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Synchronous Reluctance Motor Drives: Still a Niche Technology? Istanbul, August 28, 2019 [email protected] ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino 1

Synchronous Reluctance Motor Drives: Still a Niche …...Aug 28, 2019  · Background: Synchronous Reluctance Torque. Reluctance motors operate according to the principle of . magnetic

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  • Synchronous Reluctance Motor Drives:Still a Niche Technology?Istanbul , August 28, 2019

    gianmar io.pel legr ino@pol i to . i t

    ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino 1

  • Outline

    ◦ Introduction◦ Politecnico di Torino and the Power Electronics Innovation Center (PEIC)

    ◦ The Synchronous Reluctance Motor

    ◦ Background: history of the SyR motor technology◦ Where we Stand◦ Today’s Challenges◦ SyR-e: Synchronous Reluctance Evolution◦ Conclusion

    2ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • Politecnico di Torino

    Founded in 1859, as Technical School for Engineers Politecnico di Torino since 1906

    Home to Galileo Ferraris, pioneer of electrical engineering. He was a professor here, and a Senator of the former Reign of Italy

    35000 students, 700 PhD students

    850 Faculty members, 890 Administrative Technical staff

    Budget (2018): 250 M€(55% State, 12% student fees, 30% projects)

    Tuition fee:1000 - 2000 € / year

    3ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Galileo Ferraris(1847 – 1897)

  • PEIC: The Power Electronics Innovation Center

    Inter-Departmental Center dedicated to Power Electronics, from Si wafer to final applications, founded in 2017

    20 faculty members, 2 technicians, 25 PhD students

    Key lines of application: Transportation electrification, Energy, Industry

    Capability of delivering TRL4 demonstrators, support to higher-TRL prototyping

    Home to SLED 2019, September 9-10 2019 https://attend.ieee.org/sled-2019/

    4ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    http://www.peic.polito.it/

    https://attend.ieee.org/sled-2019/http://www.peic.polito.it/

  • PEIC: The Power Electronics Innovation Center

    Inter-Departmental Center dedicated to Power Electronics, from Si wafer to final applications, founded in 2017

    20 faculty members, 2 technicians, 25 PhD students

    Key lines of application: Transportation electrification, Energy, Industry

    Capability of delivering TRL4 demonstrators, support to higher-TRL prototyping

    Home to SLED 2019, September 9-10 2019 https://attend.ieee.org/sled-2019/

    5ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    http://www.peic.polito.it/

    https://attend.ieee.org/sled-2019/http://www.peic.polito.it/

  • The Synchronous Reluctance Motor Technology

    ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino 6

  • Background: Synchronous Reluctance Torque

    Reluctance motors operate according to the principle of magnetic reluctance ….The rotor consisting of air and iron has the least possible magnetic reluctance in one direction and the highest possible reluctance in the direction perpendicular to that. Because the system always moves toward the lowest magnetic reluctance, rotational movement results.

    Source: “Dynamic Energy Efficiency”, in Advance 1/2015, April 2015, Siemens AG

    7ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Excitation oflow reluctance rotor axis

    Excitation ofhigh reluctance rotor axis

  • Advantages of SyR Motors

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    Source: new.abb.com

    1. Standard distributed-winding stator

    2. Rotor simplicity

    - no windings substantial loss reduction, ease of manufacturing

    - no PMs cost reduction, no de-magnetization, no back-emf voltage when uncontrolled

    - low moment of inertia Dynamic performance

    Vs Asynchronous Motors:

    - smaller frame size per continuous torque or higher efficiency

    - faster speed dynamics

    Vs PM Synchronous Motors:

    - lower cost of production (no PM cost, ease of manufacturing)

    - higher transient overload capability (no demag)

  • Advantages of SyR Motors

    9ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Source: new.abb.com

    1. Standard distributed-winding stator

    2. Rotor simplicity

    - no windings substantial loss reduction, ease of manufacturing

    - no PMs cost reduction, no de-magnetization, no back-emf voltage when uncontrolled

    - low moment of inertia Dynamic performance

    Vs Asynchronous Motors:

    - smaller frame size per continuous torque or higher efficiency

    - faster speed dynamics

    Vs PM Synchronous Motors:

    - lower cost of production (no PM cost, ease of manufacturing)

    - higher transient overload capability (no demag)

