Pub Date : 2025-07-03DOI: 10.1109/TIA.2025.3584599
{"title":"Get Published in the New IEEE Open Journal of Industry Applications","authors":"","doi":"10.1109/TIA.2025.3584599","DOIUrl":"https://doi.org/10.1109/TIA.2025.3584599","url":null,"abstract":"","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 4","pages":"6843-6844"},"PeriodicalIF":4.2,"publicationDate":"2025-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=11069369","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144550130","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-07-03DOI: 10.1109/TIA.2025.3584597
{"title":"IEEE Women in Engineering","authors":"","doi":"10.1109/TIA.2025.3584597","DOIUrl":"https://doi.org/10.1109/TIA.2025.3584597","url":null,"abstract":"","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 4","pages":"6842-6842"},"PeriodicalIF":4.2,"publicationDate":"2025-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=11069364","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144550309","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-07-02DOI: 10.1109/TIA.2025.3585082
Rubén Usamentiaga;Adrian G. Gayo;Francisco J. delaCalle;Dario G. Lema;Stefano Sfarra;Hai Zhang
Real-time temperature information is crucial for optimizing cooling processes during steel strip rolling, ensuring the attainment of desired microstructural properties and surface quality at an optimal cooling rate. Infrared line scanners emerge as the preferred choice for temperature measurement in high-speed rolling operations, delivering temperature readings with high resolution and enabling the capture of detailed temperature profiles. By analyzing these profiles, cooling systems can be finely adjusted and precisely controlled to optimize the rolling operation. However, developing effective cooling strategies becomes challenging when dealing with temperature profiles comprising numerous discrete data points, often numbering in the thousands per profile. This study presents an innovative approach that integrates the detection of steel strip boundaries within temperature profiles and subsequent temperature pattern characterization using polynomial fitting. A significant advantage is demonstrated by leveraging the coefficients of Legendre polynomials, which provide a concise description of temperature profile shapes, facilitating straightforward approaches to cooling strategies. By integrating boundary detection with temperature characterization, the system enhances its ability to predict tailored cooling patterns, optimizing cooling efficiency, and enhancing product quality in the manufacturing process. Rigorous testing using both synthetic data and real-world applications in cold and hot rolling validates the proposed system’s practical utility and reliability. These results underscore its potential to enhance efficiency and quality in industrial steel manufacturing operations.
{"title":"Analyzing Infrared Linescan Profiles of Steel Strips for Enhanced Cooling Pattern Prediction","authors":"Rubén Usamentiaga;Adrian G. Gayo;Francisco J. delaCalle;Dario G. Lema;Stefano Sfarra;Hai Zhang","doi":"10.1109/TIA.2025.3585082","DOIUrl":"https://doi.org/10.1109/TIA.2025.3585082","url":null,"abstract":"Real-time temperature information is crucial for optimizing cooling processes during steel strip rolling, ensuring the attainment of desired microstructural properties and surface quality at an optimal cooling rate. Infrared line scanners emerge as the preferred choice for temperature measurement in high-speed rolling operations, delivering temperature readings with high resolution and enabling the capture of detailed temperature profiles. By analyzing these profiles, cooling systems can be finely adjusted and precisely controlled to optimize the rolling operation. However, developing effective cooling strategies becomes challenging when dealing with temperature profiles comprising numerous discrete data points, often numbering in the thousands per profile. This study presents an innovative approach that integrates the detection of steel strip boundaries within temperature profiles and subsequent temperature pattern characterization using polynomial fitting. A significant advantage is demonstrated by leveraging the coefficients of Legendre polynomials, which provide a concise description of temperature profile shapes, facilitating straightforward approaches to cooling strategies. By integrating boundary detection with temperature characterization, the system enhances its ability to predict tailored cooling patterns, optimizing cooling efficiency, and enhancing product quality in the manufacturing process. Rigorous testing using both synthetic data and real-world applications in cold and hot rolling validates the proposed system’s practical utility and reliability. These results underscore its potential to enhance efficiency and quality in industrial steel manufacturing operations.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"62 1","pages":"742-754"},"PeriodicalIF":4.5,"publicationDate":"2025-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=11062598","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146006860","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-07-02DOI: 10.1109/TIA.2025.3585081
