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UNIVERSITI PUTRA MALAYSIA
RAJA NOR FIRDAUS KASHFI RAJA OTHMAN
FK 2013 128
DESIGN OF A HIGH FUNDAMENTAL TORQUE SINGLE PHASE DOUBLE STATOR BRUSHLESS DC MOTOR
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DESIGN OF A HIGH FUNDAMENTAL TORQUE SINGLE
PHASE DOUBLE STATOR BRUSHLESS DC MOTOR
By
RAJA NOR FIRDAUS KASHFI RAJA OTHMAN
Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia
in Fulfillment of the Requirements for the Degree of Doctor of Philosophy
May 2013
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COPYRIGHT
All material contained within the thesis, including without limitation text, logos,
icons, photographs and all other artwork, is copyright material of Universiti Putra
Malaysia unless otherwise stated. Use may be made of any material contained within
the thesis for non-commercial purposes from the copyright holder. Commercial use
of material may only be made with the express, prior, written permission of
Universiti Putra Malaysia.
Copyright © Universiti Putra Malaysia
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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfillment
of the requirements for the degree of Doctor of Philosophy
DESIGN OF A HIGH FUNDAMENTAL TORQUE SINGLE PHASE DOUBLE
STATOR BRUSHLESS DC MOTOR
By
RAJA NOR FIRDAUS KASHFI RAJA OTHMAN
May 2013
Chairman : Eng. Norhisam Misron, PhD
Faculty : Engineering
Single phase brushless DC motors (BLDC) are adopted for many low cost
applications such as in fans, blowers and other domestic appliances. Recently, single
phase BLDC motors are used for portable application such as the mechanical
chopper, cutter and grinder. The requirement for such type of motor application is
high torque density. However, consideration in the qualities of torque waveform is
required in determine the torque density. This is because the fundamental torque
which shows the average torque should be used as the torque values compare to
maximum torque in calculating the torque density. Maximum torque with large
distortion of torque waveform which means that high THD value is not acceptable
since does not contributes higher average torque. Besides, low THD in torque
waveform subject less ripple and vibration on the motor performance. All of this can
be derived by properly design magnetic circuit of BLDC motor. Hence, the
motivation of this research work is to design a BLDC motor that has high
fundamental torque and low THD by improvise its magnetic circuit.
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Finite Element Analysis (FEA) is used to analyze the magnetic characteristic
including the electro-magnetic torque characteristics in this research. For all cases,
volume of the permanent magnet is fixed at 400 mm3 per each pole. The coil
magnetomotive force is set for 480 AT per pole. Initially, parallel magnetic circuit in
typical type BLDC motor is being studied including the flux distribution, air-gap flux
density, and torque characteristic with their harmonic components. Then, several
magnetic circuit designs in single and double stator are proposed to overcome the
limitation of typical type BLDC motor. Further, analysis on the taper parameters that
affect the torque characteristics is carried out among proposed magnetic circuit in
BLDC motor.
Determination for maximum torque (max. Tm), minimum cogging torque (min. Tc),
maximum fundamental torque (max. Tf), and minimum total harmonic distortion
(min. THD) are used to select the best model for fabrication. Several proposed
magnetic circuits of BLDC motor is fabricated and experimentally evaluated. The
simulation results from the FEA analysis are verified with the measurement result.
For comparative analysis, motor constant square density, G is used. It can be seen
that the motor constant square density, G for single stator Typical SS Parallel and SS
Series are 5.54 and 8.54, respectively. Meanwhile, motor constant square density, G
for double stator DS Parallel, DS Series A and DS Series B are 2.365, 4.24, and 15.0,
respectively. Therefore, it shows that double stator type DS Series B is the best
choice among all motors that been studied. In conclusions, the research proposed an
optimal magnetic circuit configuration that could provide high fundamental torque
and low THD. Finally, this thesis provides guidelines, suggestions and proposes
better magnetic circuit in designing BLDC motor.