  • Advantages of SyR Motors

    10ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Source: new.abb.com

    1. Standard distributed-winding stator

    2. Rotor simplicity

    - no windings substantial loss reduction, ease of manufacturing

    - no PMs cost reduction, no de-magnetization, no back-emf voltage when uncontrolled

    - low moment of inertia Dynamic performance

    Vs Asynchronous Motors:

    - smaller frame size per continuous torque or higher efficiency

    - faster speed dynamics

    Vs PM Synchronous Motors:

    - lower cost of production (no PM cost, ease of manufacturing)

    - higher transient overload capability (no risk for demagnetization)

  • Control: Mandatory Aspects

    MTPA Operation

    The high efficiency at partial load is obtained viaMaximum Torque per Ampere operation

    Sensorless Control (no encoder)

    This keeps the variable speed SyR motor drivecost competitive respect to the asynchronouscounterpart (exception: servo applications;

    11ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • Well Known Disadvantages

    Low Power Factor and High Torque Ripple

    - low PF

    - high torque ripple

    Need for precise Motor Commissioning (also said non standard control)

    - respect of MTPA law

    - stable Sensorless Control

    High Speed Applications

    - rotor ribs scale with 𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚2

    Low Speed Applications

    - high number of poles harmed by increase of p.u. excitation current

    12ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • Well Known Disadvantages

    Low Power Factor and High Torque Ripple

    - low PF

    - high torque ripple

    Non-standard control, need for precise Motor Commissioning

    - respect of MTPA law

    - stable Sensorless Control

    High Speed Applications

    - rotor ribs scale with 𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚2

    Low Speed Applications

    - high number of poles harmed by increase of p.u. excitation current

    13ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    We will discuss each point later on

  • History of the Synchronous Reluctance Motor Technology

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  • 1923: The Idea of Flux Barriers

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    Kostko, J.K., "Polyphase reaction synchronous motors,“American Institute of Electrical Engineers, Journal of the, 1923

  • 1972: The Synduction Motor

    First exemplar for both variable speed(constant V/f) or direct online application

    Cast aluminium cage in the rotor, design optimized for best trade-off between a high pull-out torque (low 𝐿𝐿𝑞𝑞) and a low critical frequency of oscillation (high 𝐿𝐿𝑞𝑞)

    Adoption limited to special applications, such as textile industry (multiple motors driven with the same converter, at same speed)

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    Honsinger, V.B., “Synchronous reluctance motor”, US3652885, 1972 (Allis Chalmers, Ohio)Honsinger, V. B., "Inherently Stable Reluctance Motors Having Improved Performance," in IEEE Transactions on Power Apparatus and Systems, vol. PAS-91, no. 4, pp. 1544-1554, July 1972

  • 1990s: Variable Speed Drives

    With the advent of modern power electronics and vector control, the SyR Motor solution became widely studied and developed◦ flux barriers Vs axially laminated (ALA)◦ Motor design rules

    ◦ saliency maximization

    ◦ torque ripple minimization

    ◦ Vector control schemes◦ First sensorless control schemes

    17ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    [*] Kolehmainen, J. (2010). Synchronous reluctance motor with form blocked rotor. IEEE Transactions on Energy Conversion[**] Vagati, A. (1998) "Synchronous reluctance electrical motor having a low torque-ripple design." U.S. Patent No. 5,818,140

    [*] [**]

    (ALA)

    (Flux Barriers)

  • Technology Development Timeline

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    Source: Google Scholar

  • The Roaring Nineties

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    Source: Google Scholar

  • Milestones: 1991

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    1991

    Lipo, T. A. "Synchronous reluctance machines - a viable alternative for ac drives?“ Electric Machines and Power Systems 19.6 (1991): 659-671Xu, L., Xu, X., Lipo, T. A., Novotny, D. W. (1991). “Vector control of a synchronous reluctance motor including saturation and iron loss”, IEEE Transactions on Industry Applications, 27(5), 977-985.

  • Milestones: 1992

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    1992 Vagati, A., Franceschini, G., Marongiu, I., & Troglia, G. P. (1992, October). “Design criteria of high performance synchronous reluctance motors”, In Conference Record of the 1992 IEEE Industry Applications Society Annual Meeting (pp. 66-73). IEEE.