Shaik Mullapathi Farooq;S. M. Suhail Hussain;Mohd. Asim Aftab;Taha Selim Ustun;Charalambos Konstantinou;Mohammad A. Abido
Phasor Measurement Unit (PMU) data transmitted over public wide area networks and following standardized protocols becomes increasingly vulnerable to cyberattacks. The IEC 61850-90-5 standard introduces cryptographic measures like encryption algorithms and message authentication codes (MACs) for PMU data security. To facilitate the exchange of keys for these symmetric algorithms, the standard specifies a key distribution mechanism that includes the authentication of participating entities. Certificate-based authentication is recommended for key distribution, but this approach faces challenges, including complex certificate management and key escrow issues. To address these issues, this paper proposes a certificateless authentication protocol based on Elliptic Curve Cryptography (ECC) for IEC 61850-90-5 PMU communication. The proposed scheme eliminates reliance on Certificate Authorities and resolves key escrow issues while ensuring efficient mutual authentication. A formal security analysis using the Real-Or-Random (ROR) model and validation through the AVISPA tool confirm the scheme’s robustness against impersonation, replay, and MITM attacks, demonstrating its superior security and efficiency compared to existing methods.
{"title":"Certificateless Authentication Scheme for Key Distribution in IEC 61850-90-5 PMU Communication Network","authors":"Shaik Mullapathi Farooq;S. M. Suhail Hussain;Mohd. Asim Aftab;Taha Selim Ustun;Charalambos Konstantinou;Mohammad A. Abido","doi":"10.1109/TIA.2025.3585081","DOIUrl":"https://doi.org/10.1109/TIA.2025.3585081","url":null,"abstract":"Phasor Measurement Unit (PMU) data transmitted over public wide area networks and following standardized protocols becomes increasingly vulnerable to cyberattacks. The IEC 61850-90-5 standard introduces cryptographic measures like encryption algorithms and message authentication codes (MACs) for PMU data security. To facilitate the exchange of keys for these symmetric algorithms, the standard specifies a key distribution mechanism that includes the authentication of participating entities. Certificate-based authentication is recommended for key distribution, but this approach faces challenges, including complex certificate management and key escrow issues. To address these issues, this paper proposes a certificateless authentication protocol based on Elliptic Curve Cryptography (ECC) for IEC 61850-90-5 PMU communication. The proposed scheme eliminates reliance on Certificate Authorities and resolves key escrow issues while ensuring efficient mutual authentication. A formal security analysis using the Real-Or-Random (ROR) model and validation through the AVISPA tool confirm the scheme’s robustness against impersonation, replay, and MITM attacks, demonstrating its superior security and efficiency compared to existing methods.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"62 1","pages":"716-728"},"PeriodicalIF":4.5,"publicationDate":"2025-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146006893","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This paper introduces an Optimized Second-Order Adaptive Integrator (OSO-AI) control and ground-breaking Predictive Self-Tuned Perturb & Observe (PSPO) Maximum Power Point Tracking (MPPT) technique for a single-phase two-stage grid integrated Solar Photovoltaic (SPV) system, aimed at enhancing power quality in distribution networks. The architectural structure includes a boost converter and a Voltage Source Converter (VSC), designed to maximize solar power extraction and ensure seamless grid integration with minimal harmonics. The system’s Point of Common Coupling (PCC) have two distinct non-liner loads. The proposed OSO-AI control algorithm effectively manages the VSC to provide reactive power compensation and improve grid stability. Extensive simulation tests and rigorous laboratory experiments on hardware system are performed to verify its robustness against dynamic load perturbations, grid disturbances, and fluctuating solar irradiance. The experimental results demonstrate the robustness of the proposed approach, with total harmonic distortion (THD) under 5%. The findings highlight the system’s compliance with stringent power quality norms, validating the effectiveness of the PSPO MPPT and OSO-AI control in optimizing performance in grid-connected SPV systems.