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Abstrak thesis yang dikemukakan kepada Senat Universiti Putra Malaysia
sebagai memenuhi keperluan untuk ijazah Doktor Falsafah
MEREKABENTUK DAYA PUTARAN ASAS YANG TINGGI MOTOR DUA
PEMEGUN BERARUS TERUS TANPA BERUS SATU FASA
Oleh
RAJA NOR FIRDAUS KASHFI RAJA OTHMAN
Mei 2013
Pengerusi : Eng. Norhisam Misron, PhD
Fakulti : Kejuruteraan
Motor Satu Fasa Tanpa Berus (BLDC) diguna pakai untuk banyak aplikasi kos
rendah seperti dalam dalam kipas, peniup dan lain-lain peralatan domestik. Baru-baru
ini, motor satu fasa BLDC yang digunakan untuk aplikasi mudah alih seperti
pemotong mekanikal, pemotong dan pengisar. Keperluan untuk aplikasi motor jenis
ini ialah tork kepadatan tinggi. Walau bagaimanapun, pertimbangan dalam qualiti
gelombang daya putaran diperlukan dalam menentukan kepadatan daya putaran. Ini
adalah kerana daya putaran asas yang menunjukkan purata daya putaran boleh
digunakan sebagai nilai daya putaran berbanding dengan daya putaran maksimum
dalam pengiraan kepadatan daya putaran. Daya putaran maksimum dengan ganguan
besar gelombang daya putaran yang bermaksud bahawa nilai THD tinggi tidak boleh
diterima memandangkan tidak menyumbang daya putaran purata yang lebih tinggi.
Selain itu, THD rendah dalam bentuk gelombang daya putaran tertakluk kepada
kurang riak dan getaran pada prestasi motor. Semua ini boleh diperolehi dengan
mereka bentuk litar magnet BLDC yang betul. Oleh itu, motivasi kerja penyelidikan
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ini adalah untuk mereka bentuk motor BLDC yang mempunyai daya putaran asas
yang tinggi dan THD yang rendah dengan penambahbaikan litar magnet tersebut.
Analisis Unsur Terhingga (FEA) digunakan untuk menganalisis ciri-ciri magnetik
termasuk ciri-ciri daya putaran elektro-magnet dalam kajian ini. Bagi semua kes,
jumlah magnet kekal ditetapkan pada 400 mm3 bagi setiap tiang. Gegelung kuasa
magnetomotif ditetapkan untuk 480 AT setiap tiang. Pada mulanya, litar magnetik
selari dalam motor BLDC jenis biasa dikaji termasuk pengagihan fluks, ketumpatan
fluks jurang udara, dan ciri-ciri daya putaran dengan komponen harmonik mereka.
Kemudian, beberapa rekabentuk litar magnetik dengan satu dan dua pemegun
dicadangkan untuk mengatasi kekangan motor BLDC jenis biasa. Seterusnya,
analisis pada parameter tirus yang memberi kesan kepada ciri-ciri daya putaran
dijalankan untuk litar magnetik yang dicadangkan dalam motor BLDC.
Penentuan bagi daya putaran yang maksimum (maksimum Tm), daya putaran cogging
yang minimum (minimum Tc), daya putaran asas yang maksimum (maksimum Tf)
dan jumlah herotan harmonik yang minimum (minimum THD) digunakan untuk
memilih model terbaik untuk fabrikasi. Beberapa cadangan litar magnetik motor
BLDC difabrikasi dan eksperimennya dinilai. Keputusan simulasi daripada analisis
FEA telah disahkan dengan keputusan pengukuran. Untuk analisis perbandingan,
pemalar kepadatan motor kuasa dua, G digunakan. Ia boleh dilihat bahawa pemalar
kepadatan motor kuasa dua, G untuk motor BLDC satu pemegun “Typical SS
Parallel” dan “SS Siri” adalah 5.54 dan 8.54 masing-masing. Sementara itu, pemalar
kepadatan motor kuasa dua, G untuk motor BLDC dua pemegun “DS Parallel, DS
Series A dan DS Series B” ialah 2.365, 4.24, dan 15.0 masing-masing. Oleh itu, ia
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menunjukkan bahawa motor BLDC dua pemegun jenis DS Series B merupakan
pilihan yang terbaik di kalangan semua motor yang dikaji. Dalam kesimpulan, kajian
ini mencadangkan konfigurasi litar magnetik yang optimum yang boleh memberi
daya putaran asas yang tinggi dan THD yang rendah. Akhirnya, tesis ini
menyediakan garis panduan, cadangan dan mencadangkan litar magnetik yang lebih
baik dalam merekabentuk motor BLDC.
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ACKNOWLEDGEMENTS
All praise to supreme Almighty Allah swt. the only creator, cherisher, sustainer and
efficient assembler of the world and galaxies whose blessings and kindness have
enabled the author to accomplish this project successfully.
The author also would like to take this opportunity to gratefully acknowledge the
guidance, advice, support, and encouragement from the supervisor, Assoc. Prof. Dr.
