Design and Optimization of a Low-Torque-Ripple High-Torque-Density Vernier Machine Using Ferrite Magnets for Low-Speed Direct-Drive Applications

Cheng Gong, Fang Deng
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引用次数: 2

Abstract

In recent years, Vernier permanent magnet machines (VPMs) have gained much interest in academia. However, due to the large leakage flux, the power factor of Vernier machines is too low to be applied in real industry. In this paper, a novel split-tooth, concentrated-winding Vernier machine using ferrite magnets is proposed for high-torque, low-speed direct drive applications in home appliance industry. It uses consequent-pole magnets in the rotor, as well as additional assistant magnets in the stator teeth, in order to reduce the leakage flux and boost the torque density. A systematic way of reducing the torque ripple from 40% to 4% is proposed by carefully choosing the right combination of stator/rotor pole pair numbers. A comprehensive design optimization is conducted to achieve the optimal performance. The magnets in the stator are shaped on both corners to reduce the saturation level. The key findings during the optimization are described in detail. Finally the total number of turns per phase is carefully reduced to meet the torque, saturation, power factor and space requirements. The test results of a prototyped machine show that the proposed design can achieve 34% more torque and 20% less loss with a reasonable power factor of 0.63, compared with an optimized PM synchronous machine under the same volume. It is found that the significant torque boost is attributed to the multiple working harmonics of the air gap flux density.
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用于低速直接驱动的低转矩脉动高转矩密度游标机的设计与优化
近年来,游标永磁电机引起了学术界的广泛关注。然而,由于泄漏磁通大,游标机的功率因数太低,无法在实际工业中应用。本文提出了一种适用于家电行业大转矩、低速直接驱动的铁氧体磁体分齿集中卷绕游标机。它在转子中使用顺极磁铁,以及在定子齿中使用额外的辅助磁铁,以减少泄漏磁通并提高扭矩密度。通过选择正确的定子/转子极对组合,提出了将转矩脉动从40%降低到4%的系统方法。为了达到最佳性能,进行了全面的设计优化。定子中的磁铁在两个角上都有形状,以降低饱和水平。详细描述了优化过程中的关键发现。最后,每相的总匝数仔细减少,以满足扭矩,饱和,功率因数和空间要求。样机的试验结果表明,与优化后的永磁同步电机相比,在相同体积下,在合理的功率因数为0.63的情况下,所设计的永磁同步电机的转矩增加34%,损耗减少20%。结果表明,显著的转矩提升是由于气隙磁通密度的多重工作谐波引起的。
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