{"title":"Single-Phase Two-Stage Grid Integrated Solar PV System With OSO-AI Control and PSPO MPPT","authors":"Arun Kumar;Aryan Prajapati;Nishant Kumar;Jyoti Dhayal","doi":"10.1109/TIA.2025.3584292","DOIUrl":"https://doi.org/10.1109/TIA.2025.3584292","url":null,"abstract":"This paper introduces an Optimized Second-Order Adaptive Integrator (OSO-AI) control and ground-breaking Predictive Self-Tuned Perturb & Observe (PSPO) Maximum Power Point Tracking (MPPT) technique for a single-phase two-stage grid integrated Solar Photovoltaic (SPV) system, aimed at enhancing power quality in distribution networks. The architectural structure includes a boost converter and a Voltage Source Converter (VSC), designed to maximize solar power extraction and ensure seamless grid integration with minimal harmonics. The system’s Point of Common Coupling (PCC) have two distinct non-liner loads. The proposed OSO-AI control algorithm effectively manages the VSC to provide reactive power compensation and improve grid stability. Extensive simulation tests and rigorous laboratory experiments on hardware system are performed to verify its robustness against dynamic load perturbations, grid disturbances, and fluctuating solar irradiance. The experimental results demonstrate the robustness of the proposed approach, with total harmonic distortion (THD) under 5%. The findings highlight the system’s compliance with stringent power quality norms, validating the effectiveness of the PSPO MPPT and OSO-AI control in optimizing performance in grid-connected SPV systems.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 6","pages":"9662-9670"},"PeriodicalIF":4.5,"publicationDate":"2025-06-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145100374","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-26DOI: 10.1109/TIA.2025.3583651
Baihe Su;Yu-Chuan Li;Zhijie Liu;Ke-Jun Li;Zhenshan Huang;Yuanzong Song
With promoting the application of renewable energy, distributed photovoltaic (PV) generation has become an important form of electrical source. More and more distributed PVs are connected into the power distribution system via traditional converters. With the continuous increase of PV penetration, the power grid is facing many challenges due to the inherent randomness and fluctuations of PV sources. Micro Energy Control Unit (MECU) is proposed as an alternative approach for the safe, economical, and efficient utilization of PV sources. Based on a multi-port structure, MECU connects photovoltaics, energy storage, the grid, and demand side loads. MECU can offer advantages of energy self-balancing, transient stability support, flexible demand-side integration, and power quality improvement. Two prototypes of MECU are developed for different application scenarios. Light-MECU is designed for small-capacity PV systems with strict space limits; The Modular Stackable Common-bus MECU (MSC-MECU) is used in high-power distributed PV grid-connected scenarios, such as rooftop PV systems. Experimental results show that MECU achieves energy self-balancing and transient stability support. MECU can be an effective solution for ensuring the reliable operation of power systems in the case of high PV penetration.
{"title":"On the Future of Micro Energy Control Unit (MECU) Integrated Grid","authors":"Baihe Su;Yu-Chuan Li;Zhijie Liu;Ke-Jun Li;Zhenshan Huang;Yuanzong Song","doi":"10.1109/TIA.2025.3583651","DOIUrl":"https://doi.org/10.1109/TIA.2025.3583651","url":null,"abstract":"With promoting the application of renewable energy, distributed photovoltaic (PV) generation has become an important form of electrical source. More and more distributed PVs are connected into the power distribution system via traditional converters. With the continuous increase of PV penetration, the power grid is facing many challenges due to the inherent randomness and fluctuations of PV sources. Micro Energy Control Unit (MECU) is proposed as an alternative approach for the safe, economical, and efficient utilization of PV sources. Based on a multi-port structure, MECU connects photovoltaics, energy storage, the grid, and demand side loads. MECU can offer advantages of energy self-balancing, transient stability support, flexible demand-side integration, and power quality improvement. Two prototypes of MECU are developed for different application scenarios. Light-MECU is designed for small-capacity PV systems with strict space limits; The Modular Stackable Common-bus MECU (MSC-MECU) is used in high-power distributed PV grid-connected scenarios, such as rooftop PV systems. Experimental results show that MECU achieves energy self-balancing and transient stability support. MECU can be an effective solution for ensuring the reliable operation of power systems in the case of high PV penetration.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 6","pages":"8866-8878"},"PeriodicalIF":4.5,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145090088","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-26DOI: 10.1109/TIA.2025.3583682