  • Milestones: 1993

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    1993

    Staton, D. A., Miller, T. J. E., & Wood, S. E. (1993, July). “Maximising the saliency ratio of the synchronous reluctance motor”, In IEE Proceedings B (Electric Power Applications) (Vol. 140, No. 4, pp. 249-259). IET Digital Library.Betz, R. E., Lagerquist, R., Jovanovic, M., Miller, T. J., & Middleton, R. H. (1993). “Control of synchronous reluctance machines”, IEEE Transactions on Industry Applications, 29(6), 1110-1122.

  • Milestones: 1994

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    1994

    Matsuo, T., & Lipo, T. A. (1994). “Rotor design optimization of synchronous reluctance machine”, IEEE Transactions on Energy Conversion, 9(2), 359-365.Lagerquist, R., Boldea, I., & Miller, T. J. (1994). “Sensorless-control of the synchronous reluctance motor”, IEEE Transactions on Industry Applications, 30(3), 673-682.Boldea, I., Fu, Z. X., & Nasar, S. A. (1994). “Performance evaluation of axially-laminated anisotropic (ALA) rotor reluctance synchronous motors”, IEEE transactions on industry applications, 30(4), 977-985.

  • Milestones:1996

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    1996 Kamper, M. J., Van der Merwe, F. S., & Williamson, S. (1996), “Direct finite element design optimisation of the cageless reluctance synchronous machine”, IEEE Transactions on Energy Conversion, 11(3), 547-555.

  • Milestones: 1998

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    1998 Vagati, A., Pastorelli, M., Francheschini, G., & Petrache, S. C. (1998), “Design of low-torque-ripple synchronous reluctance motors”, IEEE Transactions on Industry Applications, 34(4), 758-765.

  • Milestones: 1999

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    1999

    Ha, J. I., Kang, S. J., & Sul, S. K. (1999). Position-controlled synchronous reluctance motor without rotational transducer. IEEE transactions on Industry Applications, 35(6), 1393-1398.Consoli, A., Russo, F., Scarcella, G., & Testa, A. (1999). Low-and zero-speed sensorless control of synchronous reluctance motors. IEEE Transactions on Industry Applications, 35(5), 1050-1057.

  • Milestones: 2000

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    2000 Vagati, A., Pastorelli, M., Scapino, F., & Franceschini, G. (2000). Impact of cross saturation in synchronous reluctance motors of the transverse-laminated type. IEEE Transactions on Industry Applications, 36(4), 1039-1046.

  • Bottom Line

    By 2000, the technology was ready, including motor design, vector control and sensorlesscontrol aspects

    However, the interest on SyR motors did not ramp again until 2013 – 2014

    Enabling opportunities:

    - New regulations on electric motors effy

    - Price volatility of rare-earth PMs

    28ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • Bottom Line

    By 2000, the technology was ready, including motor design, vector control and sensorlesscontrol aspects

    However, the interest on SyR motors did not ramp again until 2013 – 2014

    Enabling opportunities:

    - New regulations on electric motors effy

    - Price volatility of rare-earth metals

    29ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • Improve the Efficiency

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    Note: efficiency classes IE2, IE3 defined according to IEC 60034-30 standard

  • Reduce the Rare-Earth Magnet Content

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    June 2011

  • Consequent Boom of the SyR Motor Technology

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    IE2 andrare-earth peak

    IE3 compulsory

    Source: Google Scholar

  • Source: new.abb.com

    Main Players on the Market (2019)

    ABBIE4 SynRM range - High output SynRM range (M3AL/M3BL), 5.5–315 kW, Frames: 132–315

    SiemensSimotics GP – Simotics SD (VSD4000), IES2 (EN 50598), 0.55 – 48 kWFrames: 80 - 200

    KSB: REEL SuPremE, IE4/IE5, 0.55 .. 450 kW

    Oemer: QSR SincroSPE, IE4, 0.3 .. 500 kW

    Bonfiglioli: BSR Series, IES2 (IEC 61800-9-2), 0.3 .. 18.5 kW

    Regal Beloit (Genteq HERMETIC): 0.5 .. 150 kW

    … probably incomplete

    33ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Source: Google Scholar

  • SyR motor technology: where we stand

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  • Review of Known Disadvantages

    Low Power Factor and High Torque Ripple

    - low PF

    - high torque ripple

    Non-standard control, need for precise Motor Commissioning

    - respect of MTPA law

    - stable Sensorless Control

    High Speed Applications

    - rotor ribs scale with 𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚2

    Low Speed Applications

    - high number of poles harmed by increase of p.u. excitation current

    35ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • About the Low Power Factor

    Low Power Factor and High Torque Ripple

    - low PF: related to the rotor ribs width

    36ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Pellegrino, G., Armando, E., Guglielmi, P., & Vagati, A. (2009), “A 250kW transverse-laminated Synchronous Reluctance motor”, In 2009 13th European Conference on Power Electronics and Applications. IEEE.

