Applied Magnetics and Drives

Dr Howard Lovatt CSIRO Material Science and Engineering May 2009

Electric Machine Technology

Magnetic Materials

•  Permanent Magnets

•  sintered commercial magnets, Nd2Fe14B, Sm2Co17, ferrites • Novel shapes – wire and water

jet cutting •  polymer bonded magnets, anisotropic HDDR (MQA-T

powder) • Magnetically soft materials

•  glassy metals •  powdered iron cores •  low-loss electrical steels

•  rotational and high-frequency losses

Machine Design – Motors and Generators

•  Design of Induction, Switched Reluctance and Permanent Magnet machines

•  Machine design (magnetic circuit design) using 2D and 3D finite element analysis.

•  Optimisation •  objective function, (e.g. cost,

efficiency) is sought over key variables subject to constraint of motor specification (volume, torque etc)

•  Circuit Analysis •  Novel Machine Topology

•  slotless, ironless, axial flux, permanent magnet reluctance

Machine Design – Motors and Generators

•  Winding Design •  Magnetic Couplings •  Solenoids •  Magnetic separators •  Mechanical design of machine, and

solid modelling of machine and power electronics (AutoDesk Inventor)

Advantages of brushless rare-earth permanent magnet motors

•  High Efficiency - typically greater than 90%

•  Improved Reliability (no brushes)

•  High Torque-to-Weight Ratio

•  Increased Power-to-Weight Ratio

•  Reduced Dimensions - Compactness

•  Cool Operation •  Quiet Operation •  Possible Lower Cost

Power Electronics and Control

•  Power electronic circuits •  Hardware: Analogue and digital

circuits design and prototype •  Software development for

microcontrollers, DSPs and PLDs •  Sensor and sensorless control

techniques •  Circuit simulation and modelling •  Matlab, Simulink and dSpace

platforms •  microAutoBox for automotive

Power Electronics and Control

Design for Manufacture

•  Integration of motor and controller

•  Lamination production •  Use of existing stator or

housing •  Bearings, seals and cooling •  Testing

•  loss separation •  thermal

•  In-situ multi-pole magnetisation

•  design and construction of multi-pole magnetising fixture

Magnetic Separator

Solenoids

•  Very low cost •  Constant force characteristic •  Uses DC •  Silent - plunger does not

impact on end stop •  Does not burn-out as

resistance constant in any position

Innovative Motors - Motor and Sensorless Controller

•  3-phase brushless pm motor

•  740 W at 20,000 rev/min

•  high-efficiency >90% •  no magnetic

hysteresis losses •  1 kW sensorless

controller

Permanent Magnet Generators: Cogeneration and Wind

Innovative Motors - Wool Shear Motor

•  Wool shearing hand-piece motor

•  Efficiency ~96% •  Slotless winding and

glassy metal stator •  Hand piece stays cool •  150 W, 13,300 rpm,

(total losses 6 W)

Innovative Motors – High Speed Motor

High-speed compressor motor  Customer: Danfoss/Turbocor (US based but

formerly Multistack in Australia)  Patents in ~15 countries  Collaborators: CIP and UTS  High-speed motor developed, ~50 kW, 50,000

rpm  Won many international awards

US EPA Climate Protection Award

ASHRAE/AHR Expo "Energy Innovation“ Award

Canadian Energy Efficiency Award

Innovative Motors - Actuator

•  Valve actuator •  Customer:

•  Transfield •  High-torque motor, 120 Nm •  Direct-drive (no gearbox) •  Mounted axially with valve

Innovative Motors - Oil-Well Mule

•  Oil-Well Mule Motor •  Customer:

•  ORAD Ltd •  Slotless winding •  500 W, 92% efficient, 2-

pole Sm2Co17 rotor •  Operates at 150OC and at

500 atmospheres

Innovative Motors - Solar Powered Pump

•  Rural/Agricultural Pumps

•  Customer: •  Mono Pumps

•  Pumps twice as much water in a day as competitors

•  Water filled 300 W, >85% efficient

•  Powered by the sun through solar panels

•  Bore-hole depths to 120 m and 100 mm diameter

•  Mechanically simple

Innovative Motors - Solar Car Motor

•  Solar Car Motor Ironless, axial flux, 98% efficient, 1.8 kW (rated 3.6 kW), 1,060 rpm (100 kph), 16 Nm, Active mass 5 kg

Innovative Motors - Solar Car Motor

Innovative Motors - Switched Reluctance Motors

•  The Benefits •  Lowest production cost of all

electrical motors •  Ideal for applications in

domestic appliances and vehicles

•  Torque/Volume ratio intermediate between Rare Earth Permanent Magnet and Induction motors

•  Operate over wide speed range •  Mechanically robust design

suited to harsh environments

Switched Reluctance Motor - circuit coupled FEA

Innovative Motors - Switched Reluctance Motors

Innovative Motors - Switched Reluctance Motors

Hybrid Electric Vehicles

aXcess Australia LEV (series HEV)

Holden ECOmmodore (parallel HEV)

Hybrid Electric Vehicles

Thank You

CSIRO Material Science and Engineering Name Dr Howard Lovatt Phone +61 2 9413 7412 Email howard.lovatt@csiro.au Web www.csiro.au

Contact CSIRO Phone 1300 363 400

+61 3 9545 2176

Email enquiries@csiro.au

Web www.csiro.au