Chandrakala Devi Sanjenbam;Bhim Singh
This work presents a strategy for enhancing power quality (PQ) in a standalone distributed generation system (DGS) supplying power to sensitive and nonlinear loads. This system integrates a permanent magnet synchronous generator (PMSG) driven by a hydropower turbine, a solar photovoltaic (PV) array, and a battery storage unit controlled through a universal active filtering system (UAFS). A modified generalized integrator (mGI) control is proposed to enhance PQ by efficiently compensating voltage deviations and suppressing harmonics. Simulation results show that this system reduces total harmonic distortion (THD) of source currents and load voltages to 2.6% and 1.1%, respectively, which are within the IEEE 519 standard limit, even though load current THD is 26.7%. Additionally, the system maintains a constant load voltage amplitude of 220 V despite generator-side fluctuations. During sudden unavailability of solar PV power, battery seamlessly discharges, ensuring uninterrupted operation. System’s performance is validated using a hardware prototype, demonstrating consistent PQ improvement under both steady-state and dynamic conditions. Proposed setup is suitable for standalone DGS applications requiring high-quality power delivery. Moreover, effectiveness of presented system is compared with other control techniques.
{"title":"PMSG Based Standalone Distributed Generation Integrated Universal Active Filtering System","authors":"Chandrakala Devi Sanjenbam;Bhim Singh","doi":"10.1109/TIA.2025.3583682","DOIUrl":"https://doi.org/10.1109/TIA.2025.3583682","url":null,"abstract":"This work presents a strategy for enhancing power quality (PQ) in a standalone distributed generation system (DGS) supplying power to sensitive and nonlinear loads. This system integrates a permanent magnet synchronous generator (PMSG) driven by a hydropower turbine, a solar photovoltaic (PV) array, and a battery storage unit controlled through a universal active filtering system (UAFS). A modified generalized integrator (mGI) control is proposed to enhance PQ by efficiently compensating voltage deviations and suppressing harmonics. Simulation results show that this system reduces total harmonic distortion (THD) of source currents and load voltages to 2.6% and 1.1%, respectively, which are within the IEEE 519 standard limit, even though load current THD is 26.7%. Additionally, the system maintains a constant load voltage amplitude of 220 V despite generator-side fluctuations. During sudden unavailability of solar PV power, battery seamlessly discharges, ensuring uninterrupted operation. System’s performance is validated using a hardware prototype, demonstrating consistent PQ improvement under both steady-state and dynamic conditions. Proposed setup is suitable for standalone DGS applications requiring high-quality power delivery. Moreover, effectiveness of presented system is compared with other control techniques.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 6","pages":"9652-9661"},"PeriodicalIF":4.5,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145100497","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-26DOI: 10.1109/TIA.2025.3583676
A S L K Gopalamma;Srinu Naik Ramavathu
The safety, reliability, and resilience of industrial equipment, including drives, Power Electronic Systems (PES), and Distributed Control Systems (DCS), are contingent upon their level of protection. Essential requirements for this sensitive equipment include managing Electro-Magnetic Interference (EMI) and ensuring power quality. Inadequate potential equalization can result in failures or malfunctions of controller cards and internal boards within power electronic devices and distributed control systems. This research offers valuable perspectives obtained from tackling a major challenge within the industry. The research led to the development of a safe, cost-effective, and robust earthing system (SERES) that employs frequency-dependent dynamic soil properties (FDDSP), while also taking into account constraints such as spacing factor (SF) and zone of influence (ZoI). The proposed extension work examines the case study across various seasons and conditions at the test site, emphasizing the performance of the proposed design under dynamic circumstances and evaluating the system’s efficacy through a new SERES model based on impedance parameters.