    𝑐𝑐𝑐𝑐𝑐𝑐 𝜑𝜑𝑛𝑛 = 0.79 𝑐𝑐𝑐𝑐𝑐𝑐 𝜑𝜑𝑛𝑛 = 0.87

  • Torque Ripple

    Low Power Factor and High Torque Ripple

    - low PF

    - high torque ripple:• rules for minimization (e.g. 𝒏𝒏𝒓𝒓 = 𝒏𝒏𝒔𝒔 ± 𝟒𝟒) + skewing, same as Asynchronous Motor• Numeric optimization is widely adopted

    37ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Pellegrino, G., Cupertino, F., & Gerada, C. (2014), “Automatic design of synchronous reluctance motors focusing on barrier shape optimization”,IEEE Transactions on Industry Applications, 51(2), 1465-1474.

  • Low Power Factor and High Torque Ripple

    - low PF

    - high torque ripple

    Non-standard control, need for precise Motor Commissioning

    - respect of MTPA law

    - stable Sensorless Control

    Flux Maps

    Motor Identification and Control

    38ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    a) Experimental Flux Maps of ABB M3AL 90LA4, 1.1 kW SyR Motor; b) MTPA trajectory (red) and incremental saliency contours

    Measured characteristics of 1.1 kW ABB SyR Motor (M3AL 90LA4)MTPA was off-line evaluated by flux maps manipulationIncremental saliency defines the area of feasibility of high-frequency

    response based sensorless control

  • Low Power Factor and High Torque Ripple

    - low PF

    - high torque ripple

    Need for precise Motor Commissioning

    - respect of MTPA law

    - stable Sensorless Control

    High Speed Applications

    - rotor ribs scale with 𝒏𝒏𝒎𝒎𝒎𝒎𝒎𝒎𝟐𝟐 T and PF drop

    High-speed Scalability

    39ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Ferrari, S.; Pellegrino, G.; Bonisoli, Elvio (2016) “Magnetic and structural co-design of synchronous reluctance electric machines in an open-source framework”, International Journal Of Mechanics And Control, Levrotto&Bella, pp. 8, 2016, Vol. 17, ISSN: 1590-8844

    Torque reduction as the ribs size is increased to withstand a larger max speed

  • Low-speed Applications

    Low Power Factor and High Torque Ripple

    - low PF

    - high torque ripple

    Need for precise Motor Commissioning

    - respect of MTPA law

    - stable Sensorless Control

    High Speed Applications

    - rotor ribs scale with 𝑛𝑛𝑚𝑚𝑚𝑚𝑚𝑚2

    Low Speed Applications

    - high number of poles harmed by p.u. excitation currentp.u. airgap grows PM assistance adjusts the Power Factor

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    Boazzo, B., Vagati, A., Pellegrino, G., Armando, E., Guglielmi, P. (2014). Multipolar ferrite-assisted synchronous reluctance machines: A general design approach. IEEE Transactions on Industrial Electronics, 62(2), 832-845.

    14-pole, ferrite assisted SyR motor prototype, for direct drive application

  • Today ’s Challenges

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  • Today’s Challenges

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    Motor Design Keys

    Develop trustable design tools • Balanced use of magnetic FEA• Saturated steel properties

    Find the reliable minimum width of rotor ribs • Structural FEA in the loop• Fatigue test campaigns

    Have a vector controlled test-rig • Flux maps identification for design validation

    MTPA Law and Sensorless Control Keys

    Know the motor parameters • Download from Motor Database• On-site Sensorless self-commissioning

  • Challenge 1: Motor Design Procedures

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    Motor Design Keys

    Develop trustable design tools • Balanced use of magnetic FEA• Saturated steel properties

