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© COPYRIGHT UPM 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

Transcript of Front Cover 16.7.13psasir.upm.edu.my/id/eprint/56194/1/FK 2013 128RR.pdfselari dalam motor BLDC...

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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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Tf, Fundamental torque

THD Total harmonic distortion

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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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