Norhisam Misron . Great appreciations are expressed to Prof. Ir. Dr. Norman Mariun
and Prof. Dr. Ishak Aris for their valuable remarks, help, advice, and encouragement.
The author also would like to express the biggest appreciation to Hiroyuki
Wakiwaka, Professor of Shinshu University and Masami Nirei, Professor of Nagano
National College and Technology for their support and assistant during the visit for
advanced research in Nagano, Japan in 2011. The visit provides major contribution
through the support in the design analysis that contributes to the outcome of this
research. The author would like to express gratitude for Universiti Teknikal Malaysia
Melaka for their financial assistance and support towards the completion of this
work. In addition, the author would like to express deepest thanks to all laboratory
colleague Mohamad Reza Zare, Chockalingam Aravind Vaithilingam, Suhairi
Ridzuan, Mohamad Harizan and Ng Seng Hin for their kind assistance and help
throughout the research period. Lastly, an appreciation also to the Department of
Electrical and Electronics, Faculty of Engineering for providing the facilities and the
components required for undertaking this project.
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I certify that a Thesis Examination Committee has met on 16th
May 2013 to
conduct the final examination of Raja Nor Firdaus Kashfi Raja Othman on his Doctor
of Philosophy thesis entitled “Design of A High Fundamental Torque Single
Phase Double Stator Brushless DC Motor” in accordance with Universities and University Colleges Act 1971 and the Constitution of the Universiti Putra Malaysia [P.U.(A) 106] 15 March 1998. The Committee recommends that the
candidate be awarded the Doctor of Philosophy. Members of the Thesis Examination Committee were as follows:
Assoc. Prof. Dr. Hashim b. Hizam,
Department of Electrical & Electronics Engineering,
Faculty of Engineering,
Universiti Putra Malaysia.
(Chairman)
Assoc. Prof. Dr. Mohammad Hamiruce b. Marhaban,
Department of Electrical & Electronics Engineering,
Faculty of Engineering,
Universiti Putra Malaysia,
(Internal Examiner)
Assoc. Prof. Dr. Chandima Gomes,
Department of Electrical & Electronics Engineering,
Faculty of Engineering,
Universiti Putra Malaysia.
(Internal Examiner)
Prof. Dr. Sotoshi Yamada,
Division of Biological Measurement and Applications,
Institute of Nature and Environmental Technology,
Kanazawa University
(External Examiner)
___________________________________
SEOW HENG FONG, PhD Professor and Deputy Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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This thesis submitted to the Senate of Universiti Putra Malaysia and has been
accepted as fulfilment of the requirement for the degree of Doctor of Philosophy. The
members of the Supervisory Committee were as follows:
Norhisam Misron, PhD
Associate Professor
Faculty of Engineering
University Putra Malaysia
(Chairman)
Norman Mariun, PhD, Ir
Professor
Faculty of Engineering
University Putra Malaysia
(Member)
Ishak Aris, PhD
Professor
Faculty of Engineering
University Putra Malaysia
(Member)
___________________________
BUJANG BIN KIM HUAT, PhD
Professor and Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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DECLARATION
I declare that the thesis is my original work except for quotations and citations which
have been duly acknowledged. I also declare that it has not been previously or
concurrently submitted for any other degree at Universiti Putra Malaysia or other
institutions.