    Find the reliable minimum width of rotor ribs • Structural FEA in the loop• Fatigue test campaigns

    Have a vector controlled test-rig • Flux maps identification for design validation

    MTPA Law and Sensorless Control Keys

    Know the motor parameters • Download from Motor Database• On-site Sensorless self-commissioning

  • Challenge 2: Standardize Motor Identification

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    Motor Design Keys

    Develop trustable design tools • Balanced use of magnetic FEA• Saturated steel properties

    Find the reliable minimum width of rotor ribs • Structural FEA• Fatigue test campaigns

    Have a vector controlled test-rig • Flux maps identification for design validation

    MTPA Law and Sensorless Control Keys

    Know the motor parameters • Download from Motor Database• On-site Sensorless self-commissioning

    Armando, E., Boglietti, A., Bojoi, R., “Electrical drives measurements and testing: Past, Present and Future”, Tutorial at ECCE 2018, Portland, USA

  • Challenge 3: Plug-and-play Control

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    Motor Design Keys

    Develop trustable design tools • Balanced use of magnetic FEA• Saturated steel properties

    Find the reliable minimum width of rotor ribs • Structural FEA• Fatigue test campaigns

    Have a vector controlled test-rig • Flux maps identification for design validation

    MTPA Law and Sensorless Control Keys

    Know the motor parameters • Download from Motor Database• On-site Sensorless self-commissioningPescetto, P., Pellegrino, G. (2018). Automatic Tuning for SensorlessCommissioning of Synchronous Reluctance Machines Augmented With High-Frequency Voltage Injection. IEEE Transactions on Industry Applications, 54(5), 4485-4493.

    a) Explored points in the 𝑖𝑖𝑑𝑑 , 𝑖𝑖𝑞𝑞 plane;b) Obtained current vs flux curves (fit)

  • SyR-e: Synchronous Reluctance Evolution

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    https://sourceforge.net/projects/syr-e/

    https://sourceforge.net/projects/syr-e/

  • What is SyR-e

    SyR-e: Synchronous Reluctance – evolution is a design tool for synchronous e-machines

    Launched on September 2014 in occasion of a Tutorial presented at ECCE - Pittsburg,from a collaboration between Politecnico di Torino and Politecnico di Bari, in Italy

    It runs under Matlab (or GNU Octave), using FEMM as a client for magneto-static FEA

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    SyR-e is downloadable at https://sourceforge.net/projects/syr-e/, under the APACHE License, Version 2.0. FEMM is at www.femm.info

    https://sourceforge.net/projects/syr-e/http://www.apache.org/licenses/http://www.femm.info/

  • GUI

    SyR-e has a Graphical User Interface (GUI) built in Matlab, for ease of data/command input

    Design examples are provided:◦ mot_01.fem, mot_01.mat

    (default initial design)◦ RAWP.fem, RAWP.mat

    (demo)

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  • What SyR-e can do

    The key feature of SyR-e is the capability of parametric FEA modelling and fast simulation

    Moreover, SyR-e includes:◦ Design Equations (x,b plane approach) FEAfix: fixing the equations with few selected FEA runs◦ Optimization of selected design goals using MODE◦ Simplified copper temperature and centrifugal stress models◦ Scripts for advanced manipulation of FEA output (flux maps, effy maps)◦ Exporting capability to other CAD environments (Autocad, Infolytica, MotorCAD)

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    Save Machine Post Processing\Start

  • Machine Types

    Synchronous Reluctance and PM-assisted Synchronous Reluctance machines:◦ circular barriers◦ angled barriers (called SEG)◦ fluid barriers

    Interior PM rotors (V-type IPM), Surface-mounted PM machines (SPM)

    Distributed and concentrated winding stator configurations, multi-three-phase

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    Circular barriers SEG barriers Surface-mounted PMSM Concentrated Windings

  • syrmDesign(x,b): Design Equations

    Torque and power-factor contours are evaluated via design equations as a function of the two key parameters:◦ 𝑥𝑥 (rotor/stator split)◦ 𝑏𝑏 (iron/copper split)

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  • Example of Results

    Any point of the plane corresponds to one machine design: torque and PF have different trends

