3/27/2013
Recent Advances in
Electric Machine Design
and Operation
By Jim Hendershot, IEEE Fellow
IEEE Miami Section
Energy Systems Research Laboratory
Florida International University
March 22, 2013
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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
CONCENTRATION !
` AUDIENCE
2 – MAKE IT LONG ENOUGH TO COVER ALL
THE ESSENTIALS !
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Origins of electric machines
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
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
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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
permanent-magnet
and
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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)
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Two most popular motors types from the 20th Century
A.C. Motor Torque/Speed Curve
DC motor speed is controlled by
DC supply voltage
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AC induction motor speed
controlled by frequency
(according to pole number)
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Two pole wound field
Commutated motor
(AC or DC powered)
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Examples & details of Modern DC motors
MAXON Slotless DC GEMOARTOR
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Cross section of modern AC induction motor
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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
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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
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AC Induction Torque vs. Speed Curve
Driven with a Field Controlled Inverter
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Line start grid powered AC single or three phase rotors
By Andrew Frazer, Murdoch University Using Infolytica Magnet
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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
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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
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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.
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2010 Toyota Prius Motor & Generator Parts
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IPM rotor stampings used in TOYOTA hybrid vehicles
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NOVA-TORQUE Axial-Cone-Flux (Inside Cone)
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NOVA-TORQUE Axial-Cone-Flux (Outside Cone)
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QM POWER Hybrid PM-SR Motor
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Torus Axial Flux PM Synchronous Motors
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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
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Switched Reluctance Starter/Generator
For Gas Turbine Heavy Fuel Engine
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GE & Sundstrand
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Switched Reluctance motors with no magnets
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2 Phase SR motor replaces AD-DC brush type motor
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ABB Reluctance Synchronous motors & Inverters
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RSM (Reluctance Synchronous)
In order for RSM machines to
be technically competitive the
ratio of inductance
(Ld/Lq) must be greater
than 5 and closer to 9.
ABB
ABB
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Remy Corp.
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Battery
brushless power
tooltools
motors
Fromoperated
Battery powered
portable
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Some important applications using high
performance AC induction motors and
drives
Powered by:
Field Controlled Inverters
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AC, PM & SR LINEAR MOTORS
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Hi-Speed Mag-Lev Train
Largest Atom Smasher in the World
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New white goods appliance
in every US home by
middle of 21st Century
SONY Humanoid Robot
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(Remember you heard this first from
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Tesla sports car and 3 – phase AC Traction Motor
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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
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Wheel Traction Motors
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Rotor & Stator by REMY
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2010 PRIUS
ELECTRIC
DRIVE
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Siemens four pole AC tractions mounted on a transmission
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Caterpiller
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Caterpiller
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CATERPILLER PM GENERATOR
AC TRACTION MOTOR & INVERTER
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US NAVY & American Superconductor
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Rail Traction AC Induction Motor
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SIEMENS
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WIND TURBINE GENERATORS
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More Generators for large wind turbines
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WWOW!! 13 M dia. & almost 500
KG of rare earth magnets!!
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AC Induction or PM
synchronous coaster launchers
SLM Synchronous twin PM rails
attached to underside
of car & (32) 3-phase stators
attached to track.
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Flywheel Batteries using Halbach PM electric generator
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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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(3) Concentric
coil stacks
Bitter plates of thin copper sheets,
insulated and spiral stacked to
form a very flat wire coil to
facilitate liquid cooling.
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Reference books on electric motor theory and design:
ISB 0-19-859369-6
ISBN 0-9745470-2-6
ISBN 0-19-859389-9
ISBN 978-0-470-69516-6
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(AVAILABLE ON AMZON)
ISBN 978-0-9840687-0-8
ISBN 978-1-1182-1529-6
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This is only the beginning of the electric motor and drive revolution !!
We need to motivate and educate at least 250,000 Electric Engineers
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.
Thank you very much for attending,
Jim Hendershot
3-21-2013
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