____________________________________
RAJA NOR FIRDAUS KASHFI
Date: 16 May 2013
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TABLE OF CONTENTS
Page
DEDICATION i
ABSTRACT ii
ABSTRAK iv
ACKNOWLEDGEMENTS vii
APPROVAL viii
DECLARATION x
LIST OF TABLES xiv
LIST OF FIGURES xvi
LIST OF ABBREVIATIONS xviii
CHAPTER
I INTRODUCTION
1.1 Background 1
1.2 Problem Statement 3
1.3 Objectives 5
1.4 Thesis Contributions 5
1.5 Scope of Work 5
1.6 Thesis Outline 7
II LITERATURE REVIEW 9
2.1 Background of Magnetic Circuit 9
2.1.1 Magnetic Flux Density and Field Intensity 10
2.1.2 Relative Permeability 10
2.1.3 Reluctance and Permeance 11
2.1.4 Series Magnetic Circuit 12
2.1.5 Parallel Magnetic Circuit 14
2.1.6 Magnetic Circuit in Air Gap 15
2.1.7 Inductance 17
2.1.8 Summary of Magnetic and Electrical Circuit
Quantities 19
2.2 Background of Brushless DC Motor 20
2.2.1 Typical Structure and Magnetic Circuit of
BLDC 21
2.2.2 Basic Operation of Single Phase BLDC 22
2.2.3 Comparison of Brushless Motor Compared to
Brush DC Motor 26
2.3 Comparison of DC, Synchronous and Stepper Motor 28
2.4 Overview of Related Research 31
2.5 Selection of Brushless DC Motor for Comparison 38
2.6 Component of Torque Characteristics 39
2.6.1 Maximum Torque, Tm 39
2.6.2 Cogging Torque, Tc 39
2.6.3 Fundamental Torque, Tf 40
2.6.4 Total Harmonic Distortion, THD 40
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2.7 Summary 41
III METHODOLOGY 42
3.1 Research Methodology 42
3.2 Finite Element Analysis (FEA) 45
3.3 Initial Motor Parameter for Overall Research 51
3.4 Computation Parameter for Parallel Magnetic Circuit in
Typical BLDC 53
3.5 Computation Result of Parallel Magnetic Circuit of
Typical BLDC (SS Parallel) 56
3.5.1 Flux Distribution of Parallel Magnetic Circuit
in Typical BLDC 56
3.5.2 Air Gap Flux Density of Parallel Magnetic
Circuit in Typical BLDC 59
3.5.3 Torque Characteristic of Parallel Magnetic
Circuit in Typical BLDC 60
3.5.4 Summary of the Study 62
3.6 Design of New Magnetic Circuit for Single Phase
BLDC Motor 63
3.6.1 Proposed Structure and Magnetic Circuit of
Single Phase BLDC 63
3.6.2 Flux Distribution of Proposed Magnetic Circuit
in Single Phase BLDC 69
3.6.3 Air Gap Flux Density of Proposed Magnetic
Circuit in Single Phase BLDC 77
3.6.4 Summary on Proposed Magnetic Circuit in
Single Phase BLDC 81
3.7 Taper Parameters Variations 83
3.8 Analysis on the Effect of Taper Parameters 87
3.9 Evaluation of Torque Characteristics 88
3.10 Calculation of Torque Speed Characteristics 90
3.11 Measurement Setup 91
3.11.1 Static Torque Characteristics 91
3.11.2 Torque Speed Characteristics 92
3.11.3 Thermal Measurement 93
3.12 Summary 95
IV RESULTS AND DISCUSSION 96
4.1 Analysis on the Effect of Taper Parameters 96
4.1.1 Effect of Taper Parameters for Optimal Ratio is
1 97
4.1.2 Effect of Taper Parameters for Optimal Ratio is
1.01 102
4.13 Effect of Taper Parameters for Optimal Ratio is
1.04 106
4.14 Summary of the Analysis of Taper Parameters 110
4.2 Evaluation of Torque Characteristics 111
4.2.1 Selection of min. THD, max. Tf, max. Tm, min. 111
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Tc.
4.2.2 Improvement of Tm, Tc, Tf, THD For Each
Magnetic Circuit 120
4.3 Fabrication Selection 122
4.4 Measurement Result 125
4.4.1 Static Torque Characteristics 126
4.4.2 Dynamic Torque Characteristics 128
4.4.3 Thermal Measurement 135
4.5 Comparative Evaluation Based on Motor Constant
Square Density 137
4.5.1 Comparative Evaluation of Proposed Magnetic
Circuit 138
4.5.2 Comparative Evaluation Based on Previous
Published Results 139
4.6 Summary 140
V CONCLUSION AND FUTURE RECOMMENDATION 141
5.1 Conclusion 141
5.2 Suggestions and Future Recommendation 144
REFERENCES 145
APPENDICES 151
BIODATA OF STUDENT 174
LIST OF PUBLICATIONS 175
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LIST OF TABLES
Table
Page
2.1 Analogous electrical and magnetic circuit quantities. 19
2.2 Comparison of brushless dc motors compared to brush DC
motors.
27
2.3 Summarize of comparison DC, synchronous and stepper
motor
28
2.4 Selected model that will be used for comparison 38
3.1 The flux distribution of parallel magnetic circuit in typical
BLDC.