    Left to right (𝑥𝑥 up):◦ rotor gets bigger, slots get smaller

    Up to down (𝑏𝑏 down):◦ Iron paths width decreases

    All the designs have the same peak flux density(stator back iron and rotor flux carriers)

    Stator teeth size can be calibrated separately via the dedicated parameter 𝑘𝑘𝑡𝑡

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    x = 0.55, b = 0.55 x = 0.68, b = 0.55

    x = 0.68, b = 0.42

  • FEAfix: FEA-augmented Design Equations

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    Ferrari, S., & Pellegrino, G. (2018). FEA-Augmented Design Equations for Synchronous Reluctance Machines. In 2018 IEEE Energy Conversion Congress and Exposition (ECCE) (pp. 5395-5402). IEEE.

    a) Torque contours; b) Power Factor Contours

    Main design inputs + costraints

    Torque(x,b) and PF(x,b)

    Selected design

    x,b = 0.68, 0.55

    FEAfix1

    1 FEMM run

    Design equations

  • Flux Barriers Shift

    Recently added feature for building motors with asymmetric poles, and selectively eliminating torque ripple harmonics

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    Ferrari, S., Pellegrino, G., Davoli, M., Bianchini, C. (2018). Reduction of Torque Ripple in Synchronous Reluctance Machines through Flux Barrier Shift. In 2018 XIII International Conference on Electrical Machines (ICEM) (pp. 2290-2296). IEEE.

  • Design Optimization

    The Optimization tab commands MODE (Multi-Objective Differential Evolution) optimization

    Key input fields:◦ Population size and # of generations◦ Inputs are selectable◦ Goals are selectable

    Fast FEA evaluation:◦ 5 rotor positions per candidate,

    random current phase angle during optimization

    ◦ Accurate re-evaluation of the Pareto-optimal designs (30 rotor positions)

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    Cupertino, F., Pellegrino, G., & Gerada, C. (2014). Design of synchronous reluctance motors with multiobjective optimization algorithms. IEEE Transactions on Industry Applications, 50(6), 3617-3627.

  • Copper Temperature Estimate

    The inputs are:◦ Copper loss◦ Target copper temperature

    SyR-e evaluates:◦ Estimated copper temperature◦ Phase current i0 = 1 p.u. and

    resistance (given the number of turns)

    A thermal network estimates the copper temperature given the housing temperature

    Target and estimated temperaturemust be equal

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  • Structural co-design

    The overspeed input field determines the size of the additional radial ribs included for rotor integrity

    This under the assumption that each rib supports all the centrifugal load downstream of the respective layer, and imposing a stress limit equal to the yield strength of the selected silicon steel (e.g. 285 MPa for M600-50A)

    This feature is on-line during design optimization

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  • Automatic or User-defined Winding

    KOIL designs the winding distribution into slots automatically, given the slot/pole/phase number

    Example: p = 3 (pole pairs), q = 2 (slots/pole/phase)

    Takes advantage of odd-periodic symmetry conditions = one rotor pole and 6 stator slots

    Optionally, bigger portions of the machine can be modelled, for example for modifying the winding set manually (e.g. all 36 slots)

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    6 slots 36 slots

    The user can edit the winding scheme

  • FEA Evaluated Flux Maps

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    In a similar manner, output maps are produced:◦ dq flux maps◦ Torque and torque ripple maps

    d axis flux linkage q axis flux linkage

    Torque Pk-pk Torque ripple

    Phase angle = 1000 is an internal code to launch the flux map feature

  • Magnetic Curves Manipulation (syreManipulateMM)

    Out of the control GUI, additional scripts are available for flux maps manipulation:◦ Torque and torque factor [Nm/A] vs current◦ MTPA and MTPV◦ Torque and power vs speed profiles

    60ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Id, Iq control LUTs

    [Nm] vs [A]

  • Conclusion

    The literature on SyR motors and drives is rich and well established: key concepts were known as early as in the early 2000s. This technology has advantages and disadvantages, expectedly

    However, it is consistently gaining momentum as Super Premium efficiency (IE4) solution for variable speed drives. There is potential also as servomotor and direct-on-line, constant speed applications.

