The IEEE 1812 Trial-Use Guide for
Testing PM Machines –
Virtual Testing Developments
Dan M. Ionel, Ph.D., IEEE Fellow
dan.ionel@uky.edu
CWIEME Berlin, May 10, 2016
SPARK Introduction | February, 2016 | 1
Dr. Dan M. Ionel
Dan M. Ionel is Professor of Electrical Engineering and L. Stanley
Pigman Chair in Power at University of Kentucky in Lexington, KY.
Previously, he held dual appointments in industry, as Chief Engineer
with Regal Beloit Corp and before as Chief Scientist with Vestas Wind
Turbines, and in academia, as Visiting and Research Professor with
University of Wisconsin and Marquette University in Milwaukee, WI.
Dr. Ionel has more than 25 years of engineering experience and has
designed electric machines and drives with power ratings between
0.002 and 10,000hp. He holds more than 30 patents and has
published more than 100 journal and conference papers, including
two winners of IEEE best paper awards. Dr. Ionel is an IEEE Fellow,
the Chair of the IEEE Power and Energy Society Electric Motor
Subcommittee, and the General Chair of the 2017 anniversary edition
of the IEEE IEMDC Conference.
dan.ionel@uky.edu
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SPARK and PEIK at University of Kentucky
• UK enjoys a longstanding tradition in electric machines and drives
• Early developments on linear and PM motors, and vector control
• Many learned machines using the Nasar and Boldea classic books
• PEIK - Power and Energy Institute of Kentucky, launched with large DOE grant in 2010
• Core faculty in electric power engineering and many others in related fields
• Endowment established and inaugural L. Stanley Pigman Chair started in 2015
• On-going research on electric machines and drives, power electronics and systems,
renewable and alternative energy technologies
• SPARK and other laboratories
• Motor Design Ltd. and ANSYS Inc. strategic partnerships.
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Outline
• IEEE 1812 “IEEE Trial-Use Guide for Testing Permanent Magnet
Machines”
• Status review, based on WG reports and published Guide
• WG Past Chair, Dr. H. Karmaker; MSC Chair, Dr. Dan M. Ionel
• Special thanks to Dr. Karmaker for his contributions to the first section of
this presentation
• Developments for equivalent circuit parameters and losses
• PE converter controls
• DQ inductances
• Separation of losses
• Related developments - “Virtual testing”
• High fidelity models and reduced order models
• Hardware in the Loop (HIL) and Real Time Digital Simulation (RTDS).
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Outline
• IEEE 1812 “IEEE Trial-Use Guide for Testing Permanent Magnet
Machines”
• Status review, based on WG reports and published Guide
• WG Past Chair, Dr. H. Karmaker; MSC Chair, Dr. Dan M. Ionel
• Special thanks to Dr. Karmaker for his contributions to the first section of
this presentation
• Developments for equivalent circuit parameters and losses
• PE converter controls
• DQ inductances
• Separation of losses
• Related developments - “Virtual testing”
• High fidelity models and reduced order models
• Hardware in the Loop (HIL) and Real Time Digital Simulation (RTDS).
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IEEE 1812 Purpose
• There are many differences in testing the performance
characteristics of PM and non-PM machines
• In PM machines, excitation cannot be turned off and controlled
similar to electrically excited machines
• There is no known guide or standard for testing PM machines.
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IEEE 1812 Scope (1/2)
The scope of the Guide as approved by the IEEE
Standards Board is as follows:
• The guide contains instructions for conducting tests to determine
the performance characteristics and parameters of permanent
magnet (PM) machines
• The tests may be applied to both motors and generators
• This guide covers only general test methods characteristic to PM
machines
• The test methods should be applicable to the PM machines of
different sizes and configurations
• … continued ...
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IEEE 1812 Scope (2/2)
The scope of the Guide as approved by the IEEE
Standards Board is as follows:
• … continued …
• The guide shall not cover all possible tests or tests of a research
nature
• The tests covered by other applicable standards are not covered in
this guide
• This “trial-use” guide shall not be interpreted as requiring any
specific test in a given transaction or implying any guarantee as to
the specific performance indices or operating conditions.
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Working Group (WG) for IEEE 1812
• A new IEEE Power and Energy Society (PES) WG was formed by the
Motor Subcommittee (MSC) of the Electric Machinery Technical
Committee (EMC) in July 2009
• Original WG Chair, now WG Past Chair, Dr. Haran Karmaker
• Current MSC Chair, Dr. Dan M. Ionel
• The proposed project was approved for a trial-use guide in
December 2009 by IEEE Standards Board with the expiration date
of December 31, 2013
• The IEEE Industry Applications Society started to co-sponsors the
project in May 2011
• The IEEE 1812 Trial-Use Guide was approved in Dec 2014
• The final WG comprised 23 members, 16 being from industry.
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IEEE Working Group
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IEEE 1812 Overview
• WG 1812 followed the structure of the most current edition of
IEEE 115-2009 “IEEE Guide for Test Procedures for Synchronous
Machines: Part I – Acceptance and Performance Testing ; Part II –
Test Procedures and Parameter Determination for Dynamic
Analysis” to prepare the new draft for the guide
• Following the IEEE 115 structure, IEEE 1812 was drafted for
•Part I – Test Procedures
•Part II – Machine Characteristics
• According to the IEEE style guide, the first two clauses are:
•Clause 1 – Overview
•Clause 2 – Normative References
• The guide consists of a total of six (6) clauses.
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IEEE 1812 Overview (Contd.)