58
3.2 Summary of the study 62
3.3 Proposed magnetic circuit for single phase BLDC 68
3.4 Flux distribution of proposed magnetic circuit for BLDC (0°
and 10°)
73
3.5 Flux distribution of proposed magnetic circuit for BLDC (20°
and 30°)
74
3.6 Flux distribution of proposed magnetic circuit for BLDC (40°
and 50°)
75
3.7 Flux distribution of proposed magnetic circuit for BLDC
(60°)
75
3.8 Taper parameter for the simulation 84
3.9 Values of taper parameters used in the simulation 85
3.10 Optimal ratio for Typical SS Parallel and SS Series. 86
3.11 Optimal ratio for DS Parallel, DS Series A and DS Series B. 86
4.1 Effect of variations in taper parameters for optimal ratio is 1
(Tm & Tc)
100
4.2 Effect of variations in taper parameters for optimal ratio is 1
(Tf & THD)
101
4.3 Effect of variations in taper parameters for optimal ratio is
1.01 (Tm & Tc)
104
4.4 Effect of variations in taper parameters for optimal ratio is
1.01 (Tf & THD)
105
4.5 Effect of variations in taper parameters for optimal ratio is
1.04 (Tm & Tc)
108
4.6 Effect of variations in taper parameters for optimal ratio is
1.04 (Tf & THD)
109
4.7 Selection of min. THD, max. Tf, max. Tm, and max. Tc (Tm &
Tc)
114
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4.8 Selection of min. THD, max. Tf, max. Tm, and max. Tc (Tf
&THD)
115
4.9 Value of Tm, Tc, Tf, THD based on evaluation types for
Typical SS Parallel & SS Series
117
4.10 Value of Tm, Tc, Tf, THD based on evaluation types for
Improved DS Parallel, DS Series A and DS Series B
117
4.11 The final selection for fabrication selection 122
4.12 Taper parameters of the fabricated model 123
4.13 Comparison of FEA and measurement result of fabricated
BLDC
125
4.14 Comparison on FEA result of Typical SS Parallel and DS
Series B
128
4.15 Comparison on measurement of Typical SS Parallel and DS
Series B
128
4.16 Improvement of fabricated motors at max. efficiency of 50 V 135
4.17 Motor constant square density and torque density of
developed BLDC
138
4.18 Comparison of Improved DS Series B with other published
results
139
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LIST OF FIGURES
Figure Page
2.1 Example of series magnetic circuit. 13
2.2 Example of parallel magnetic circuit 15
2.3 Example of magnetic circuit with an air gap 16
2.4 Example of magnetic circuit 18
2.5 Structure of a brushless DC motor 20
2.6 Typical Structure and Magnetic Circuit of BLDC 22
2.7 Block diagram for BLDC configuration 23
2.8 The position of Hall Effect Sensor (HES) 23
2.9 Switching pattern for single phase BLDC configurations 24
2.10 Ideal torque characteristics of brushless DC motor with 2 pole. 25
2.11 Basic principle operation of BLDC 26
2.12 Brush and commutator in single phase BLDC 27
2.13 Typical torque and speed characteristic 30
2.14 A novel single phase BLDC presented by S. Ahmed et al. 32
2.15 Single phase BLDC presented by S. Bentouati et al. 33
2.16 Single phase BLDC presented by Mohammed Fazil et al. 34
2.17 Outer rotor single phase BLDC presented by Mohammed Fazil
et al. 34
2.18 Outer rotor single phase BLDC presented by Do-Kwan Hang et
al. 35
2.19 Outer rotor single phase BLDC presented by Chun-Lung Chiu
et al. 36
2.20 Outer rotor single phase BLDC presented by Chun-Lung Chiu
et al. 36
2.21 Single phase BLDC presented by Kwang-Kyu Han et al. 37
2.22 Three phase BLDC presented by K. Y. Hwang et al. 37
3.1 Research methodology that involve in this research. 43
3.2 Flowchart for FEA modeling 48
3.3 Example of geometry structure and mesh in FEA 49
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3.4 Six layer of mesh in the airgap that set for FEA 50
3.5 Parallel magnetic circuit in typical BLDC (Typical SS Parallel) 55
3.6 Selection of flux density 59
3.7 Flux density of airgap (Bag) of parallel magnetic circuit in
typical BLDC 60
3.8 Torque characteristic and harmonic spectrum of Typical SS
Parallel 61
3.9 Flux barrier is actually an air. 64
3.10 Airgap flux density for Typical SS Parallel and SS Series 78
3.11 Airgap flux density at 0 At. 79
3.12 Airgap flux density at 480 At. 81
3.13 Summary of proposed design for each model. 82
3.14 The flow chart of the analysis of taper parameter. 87
3.15 Evaluation method from the overall data in this research 89
3.16 Equipment setup for static torque measurement. 92
3.17 Equipment setup for torque speed characteristic 93
3.18 Equipment setup for thermal measurement. 94