    Most of all, what is missing is engineering and standardization

    A wider diffusion will be possible if the tight connection between motor design and (sensorless) control design aspects will be better formalized and standardized

    Key points are machine testing standards, including test bed and self-commissioning procedures

    SyR-e is online, to contribute to this process

    61ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • Thank you!QUESTIONS, PLEASE

    gianmar io.pel legr ino@pol i to . i t

    ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino 62

  • References (1/3)

    1) Kostko, J.K., "Polyphase reaction synchronous motors,“ American Institute of Electrical Engineers, Journal of the, 19232) Honsinger, V.B., “Synchronous reluctance motor”, US3652885, 19723) Honsinger, V. B., "Inherently Stable Reluctance Motors Having Improved Performance," in IEEE Transactions on Power Apparatus and Systems,

    vol. PAS-91, no. 4, pp. 1544-1554, July 19724) Kolehmainen, J. (2010). Synchronous reluctance motor with form blocked rotor. IEEE Transactions on Energy Conversion5) Vagati, A. (1998) "Synchronous reluctance electrical motor having a low torque-ripple design." U.S. Patent No. 5,818,1406) Lipo, T. A. "Synchronous reluctance machines - a viable alternative for ac drives?“ Electric Machines and Power Systems 19.6 (1991): 659-6717) Xu, L., Xu, X., Lipo, T. A., Novotny, D. W. (1991). “Vector control of a synchronous reluctance motor including saturation and iron loss”, IEEE

    Transactions on Industry Applications, 27(5), 977-985.8) Vagati, A., Franceschini, G., Marongiu, I., & Troglia, G. P. (1992). “Design criteria of high-performance synchronous reluctance motors”,

    In Conference Record of the 1992 IEEE Industry Applications Society Annual Meeting (pp. 66-73). IEEE.9) Staton, D. A., Miller, T. J. E., & Wood, S. E. (1993, July). “Maximising the saliency ratio of the synchronous reluctance motor”, In IEE Proceedings B

    (Electric Power Applications) (Vol. 140, No. 4, pp. 249-259). IET Digital Library.10) Betz, R. E., Lagerquist, R., Jovanovic, M., Miller, T. J., & Middleton, R. H. (1993). “Control of synchronous reluctance machines”, IEEE Transactions

    on Industry Applications, 29(6), 1110-1122.11) Matsuo, T., & Lipo, T. A. (1994). “Rotor design optimization of synchronous reluctance machine”, IEEE Transactions on Energy Conversion, 9(2),

    359-365.

    63ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • References (2/3)

    12) Lagerquist, R., Boldea, I., & Miller, T. J. (1994). “Sensorless-control of the synchronous reluctance motor”, IEEE Transactions on Industry Applications, 30(3), 673-682.

    13) Boldea, I., Fu, Z. X., & Nasar, S. A. (1994). “Performance evaluation of axially-laminated anisotropic (ALA) rotor reluctance synchronous motors”, IEEE transactions on industry applications, 30(4), 977-985. Kamper, M. J., Van der Merwe, F. S., & Williamson, S. (1996), “Direct finite element design optimisation of the cageless reluctance synchronous machine”, IEEE Transactions on Energy Conversion, 11(3), 547-555.

    14) Kamper, M. J., Van der Merwe, F. S., & Williamson, S. (1996), “Direct finite element design optimisation of the cageless reluctance synchronous machine”, IEEE Transactions on Energy Conversion, 11(3), 547-555.

    15) Vagati, A., Pastorelli, M., Francheschini, G., & Petrache, S. C. (1998), “Design of low-torque-ripple synchronous reluctance motors”, IEEE Transactions on Industry Applications, 34(4), 758-765.

    16) Ha, J. I., Kang, S. J., & Sul, S. K. (1999). Position-controlled synchronous reluctance motor without rotational transducer. IEEE transactions on Industry Applications, 35(6), 1393-1398.

    17) Consoli, A., Russo, F., Scarcella, G., & Testa, A. (1999). Low-and zero-speed sensorless control of synchronous reluctance motors. IEEE Transactions on Industry Applications, 35(5), 1050-1057.

    18) Vagati, A., Pastorelli, M., Scapino, F., & Franceschini, G. (2000). Impact of cross saturation in synchronous reluctance motors of the transverse-laminated type. IEEE Transactions on Industry Applications, 36(4), 1039-1046. Pellegrino, G., Armando, E., Guglielmi, P., & Vagati, A. (2009), “A 250kW transverse-laminated Synchronous Reluctance motor”, In 2009 13th European Conference on Power Electronics and Applications. IEEE.