{"title":"Design and Analysis of Frequency-Dependent Dynamic Soil Properties Based Safe Economical Robust Earthing System","authors":"A S L K Gopalamma;Srinu Naik Ramavathu","doi":"10.1109/TIA.2025.3583676","DOIUrl":"https://doi.org/10.1109/TIA.2025.3583676","url":null,"abstract":"The safety, reliability, and resilience of industrial equipment, including drives, Power Electronic Systems (PES), and Distributed Control Systems (DCS), are contingent upon their level of protection. Essential requirements for this sensitive equipment include managing Electro-Magnetic Interference (EMI) and ensuring power quality. Inadequate potential equalization can result in failures or malfunctions of controller cards and internal boards within power electronic devices and distributed control systems. This research offers valuable perspectives obtained from tackling a major challenge within the industry. The research led to the development of a safe, cost-effective, and robust earthing system (SERES) that employs frequency-dependent dynamic soil properties (FDDSP), while also taking into account constraints such as spacing factor (SF) and zone of influence (ZoI). The proposed extension work examines the case study across various seasons and conditions at the test site, emphasizing the performance of the proposed design under dynamic circumstances and evaluating the system’s efficacy through a new SERES model based on impedance parameters.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 6","pages":"8879-8886"},"PeriodicalIF":4.5,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145090017","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-26DOI: 10.1109/TIA.2025.3583649
Jianan Jiang;Tianjie Zou;Salvatore La Rocca;Hailin Huang;Xiang Ren;Antonino La Rocca;Dmytro Prystupa;Dongdong Chen;David Gerada;Shaohong Zhu;Krzysztof Paciura;Chris Gerada
Hairpin winding has been widely applied in passenger electrical vehicle (EV) industry, as a key technology brick that enables step-change improvements on power density and efficiency of traction motors. Meanwhile, the advantages and challenges of hairpin windings are yet to be fully investigated for commercial EV applications. This paper deals with critical comparison between randomly stranded and hairpin windings, to provide design guideline & insight for semi-truck purposed heavy-duty traction. Based on 550Nm peak torque and 12000 rpm peak speed performance requirements, design parameters including slot-pole combinations, global geometry, conductor sizes & layouts as well as cooling strategies are evaluated. Represented design cases with different winding configurations down-selected from multi-physics domain optimization tool, are looked into in detail to quantitatively highlight the differences hairpin winding solutions can bring in power density, power losses, and thermal management. For hairpin windings, the options of variable conductor sizes in one slot are also investigated. The comparison results reveal that heavy duty applications will push hairpin winding solutions towards higher number of slots-per-pole-per-phase (q) for more balanced power loss distributions. This balanced loss distribution further simplifies the cooling strategy, making it unnecessary to employ more complex shaft cooling systems. Based on optimised designs, two prototypes with 72-slot, 8-pole stranded winding and 96-slot, 8-pole hairpin winding, respectively are manufactured and tested, which shows that the hairpin winding solution can provide 22% improvement in continuous power density at reduced temperature rise on both windings and magnets.