4.1 Flux distribution of DS Parallel contributes negative torque. 113
4.2 Comparison on the torque characteristics based on evaluation 119
4.3 The optimum value of Tm, Tc, Tf, THD 121
4.4 Final selection for fabrication 122
4.5 Fabricated motor 125
4.6 Comparison of static torque characteristics of fabricated BLDC 127
4.7 Dynamic measurement of Typical SS Parallel 130
4.8 Dynamic measurement of SS Series 132
4.9 Dynamic measurement of DS Series B 134
4.10 Measurement of coil temperature at no load condition 136
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LIST OF ABBREVIATIONS
B Magnetic flux density in (T)
φ Flux (Wb)
A Area of perpendicular to flux direction in (m2)
ℑ Air gap area (m2)
N Number of coil turn (T)
I Input current
H Magnetic field intensity
l Length of coil turn
u Absolute permeability of material
ℜ Reluctance in (Ω)
Ρ Permeance in (H)
cB Flux density of coil (T)
agB Flux density of airgap (T)
agA Area of airgap flux density of coil (T)
L Inductance (H)
ψ Flux linkage
Bag_outer Outer air-gap flux density (T)
Bag_inner Inner air-gap flux density (T)
Ws° Slot width
Wr° Rotor width
Hspt Height of stator pole teeth
Hrth Height of rotor teeth
Hsps Height of stator pole shoe
Wos° Outer stator width
Wor° Outer rotor width
Wis Inner stator width
Wir° Inner rotor width.
Tm Maximum torque or peak torque
Tc Cogging torque
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COPYRIGHT
All material contained within the thesis, including without limitation text, logos,
icons, photographs and all other artwork, is copyright material of Universiti Putra
Malaysia unless otherwise stated. Use may be made of any material contained within
the thesis for non-commercial purposes from the copyright holder. Commercial use
of material may only be made with the express, prior, written permission of
Universiti Putra Malaysia.
Copyright © Universiti Putra Malaysia
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I certify that a Thesis Examination Committee has met on (16 May 2013) to conduct
the final examination of (Raja Nor Firdaus Kashfi Raja Othman) on his (or her)
thesis entitled "Design of A High Fundamental Torque Single Phase Double
Stator Brushless DC Motor" in accordance with the Universities and University
Colleges Act 1971 and the Constitution of the Universiti Putra Malaysia [P.U.(A)
106] 15 March 1998. The Committee recommends that the student be awarded the
Doctor of Philosophy.
Members of the Thesis Examination Committee were as follows:
Hashim b. Hizam, PhD Associate Professor,
Faculty of Engineering,
Universiti Putra Malaysia.
(Chairman)
Mohammad Hamiruce b. Marhaban, PhD
Associate Professor,
Faculty of Engineering,
Universiti Putra Malaysia,
(Internal Examiner)
Gorakanage Arosha Chandima Gomes, PhD
Associate Professor,
Faculty of Engineering,
Universiti Putra Malaysia.
(Internal Examiner)
Sotoshi Yamada, PhD
Professor,
School of Electrical and Computer Engineering,
Kanazawa University,
Japan.
(External Examiner)
NORITAH OMAR, PhD
Assoc. Professor and Deputy Dean
School of Graduate Studies
Universiti Putra Malaysia
Date: 17 July 2013
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CHAPTER 1
INTRODUCTION
1.1 Background
The advancement in the permanent magnet technology has brought major impact in
the electrical machine field. With advantages of such high efficiency and compact
size, permanent magnet is used to form the fundamental field replacing the field
winding in machines. Extensive usage of high energy permanent magnet has brought
better thrust densities and energy conversion ratios has made it as a competitive
machine for almost all the applications in recent times. The growths in the power
electronic technology enhance the control of operation of such machines [1, 2].
In conjunction with the growths in the power electronic technology, development of
the permanent magnet motor developed in this investigations pave way to improvise
the torque density through the magnetic circuit analysis. The main advantage of
permanent magnet structure is that it can be operated as a brushless or as a
synchronous motor. Moreover, this motor has a structure that enables for broader
applications, especially applications that require high torque and speed. Interior
permanent magnet topology is widely used since it has mechanical strength in the
rotor assembly compared to the surface permanent magnet topology since this motor
is used for high torque application [3].