    64ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

  • References (3/3)

    19) Pellegrino, G., Cupertino, F., & Gerada, C. (2014), “Automatic design of synchronous reluctance motors focusing on barrier shape optimization”, IEEE Transactions on Industry Applications, 51(2), 1465-1474.

    20) Pellegrino, G., Cupertino, F., & Gerada, C. (2014), “Automatic design of synchronous reluctance motors focusing on barrier shape optimization”, IEEE Transactions on Industry Applications, 51(2), 1465-1474.

    21) Ferrari, S.; Pellegrino, G.; Bonisoli, Elvio (2016) “Magnetic and structural co-design of synchronous reluctance electric machines in an open-source framework”, International Journal Of Mechanics And Control, Levrotto&Bella, pp. 8, 2016, Vol. 17, ISSN: 1590-8844

    22) Boazzo, B., Vagati, A., Pellegrino, G., Armando, E., Guglielmi, P. (2014). Multipolar ferrite-assisted synchronous reluctance machines: A general design approach. IEEE Transactions on Industrial Electronics, 62(2), 832-845.

    23) Armando, E., Boglietti, A., Bojoi, R., “Electrical drives measurements and testing: Past, Present and Future”, Tutorial at ECCE 2018, Portland, USA24) Pescetto, P., Pellegrino, G. (2018). Automatic Tuning for Sensorless Commissioning of Synchronous Reluctance Machines Augmented With High-

    Frequency Voltage Injection. IEEE Transactions on Industry Applications, 54(5), 4485-4493.25) Ferrari, S., Pellegrino, G. (2018). FEA-Augmented Design Equations for Synchronous Reluctance Machines. In 2018 IEEE Energy Conversion

    Congress and Exposition (ECCE) (pp. 5395-5402). IEEE.26) Cupertino, F., Pellegrino, G., Gerada, C. (2014). Design of synchronous reluctance motors with multiobjective optimization algorithms. IEEE

    Transactions on Industry Applications, 50(6), 3617-362727) Ferrari, S., Pellegrino, G., Davoli, M., Bianchini, C. (2018). Reduction of Torque Ripple in Synchronous Reluctance Machines through Flux Barrier

    Shift. In 2018 XIII International Conference on Electrical Machines (ICEM) (pp. 2290-2296). IEEE.

    65ACEMP OPTIM 2019, Istanbul - © 2019 Gianmario Pellegrino

    Synchronous Reluctance Motor Drives:�Still a Niche Technology?OutlinePolitecnico di TorinoPEIC: The Power Electronics Innovation CenterPEIC: The Power Electronics Innovation CenterDiapositiva numero 6Background: Synchronous Reluctance TorqueAdvantages of SyR MotorsAdvantages of SyR MotorsAdvantages of SyR MotorsControl: Mandatory AspectsWell Known DisadvantagesWell Known DisadvantagesDiapositiva numero 141923: The Idea of Flux Barriers1972: The Synduction Motor1990s: Variable Speed DrivesTechnology Development TimelineThe Roaring NinetiesMilestones: 1991Milestones: 1992Milestones: 1993Milestones: 1994Milestones:1996Milestones: 1998Milestones: 1999Milestones: 2000Bottom LineBottom LineImprove the EfficiencyReduce the Rare-Earth Magnet ContentConsequent Boom of the SyR Motor TechnologyMain Players on the Market (2019)Diapositiva numero 34Review of Known DisadvantagesAbout the Low Power FactorTorque RippleMotor Identification and ControlHigh-speed ScalabilityLow-speed ApplicationsDiapositiva numero 41Today’s ChallengesChallenge 1: Motor Design ProceduresChallenge 2: Standardize Motor IdentificationChallenge 3: Plug-and-play ControlDiapositiva numero 46What is SyR-eGUIWhat SyR-e can doMachine TypessyrmDesign(x,b): Design EquationsExample of ResultsFEAfix: FEA-augmented Design EquationsFlux Barriers ShiftDesign OptimizationCopper Temperature EstimateStructural co-designAutomatic or User-defined WindingFEA Evaluated Flux MapsMagnetic Curves Manipulation (syreManipulateMM)ConclusionThank you!References (1/3)References (2/3)References (3/3)