Recent Advances in Electric Machine Design and Operation

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IEEE Miami Section Energy Systems Research Laboratory

Florida International University

March 22, 2013

Recent Advances in Electric Machine Design

and Operation

By Jim Hendershot, IEEE Fellow

JR Hendershot 2013 1

JR Hendershot 2013

In planning a SPEECH OR LECTURE I was once advised to employ the design principles frequently used by fashion designers for “MINI-SKIRTS” Therefore in preparation for this lecture I have tried to adhere to those important principles which are: 1- MAKE IT SHORT ENOUGH TO MAINTAIN ` AUDIENCE CONCENTRATION ! 2 – MAKE IT LONG ENOUGH TO COVER ALL THE ESSENTIALS !

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Origins of electric machines

JR Hendershot 2013

I assume by now that many of you think you know a lot about the origins of electric machines and most of you were taught that they have been around for only about 150 years give or take. Well I have a surprise for you !! Electric motors have been around for thousands of years or even longer. If you don’t believe me I have photographs and models of these early motors coming up. They are inside each of our bodies, as well as in the food and beverages we intake each day Biologists call them Bacterial flagella motors

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First known electric propulsion motor

Microscopic Bacteria

Propulsion Motors Plastic model of first motor


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Bacterial flagella propulsion motor

JR Hendershot 2013

45nm diameter with 20 parts & spins several hundred Hz cw & ccw Spins filaments like fish tails for rapid propulsion in liquids

Prof. Howard Berg

Harvard University

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One of Tesla’s first motor prototypes


Another of Tesla’s examples


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What resulted from Faraday & Tesla’s (plus others) efforts over the last 120 or so years ?

Single phase powered AC induction motors Three phase AC induction motors DC motors, shunt, series ,compound wound and permanent-magnet



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Motors consume about 67% of USA grid power. (Ref: DOE)

Single Phase Induction Motors Line start AC Induction Three Phase Motors VFD (variable speed drives) DC motors, Steppers, brushless DC, switched reluctance & even VFD systems (variable speed drives)


AC induction motor speed controlled by frequency (according to pole number)

DC motor speed is controlled by DC supply voltage

A.C. Motor Torque/Speed Curve


Two most popular motors types from the 20th Century

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Two pole wound field Commutated motor (AC or DC powered)

Examples & details of Modern DC motors


MAXON Slotless DC GEMOARTOR

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Cross section of modern AC induction motor


Modern Reliance high performance AC Induction Motor.


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35,000 HP TECO-WESTINGHOUSE DC SHUNT MOTOR


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Large Dual Fed AC Machine by Siemens


Single Phase Die Cast Aluminum Rotor


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Wound rotor AC Induction machines

Formerly used for lifting crane drives Currently used for wind turbine generators.



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Die Cast Copper Rotors


AC Induction Torque vs. Speed Curve Driven with a Field Controlled Inverter


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By Andrew Frazer, Murdoch University Using Infolytica Magnet

Line start grid powered AC single or three phase rotors


New motor technologies driven by inverters & microprocessors Stepping Motors PM Brushless DC PM-AC Synchronous (SPM & IPM) (axial & radial) Switched Reluctance Synchronous Brushless Reluctance Synchronous Brushless Linear machines of all above types


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Hybrid & PM Stepping motors


BRUSHLESS & PM-AC SPM & IPM ROTORS


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Honda IPM Brushless AC



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High performance stator encapsulated in thermal conductive epoxy. Note liquid cooling jacket around stator. AC PM Synchronous motors and inverters used for high speed machining in machine tool spindles. ATE System GmbH


High copper fill used in FORD Hybrid Vehicles


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STATOR EXAMPLES OF HI-SLOT FILLS AND SHORT END TURNS


Automated hair-pin stator windings 60 slots & 10 poles REMY CORP.

2010 Toyota Prius Motor & Generator Parts


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IPM rotor stampings used in TOYOTA hybrid vehicles


NOVA-TORQUE Axial-Cone-Flux (Inside Cone)


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NOVA-TORQUE Axial-Cone-Flux (Outside Cone)

QM POWER Hybrid PM-SR Motor


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Torus Axial Flux PM Synchronous Motors


EXRO direct drive multiple PM generators for wind turbines


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Brushless motors with no magnets Switched Reluctance Simple construction Robust & low cost Can be noisy Difficult to control


Switched Reluctance Starter/Generator For Gas Turbine Heavy Fuel Engine

GE & Sundstrand JR Hendershot 2013 46

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Switched Reluctance motors with no magnets


2 Phase SR motor replaces AD-DC brush type motor


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ABB Reluctance Synchronous motors & Inverters

JR Hendershot 2013

In order for RSM machines to be technically competitive the ratio of inductance (Ld/Lq) must be greater than 5 and closer to 9.

RSM (Reluctance Synchronous)

ABB ABB

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Remy Corp.

JR Hendershot 2013

From Battery powered portable tools

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Battery operated brushless power tool motors

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Some important applications using high performance AC induction motors and

drives

Powered by:

Field Controlled Inverters


AC, PM & SR LINEAR MOTORS


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Largest Atom Smasher in the World Hi-Speed Mag-Lev Train

JR Hendershot 2013) 56

SONY Humanoid Robot

New white goods appliance in every US home by

middle of 21st Century

(Remember you heard this first from

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Tesla sports car and 3 – phase AC Traction Motor


Two seat 1600 lb sports car by Ian Wright in an Ariel Atom chassis Acceleration, 0 – 60 in 2.9 sec, ¼ mile in 11.5 sec, 236 HP, 3 Phase

AC induction motor and drive by AC Propulsion, batteries A123 Systems

WRIGHTSPEED JR Hendershot 2013 58

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Wheel Traction Motors


Rotor & Stator by REMY


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2010 PRIUS ELECTRIC DRIVE


Siemens four pole AC tractions mounted on a transmission


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Caterpiller


Caterpiller


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CATERPILLER PM GENERATOR AC TRACTION MOTOR & INVERTER


US NAVY & American Superconductor


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Rail Traction AC Induction Motor


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SIEMENS


WIND TURBINE GENERATORS


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More Generators for large wind turbines


WWOW!! 13 M dia. & almost 500 KG of rare earth magnets!!


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SLM Synchronous twin PM rails attached to underside of car & (32) 3-phase stators attached to track.

AC Induction or PM synchronous coaster launchers


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Flywheel Batteries using Halbach PM electric generator



Flywheel Batteries using low loss RSM electric generator

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Hi powered electro-magnets with no PMs or iron.

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45 Tesla Magnet construction


Bitter plates of thin copper sheets, insulated and spiral stacked to form a very flat wire coil to facilitate liquid cooling.

(3) Concentric coil stacks

Reference books on electric motor theory and design: (AVAILABLE ON AMZON)


ISB 0-19-859369-6 ISBN 0-19-859389-9 ISBN 978-0-9840687-0-8

ISBN 0-9745470-2-6 ISBN 978-0-470-69516-6 ISBN 978-1-1182-1529-6

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Thank you very much for attending, Jim Hendershot 3-21-2013

I sincerely hope some of my remarks have awakened your creativity and stimulated some new thoughts and perhaps even some new inventions regarding electric machines and magnetics in general.

This is only the beginning of the electric motor and drive revolution !! We need to motivate and educate at least 250,000 Electric Engineers

Documents

Recent Advances in Electric Machine Design and Operation