For brushless, a strong electromagnetic force exists between the rotor permanent
magnets and the stator coils. The brushless DC permanent magnet is usually driven
by sinusoidal currents or rectangular currents, depending on the motor back
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electromotive force (EMF) waveforms [4-6]. The brushless DC permanent magnet
has the features of high-power density, high overload and wide range of weak
magnetic, which is much suitable for variable load application. With such
advantages, the brushless DC permanent magnet has been widely used in electric
vehicles. The brushless DC permanent magnet operates as bidirectional variable
speed operation under full torque mode. However, the operation of the brushless DC
permanent magnet motor essentially requires a rotor position sensor for proper
commutation.
This thesis presents design of high fundamental torque and low THD of single phase
brushless DC permanent magnet motor. Finite Element Analysis (FEA) is used to
simulate the magnetic characteristic including the torque waveform in this research.
Firstly, parallel magnetic circuit in typical BLDC motor is being studied including
the flux distribution, airgap flux density, torque characteristic and harmonic
components. Based on the study result, several magnetic circuits design is proposed.
Analysis on the taper parameters that affect the torque characteristics is being carried
for propose magnetic circuit brushless DC permanent magnet motor. The analysis is
to identify the factors that contribute to the sinusoidal torque waveform.
Determination of minimum total harmonic distortion (min. THD), the maximum
fundamental torque (max. Tf), the maximum torque (max. Tm) and the minimum
cogging torque (min. Tc) are used for the selection of the best model for fabrication.
The proposed magnetic circuit of single phase brushless DC permanent magnet
motor are fabricated and measured. The simulation result of FEA is verified with the
measurement result. For comparison, motor constant square density, G is used for
evaluation to all models.
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1.2 Problem Statement
Single phase brushless DC permanent magnet motors (BLDC) are adopted in many
low cost applications such as in fans, blowers and other domestic appliances [7-11].
The main disadvantage of using single phase compared to three phase permanent
magnet motor is the inability to self-start [11-13]. However, for specific application
such as the mechanical chopper, the single phase motor is the most popular
application due to the safety consideration. Such limitation of size, space, weight and
volume that usually required for portable application such as mechanical chopper as
mention above gives bigger drawback in designing a high torque density single phase
BLDC motor. However, consideration in the qualities of torque waveform is required
in determine the torque density. This is because the fundamental torque which shows
the average torque should be used as the torque values compare to maximum torque
in calculating the torque density. Maximum torque with large distortion of torque
waveform which means that high THD value is not acceptable since does not
contributes higher average torque. Besides, low THD in torque waveform subject
less ripple and vibration on the motor performance.
However, a few numbers of researchers doing research on the single phase motor
structure or its magnetic circuit to improve the torque value thus improves the torque
density. Many of researchers are focus on commutation and driver control of single
phase brushless DC motor which does not involve the motor design [14-18]. Most of
the researchers study to eliminate the dead point so that the single phase brushless
DC motor can move without applying external force to the rotor during starting
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period. Some of them studied on the improvement of torque characteristics quality
such as torque ripple and cogging torque [19-20].
Conventional method to increase the torque value is by increasing the magnetic
energy which can be realized by resizing the permanent magnet volume or applying
larger number of coil turn [21-24]. However, the flux density in some parts of stator
or rotor of permanent magnet motor leads to saturation value if volume of permanent
magnet is increase [25-27]. In addition, a high torque motor usually comes with high
cogging characteristic that introduce the torque ripple in the torque characteristic.
Whereas, a pure sinusoidal torque characteristic ensures uniform flux distribution
that produce smooth speed rotation [28-30]. Nevertheless, such pure sinusoidal
torque characteristic is hard to achieve in the presence of permanent magnet that
caused the cogging torque. Therefore, conventional method that increases the
magnetic energy cannot be used for designing high torque motor.
Therefore, this research would like to focus on the motor structure based on the
design of new magnetic circuit configurations so that the torque value can be
increased. A good magnetic circuit produced optimum air gap flux density that
perpendicular to the air gap surface so that high torque density motor with high
fundamental torque and low THD can be achieved. Currently, a high torque density
brushless DC permanent magnet motor is required in order to meet the recent
demands in portable application.
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1.3 Objectives
Based on the discussed problem statement above, several objectives have been
identified for this research. These objectives are listed as below:
1. To compute typical parallel magnetic circuit in single phase BLDC motor for
clear understanding of its limitation and performance.
2. To design and propose magnetic circuit that produce high fundamental torque
and low THD in single phase BLDC motor.
3. To analyze the effect of taper parameters on maximum torque, cogging
torque, fundamental torque and total harmonic distortion of propose magnetic
circuit in single phase BLDC motor.