{"title":"Comparative Study of Stranded and Hairpin Windings for 250 kW Continuous Operation of High-Speed Heavy-Duty EV Traction Motor","authors":"Jianan Jiang;Tianjie Zou;Salvatore La Rocca;Hailin Huang;Xiang Ren;Antonino La Rocca;Dmytro Prystupa;Dongdong Chen;David Gerada;Shaohong Zhu;Krzysztof Paciura;Chris Gerada","doi":"10.1109/TIA.2025.3583649","DOIUrl":"https://doi.org/10.1109/TIA.2025.3583649","url":null,"abstract":"Hairpin winding has been widely applied in passenger electrical vehicle (EV) industry, as a key technology brick that enables step-change improvements on power density and efficiency of traction motors. Meanwhile, the advantages and challenges of hairpin windings are yet to be fully investigated for commercial EV applications. This paper deals with critical comparison between randomly stranded and hairpin windings, to provide design guideline & insight for semi-truck purposed heavy-duty traction. Based on 550Nm peak torque and 12000 rpm peak speed performance requirements, design parameters including slot-pole combinations, global geometry, conductor sizes & layouts as well as cooling strategies are evaluated. Represented design cases with different winding configurations down-selected from multi-physics domain optimization tool, are looked into in detail to quantitatively highlight the differences hairpin winding solutions can bring in power density, power losses, and thermal management. For hairpin windings, the options of variable conductor sizes in one slot are also investigated. The comparison results reveal that heavy duty applications will push hairpin winding solutions towards higher number of slots-per-pole-per-phase (<italic>q</i>) for more balanced power loss distributions. This balanced loss distribution further simplifies the cooling strategy, making it unnecessary to employ more complex shaft cooling systems. Based on optimised designs, two prototypes with 72-slot, 8-pole stranded winding and 96-slot, 8-pole hairpin winding, respectively are manufactured and tested, which shows that the hairpin winding solution can provide 22% improvement in continuous power density at reduced temperature rise on both windings and magnets.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 6","pages":"9254-9268"},"PeriodicalIF":4.5,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145090192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-26DOI: 10.1109/TIA.2025.3583679
Rafal Wrobel;Thomas C. Werner;Xu Deng;Daniel Noal
This paper describes key aspects of the development process of an ultra-lightweight electrical motor for solar-powered high-altitude (20 km) platform applications (HAPSs). A radial-flux permanent magnet (PM) machine topology with outer rotor and integrated direct air-cooling is considered here. The mission profile of the analysed solar-powered aircraft calls for a high-torque overload (×2.5) at take-off and a high-efficiency (>95%) at high-altitude cruise operation. Consequently, a fine balance between both operating points needs to be seen when sizing the motor. Effective thermal management of the motor at take-off is critical for achieving a compact motor design. Further to these, the motor design should enable a simple and cost-effective manufacturing and sassembly process, which makes use of the lightweight composite materials for all structural elements of the motor assembly. In this work, a careful integration between both active and structural subassemblies of the motor resulted in a significant weight reduction, with contribution of all structural components less than 5% of the overall motor weight. The theoretical and experimental results discussed in the paper confirm the key design targets of the motor are met, with a motor torque density of 10Nm/kg (take-off operation) and 94% efficiency (cruise operation). Further to the motor development process, a comprehensive insight into the existing state of the art HAPS solar-powered aircrafts with focus on the commercial electrical motor technology and motor to aircraft integration is provided to highlight some of the application driven engineering challenges.
{"title":"An Ultra-Lightweight PM Electrical Motor for High-Altitude Platform Applications","authors":"Rafal Wrobel;Thomas C. Werner;Xu Deng;Daniel Noal","doi":"10.1109/TIA.2025.3583679","DOIUrl":"https://doi.org/10.1109/TIA.2025.3583679","url":null,"abstract":"This paper describes key aspects of the development process of an ultra-lightweight electrical motor for solar-powered high-altitude (20 km) platform applications (HAPSs). A radial-flux permanent magnet (PM) machine topology with outer rotor and integrated direct air-cooling is considered here. The mission profile of the analysed solar-powered aircraft calls for a high-torque overload (×2.5) at take-off and a high-efficiency (>95%) at high-altitude cruise operation. Consequently, a fine balance between both operating points needs to be seen when sizing the motor. Effective thermal management of the motor at take-off is critical for achieving a compact motor design. Further to these, the motor design should enable a simple and cost-effective manufacturing and sassembly process, which makes use of the lightweight composite materials for all structural elements of the motor assembly. In this work, a careful integration between both active and structural subassemblies of the motor resulted in a significant weight reduction, with contribution of all structural components less than 5% of the overall motor weight. The theoretical and experimental results discussed in the paper confirm the key design targets of the motor are met, with a motor torque density of 10Nm/kg (take-off operation) and 94% efficiency (cruise operation). Further to the motor development process, a comprehensive insight into the existing state of the art HAPS solar-powered aircrafts with focus on the commercial electrical motor technology and motor to aircraft integration is provided to highlight some of the application driven engineering challenges.","PeriodicalId":13337,"journal":{"name":"IEEE Transactions on Industry Applications","volume":"61 6","pages":"9243-9253"},"PeriodicalIF":4.5,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145090225","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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