Electronics.

[18]  K. O. Boynov,et al.  The Effect of PWM on Rotor Eddy-Current Losses in High-Speed Permanent Magnet Machines , 2015, IEEE Transactions on Magnetics.

[19]  Z. Q. Zhu,et al.  Simplified Analytical Optimization and Comparison of Torque Densities Between Electrically Excited and Permanent-Magnet Machines , 2014, IEEE Transactions on Industrial Electronics.

[20]  Duane C. Hanselman,et al.  Brushless Permanent-Magnet Motor Design , 1994 .

[21]  Dan M. Ionel,et al.  Multi-Objective Tradeoffs in the Design Optimization of a Brushless Permanent-Magnet Machine With Fractional-Slot Concentrated Windings , 2013, IEEE Transactions on Industry Applications.

[22]  Enrico Carpaneto,et al.  Stator-Winding Thermal Models for Short-Time Thermal Transients: Definition and Validation , 2016, IEEE Transactions on Industrial Electronics.

[23]  Z. Zhu,et al.  Modeling and Investigation of Thermal Characteristics of a Water-Cooled Permanent-Magnet Linear Motor , 2015, IEEE Transactions on Industry Applications.

[24]  D. A. Howey,et al.  Dielectric characteristics of electric vehicle traction motor winding insulation under thermal ageing , 2015, 2015 IEEE 15th International Conference on Environment and Electrical Engineering (EEEIC).

[25]  C. Gerada,et al.  A Thermal Improvement Technique for the Phase Windings of Electrical Machines , 2012, IEEE Transactions on Industry Applications.

[26]  D. Stone,et al.  Rotor loss in permanent magnet brushless AC machines , 1999, IEEE International Electric Machines and Drives Conference. IEMDC'99. Proceedings (Cat. No.99EX272).

[27]  Wenping Cao,et al.  Overview of Electric Motor Technologies Used for More Electric Aircraft (MEA) , 2012, IEEE Transactions on Industrial Electronics.

[28]  Huan Chen,et al.  Designing Backstepping Control System for Hypersonic Vehicle Based on Feedback Linearization , 2015 .

[29]  R. G. Harley,et al.  Optimal Electromagnetic-Thermo-Mechanical Integrated Design Candidate Search and Selection for Surface-Mount Permanent-Magnet Machines Considering Load Profiles , 2011, IEEE Transactions on Industry Applications.

[30]  X Jannot,et al.  Multiphysic Modeling of a High-Speed Interior Permanent-Magnet Synchronous Machine for a Multiobjective Optimal Design , 2011, IEEE Transactions on Energy Conversion.

[31]  Christopher P. Goyne,et al.  Dual-Pump Coherent Anti-Stokes Raman Spectroscopy Measurements in a Dual-Mode Scramjet , 2014 .