4. To determine the minimum Total Harmonic Distortion (min. THD), the
maximum fundamental torque (max. Tf), the maximum peak torque (max. Tm)
and the minimum cogging torque (min. Tc) of propose magnetic circuit single
phase BLDC motor.
5. To compare the measurement result with simulation result of the static torque
characteristics for verification purposes.
1.4 Thesis Contributions
The main contribution of the thesis is the proposal several design of magnetic circuit
design that produce higher fundamental torque and low THD of torque waveform is
compare with typical single phase BLDC. Finally, magnetic circuit that produce
highest fundamental torque and low THD of torque waveform among all proposed
magnetic circuits is selected for fabrication and justify using motor constant square
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density, G. For knowledge contribution aspect, the theoretical explanation of such
improvement of torque value for each proposed magnetic circuit is investigated using
Finite Element Analysis (FEA). Besides, the analysis on the taper parameter
discloses the design parameter of taper that could be used in achieving a lower total
harmonic distortion, THD of torque waveform. This provides guidance for other
researcher in selecting the best possible of taper in designing any brushless DC
permanent magnet motor.
1.5 Scope of Work
In this research, the improvement of magnetic circuit in brushless DC permanent
magnet motor carried out via Finite Element Analysis (FEA). The FEM software
package known as FEMAPH developed by Masami Nirei, Professor of Nagano
National College and Technology, Japan can determine the availability of magnetic
characteristics such as flux flow, magnetic density, and torque distribution. The
research focuses only for single phase BLDC motor topology due to safety
consideration for specific application such as mechanical cutter and chopper.
Another scope of this research is the design of single phase BLDC motor that have
high fundamental torque and low THD of torque waveform by investigating possible
magnetic circuit. This research does not conduct details study on the contribution of
losses of the proposed magnetic circuit design in details. This means that the research
don’t determine value of losses such as Eddy current loss, iron loss, copper loss and
hysteresis loss. Nevertheless, dynamic measurement such as torque and speed; input
power and speed; output power and speed; and efficiency is carried out for the
fabricated motor in this research.
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1.6 Thesis Outline
Chapter One gives an overview about this research. It includes an introduction about
the research, problem statement, scope of work and objectives of the research. The
introduction explains in general about brushless DC permanent magnet motor and its
recent application. Moreover, the problem statement addressed the motivations to
carry out this research. The listed objectives show the determination of aim that is
required for this research. Besides, the scope of work gives an outline about the
methodology focused in this research.
Chapter Two discusses the magnetic circuit in general which reflect the main
contribution of the research. This chapter also discusses about the brushless of DC
Motor includes the basic structure, operation and comparison to brush DC motor. In
addition, comparison of DC, synchronous and stepper motor is presented to enhance
reader understanding about the selection of brushless DC motor for this research.
This chapter also discusses about several related research of single phase brushless
DC motor that had been presented in various literature. Lastly, this chapter also
discusses about the definition of torque characteristic component that used in the
analysis of this research.
Chapter Three describes methodology of the overall research. An explanation about
the simulation methodology using Finite Element Analysis (FEA) is presented. Then,
initial motor parameter in the overall research is discussed. Next, parallel magnetic
circuit of typical brushless DC permanent magnet motor is presented. This study
helps the viewer to understand the limitation and performance of parallel magnetic
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circuit of typical brushless DC permanent magnet motor. Based on the study result,
the several magnetic circuits design is proposed. Furthermore, the theoretical
explanation of such several magnetic circuits design that could produce higher torque
is presented using Finite Element Analysis (FEA). Next is the methodology of the
analysis of the effect of taper parameters in several magnetic circuits design of the
proposed single phase BLDC is presented. Furthermore, the calculation method for
torque and speed characteristic of dynamic calculation is also shown. In addition, the
measurement setups for static and dynamic torque characteristic are also shown.
Chapter Four discusses the analysis result taper parameter effect of parallel magnetic
circuit and proposed series magnetic circuit in single phase BLDC motor.
Furthermore, evaluation result on all magnetic circuits design in brushless DC
permanent magnet motor is also presented in this chapter. In this evaluation four
types model is selected from each magnetic circuits design for fabrication selection.
Several models of proposed magnetic circuits design in this research are selected for
fabrication and the result of simulation is verified by the measurement. For final
comparison, motor constant square density is used to compare the typical and
proposed design of magnetic circuits in this research.
Chapter Five presents the conclusion of overall research in term of the design process
and the analysis result. This chapter also includes a few recommendations that can be
implemented in this research field in future.
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