Design Method of High Efficiency Lightweight Permanent Magnet Synchronous Motor for Electric Propulsion

doi:10.3901/JME.2023.08.181

Abstract

Abstract: Stratospheric aircraft can only rely on batteries to obtain energy at night, so its propulsion motor is required to have the characteristics of high efficiency and high torque density. To meet this requirement, a design method of high efficiency lightweight permanent magnet synchronous motor for electric propulsion is proposed. According to the propeller load of the motor, the strength and stiffness analytical model of lightweight structure for external rotor surface-mounted permanent magnet synchronous motor（ERSPMSM） is established. Based on the equivalent magnetic network, the electromagnetic model of ERSPMSM considering the influence of high-frequency current harmonics is established, and combined with the analytical model of lightweight structure, the electromagnetic-structural analytical model of ERSPMSM is obtained. Based on the model, the multi-objective optimization of motor efficiency and overall mass is carried out and the differential evolution algorithm is used to obtain the Pareto front. The correlations between design parameters and optimization objectives are analyzed. A solution in the Pareto front is selected as the motor scheme,and the validity of the proposed design method is verified by finite element analysis and prototype experiment. The designed 10kW prototype has a mass of 25.7 kg, a torque density of 10N·m/kg and a rated efficiency of 94%.

Key words: external rotor surface-mounted permanent magnet synchronous motor, lightweight structure, efficiency, overall mass, multi-objective optimization, differential evolution algorithm

CLC Number:

TM351

ZHANG Xin-tong, ZHANG Cheng-ming, LI Li-yi, FU Peng-rui. Design Method of High Efficiency Lightweight Permanent Magnet Synchronous Motor for Electric Propulsion[J]. Journal of Mechanical Engineering, 2023, 59(8): 181-195.

