Electrical Machines research at CSIRO
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Transcript of Electrical Machines research at CSIRO
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Applied Magnetics and Drives
Dr Howard Lovatt CSIRO Material Science and Engineering May 2009
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Electric Machine Technology
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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
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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
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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)
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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
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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
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Power Electronics and Control
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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
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Magnetic Separator
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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
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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
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Permanent Magnet Generators: Cogeneration and Wind
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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)
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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
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Innovative Motors - Actuator
• Valve actuator • Customer:
• Transfield • High-torque motor, 120 Nm • Direct-drive (no gearbox) • Mounted axially with valve
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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
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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
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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
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Innovative Motors - Solar Car Motor
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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
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Switched Reluctance Motor - circuit coupled FEA
Innovative Motors - Switched Reluctance Motors
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Innovative Motors - Switched Reluctance Motors
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Hybrid Electric Vehicles
aXcess Australia LEV (series HEV)
Holden ECOmmodore (parallel HEV)
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Hybrid Electric Vehicles
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Thank You
CSIRO Material Science and Engineering Name Dr Howard Lovatt Phone +61 2 9413 7412 Email [email protected] Web www.csiro.au
Contact CSIRO Phone 1300 363 400
+61 3 9545 2176
Email [email protected]
Web www.csiro.au