References

[1] RAGOT P,MARKOVIC M,PERRIARD Y. Optimization of electric motor for a solar airplane application[J]. IEEE Transactions on Industry Applications,2006,42(4):1053-1061.
[2] MECROW B C,BENNETT J W,JACK A G,et al. Drive topologies for solar-powered aircraft[J]. IEEE Transactions on Industrial Electronics,2010,57(1):457-464.
[3] WIDMER J D,SPARGO C M,ATKINSON G J,et al. Solar plane propulsion motors with precompressed aluminum stator windings[J]. IEEE Transactions on Energy Conversion,2014,29(3):681-688.
[4] BERNATT J,PISTELOK P,KRÓL E. Investigations on efficiency improvements of electrical propulsion system for a light airplane[C]//International Aegean Conference on Electrical Machines and Power Electronics and Electromotion,Joint Conference,Istanbul,2011,421-424.
[5] GUGLIELMI P,PELLEGRINO G,GRIVA G,et al. A direct-drive solution for Hydrogen supplied all-electric airplane[C]//2009 35th Annual Conference of IEEE Industrial Electronics,Porto,2009,2525-2530.
[6] YOON A,YI X,MARTIN J,et al. A high-speed,high-frequency,air-core PM machine for aircraft application[C]//2016 IEEE Power and Energy Conference at Illinois (PECI),Urbana,IL,2016,1-4.
[7] 王森. 无人机主推进高力能密度永磁电动机关键技术研究[D]. 沈阳:沈阳工业大学,2014. WANG Sen. The key technology research on main propulsion high energy density permanent magnet motor of unmanned aerial vehicle[D]. Shenyang:Shenyang University of Technology,2014.
[8] ZHANG Xintong,LI Liyi,ZHANG Chengming. Mass optimization method of a surface-mounted permanent magnet synchronous motor based on a lightweight structure[J]. IEEE Access,2020,8:40431-40444.
[9] E-Power Hobby. EP-MAD M40 electric paramotor[R]. FLORIDA:E-Power Hobby,2017.
[10] SIEMENS. Electric flight[R]. Berlin:SIEMENS,2019.
[11] MUELLER M A,MCDONALD A S,MACPHERSON D E. Structural analysis of low-speed axial-flux permanent-magnet machines[J]. IEE Proceedings-Electric Power Applications,2005,152(6):1417-1426.
[12] CHEN Yuanshan. Mechanical design of high frequency,high power density electric machine[D]. Urbana- Champaign:University of Illinois at Urbana-Champaign,2016.
[13] 张昌锦,陈志辉,梅庆枭,等. 横向磁通永磁同步电机非线性动态等效磁网络模型分析[J]. 中国电机工程学报,2019,39(1):307-314,345. ZHANG Changjin,CHEN Zhihui,MEI Qingxiao,et al. Nonlinear dynamic equivalent magnetic network model analysis of transverse flux permanent magnet synchronous motor[J]. Proceedings of the CSEE,2019,39(1):307-314,345.
[14] HSIEH M F,HSU Y C. A generalized magnetic circuit modeling approach for design of surface permanent-magnet machines[J]. IEEE Transactions on Industrial Electronics,2011,59(2):779-792.
[15] 朱龙飞,朱建国,佟文明,等. PWM逆变器供电引起的轴向磁通非晶电机谐波损耗的解析计算[J]. 电工技术学报,2017,32(16):115-123. ZHU Longfei,ZHU Jianguo,TONG Wenmin,et al. Analytical calculation of harmonic losses of an axial flux amorphous motor caused by PWM inverter supplying[J]. Transactions of CHINA electrotechnical society,2017,32(16):115-123.
[16] 赵志刚,赵瑞,张学增. 考虑PWM激励特征及松弛过程影响的铁磁材料损耗分离模型研究[J/OL]. 中国电机工程学报,1-10[2021-07-17].https://doi.org/10.13334/j.0258-8013.pcsee.201394. ZHAO Zhigang,ZHAO Rui,ZHANG Xuezeng. Loss separation model of ferromagnetic materials under PWM excitation characteristics and magnetic relaxation processes[J/OL]. Proceedings of the CSEE,1-10[2021-07-17].https://doi.org/10.13334/j.0258-8013.pcsee.201394.
[17] ISHAK D,ZHU Z Q,HOWE D. Eddy-current loss in the rotor magnets of permanent-magnet brushless machines having a fractional number of slots per pole[J]. IEEE Transactions on Magnetics,2005,41(9):2462-2469.
[18] MIN S G,SARLIOGLU B. 3-D Performance analysis and multiobjective optimization of coreless-type PM linear synchronous motors[J]. IEEE Transactions on Industrial Electronics,2018,65(2):1855-1864.
[19] FATEMI A,IONEL D M,POPESCU M,et al. Design optimization of a high torque density spoke-type PM motor for a formula E race drive cycle[J]. IEEE Transactions on Industry Applications,2018,54(5):4343-4354.
[20] MIN S G,BRAMERDORFER G,SARLIOGLU B. Analytical modeling and optimization for electromagnetic performances of fractional-slot PM brushless machines[J]. IEEE Transactions on Industrial Electronics,2018,65(5):4017-4027.
[21] DUAN Haibin,GAN Lu. Orthogonal multiobjective chemical reaction optimization approach for the brushless DC motor design[J]. IEEE Transactions on Magnetics,2015,51(1):1-7.
[22] 徐磊,朱孝勇,张超,等. 磁极径向组合轴向磁场永磁电机转矩品质分析与优化设计[J]. 中国电机工程学报,2021,41(6):1971-1983. XU Lei,ZHU Xiaoyong,ZHANG Chao,et al. Torque quality analysis and optimization design of axial field machine with radial combined permanent magnet poles[J]. Proceedings of the CSEE,2021,41(6):1971-1983.
[23] 曹永娟,冯亮亮,毛瑞,等. 轴向磁场永磁记忆电机多目标分层优化设计[J]. 中国电机工程学报,2021,41(6):1983-1992. CAO Yongjuan,FENG Liangliang,MAO Rui,et al. Multi-objective stratified optimization design of axial-flux permanent magnet memory motor[J]. Proceedings of the CSEE,2021,41(6):1983-1992.
[24] ZHANG Peng,IONEL D M,DEMERDASH N A O. Morphing parametric modeling and design optimization of spoke and V-type permanent magnet machines by combined design of experiments and differential evolution algorithms[C]//2013 IEEE Energy Conversion Congress and Exposition,2013,5056-5063.
[25] ZHU Z Q,HOWE D,BOLTE E,et al. Instantaneous magnetic field distribution in brushless permanent magnet DC motors. I. Open-circuit field[J]. IEEE Transactions on Magnetics,1993,29(1):124-135.
[26] LIANG Wenyi,WANG Jianfeng,LUK P C,et al. Analytical modeling of current harmonic components in PMSM drive with voltage-source inverter by SVPWM technique[J]. IEEE Transactions on Energy Conversion,2014,29(3):673-680.
[27] 于吉坤,李立毅,杜鹏程,等. 基于谐波注入PWM的高速永磁同步电机纹波电流抑制方法[J]. 电气工程学报,2017,12(9):1-10. YU Jikun,LI Liyi,DU Pengcheng,et al. High speed permanent magnet synchronous motors ripple current suppression based on harmonic injection PWM[J]. Journal of Electrical Engineering,2017,12(9):1-10.
[28] 张新彤,张成明,李立毅,等. 基于绕组温度约束的永磁同步电机裂比优化方法(英文)[J]. 电工技术学报,2019,34(9):1886-1899. ZHANG Xintong,ZHANG Chengming,LI Liyi,et al. Split ratio optimization for permanent magnet synchronous machines considering winding temperature limitation[J]. Transactions of China Electrotechnical Society,2019,34(9):1886-1899.
[29] FATEMI A,IONEL D M,POPESCU M,et al. Design optimization of a high torque density spoke-type PM motor for a formula E race drive cycle[J]. IEEE Transactions on Industry Applications,2018,54(5):4343-4354.
[30] CHEN Junquan,WANG Dong,CHENG Siwei,et al. Influence of manufacture process on magnetic property of FeCoV alloy[C]//2014 17th International Conference on Electrical Machines and Systems (ICEMS),2014:3054-3059.
[31] 刘春强,骆光照,涂文聪. 航空机电作动永磁同步电机自抗扰控制研究综述[J]. 电气工程学报,2021,16(4):12-24. LIU Chunqiang, LUO Guangzhao, TU Wencong. Survey on active disturbance rejection control of permanent magnet synchronous motor for aviation electro- mechanical actuator[J]. Journal of Electrical Engineering, 2021,16(4):12-24.
[32] 张江鹏. 高空飞行器用高效率高功率密度永磁同步电机研究[D]. 哈尔滨:哈尔滨工业大学,2018. ZHANG Jiangpeng. Research on high efficiency and high power density permanent magnet synchronous motor for high altitude aircraft[D]. Harbin:Harbin Institute of Technology,2018.
[33] BOLAM R C,VAGAPOV Y,ANUCHIN A. A review of electrical motor topologies for aircraft propulsion[C]//2020 55th International Universities Power Engineering Conference (UPEC),2020:1-6.