• Clause 3 - Condition and integrity tests, i.e. resistance
measurement, phase sequence, insulation resistance, dielectric
and partial discharge, polarity for magnets, shaft and bearing
currents, over-speed tests, resistance to demagnetization, acoustic
noise, vibration
• Clause 4 - Steady-state tests, i.e. open-circuit (back emf, losses,
and cogging torque), short-circuit, load, thermal performance
• Clause 5 - Transient tests, i.e. retardation (or coast-down), sudden
short-circuit (three phase and two phase)
• Clause 6 - Machine operating characteristics, i.e. stator voltage
waveform, losses and efficiency, thermal capability, torque ripple.
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Example – Dynamic Cogging Torque Measurement
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Example – Static Cogging Torque Measurement
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Example – Torque Ripple Measurement at Load
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Example – Typical Torque Ripple Waveform
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Example – Short Circuit Testing
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Example – Back-to-back Load Test
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Example – Thermal Characteristics of PM Materials
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Example – Open Circuit Core Loss Characteristic
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Example – Friction & Windage Loss Characteristic
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Example - Loss Separation
Friction and windage loss
• The PM rotor is replaced with a non-magnetized equivalent rotor (rotor with
PMs yet to be magnetized
• This test relies on the knowledge of the combined moment of inertia of the
test machine and the drive motor
• The friction and windage loss is determined as a function of speed, if inertia
and rate of change of speed are known.
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Example – Performance Curves of PM Generator
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IEEE 1812 Current Status
• The standard has been published as a trial-use guide on December
10, 2014 valid for 2 years
• Without a PAR to continue its revision for a full-use guide, the
standard will expire in 2016
• A new initiative to form a working group is now under way with
support from the Electric Machines Committees within IEEE Power
and Energy and Industry Applications Societies
• Contact
Dan M. Ionel, PhD, FIEEE, Professor and L. Stanley Pigman Chair in Power
Director, SPARK Laboratory – University of Kentucky
Chair, IEEE Power and Energy Society – Electric Motor Subcommittee
dan.Ionel@uky.edu; dan.ionel@ieee.org
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IEEE 1812 Simulation Implementation - Inductance
Isc=
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𝑉𝑜𝑐
3𝑋𝑠
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Motor-CAD Example Study for Inductance Calculation
Nissan Leaf IPM
Voc
215.15 V
Xs
0.31 Ohm
f
200 Hz
LS
0.25 mH
• Short circuit test values are tabulated
• The test could be used to determine a
value of Ld
• The field distribution under motor normal
operation is different to the one at shortcircuit.
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Example IEEE 1812 Simulation Implementation – Heath Run
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Coupled Electromagnetic and Thermal Analysis – Motor-CAD
Electromagnetics
• Ultra-fast 2D FEA in the abc reference
frame
• Seconds on a state of the art PC
workstation
• Analytical calculations for end effects
Thermal and air-flow
• Equivalent 3D networks
• Calculation time one order of magnitude shorter
than for electromagnetics
Coupling methods
• “Serial”, typ. 6 iterations for each
of Emag and thermal
• “Weak”, typ. only 2 iterations
for Emag and 6-10 for thermal
“Cutting edge”
• Design for complex duty cycles
• Large-scale optimization studies.
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Outline
• IEEE 1812 “IEEE Trial-Use Guide for Testing Permanent Magnet
Machines”
• Status review, based on WG reports and published Guide
• WG Past Chair, Dr. H. Karmaker; MSC Chair, Dr. Dan M. Ionel
• Special thanks to Dr. Karmaker for his contributions to the first section of
this presentation
• Developments for equivalent circuit parameters and losses
• PE converter controls
• DQ inductances
• Separation of losses
• Related developments - “Virtual testing”
• High fidelity models and reduced order models
• Hardware in the Loop (HIL) and Real Time Digital Simulation (RTDS).
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Example Parameters for Power Electronic Drives (VFD)
Parameters required
Motor rated capacity
Motor rated current
No. of poles
Stator resistance
d-axis inductance
q-axis inductance
Back emf constant
Mandatory
parameters
Optional parameters
Rated motor voltage
Motor pole pair number
Rated motor current
Torque constant
Rated motor power
Rated magnetization/short circuit current
Rated motor speed
Max. speed
Rated motor
frequency
Pole position information
Optimum load angle
Moment of inertia
Resistance
Stator inductance
D-axis inductance
Reluctance torque constant
Source: YASKAWA ELECTRIC TOEP
C710606 47C YASKAWA AC Drive –
V1000 Quick Start Guide
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Source: SIEMENS SINAMIX S120 Function Manual 07/2007
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Developments Considered for Inductance Measurement
• Drafted during the original development of IEEE 1812 for d and q
axes measurement
• Not incorporated in the released version.
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Equivalent Circuits for PM Machines
• Ld and Lq are functions of current components
• Cross coupling between the d and q axes is present, in principle
• Conventional equivalent circuits of PM machines do not include
ωλ q
core losses.
R
Ld
id
Vd
d axis equivalent circuit
iq
ωλ d
R
Lq
Vq
Phasor diagram
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q axis equivalent circuit
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Inductance Measurement at Standstill
• Variable voltage supply and locked rotor at different positions
• Inductance determined as:
𝑃
•𝑅 = 2,𝒁
𝐼
𝑋
• 𝐿𝑙𝑙 =
2𝜋𝑓
=
𝑽
𝑰
, |𝑋| =
|𝑍|2 − |𝑅|2
• Max associated with Lq and min with Ld.
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Alternative Methods for dq Inductance Measurements
• Standstill inductance measurements with sinusoidal or PWM voltages
• Procedure to align using the B and C phases
• Measurements using A phase
Alignment along d axis
Alignment along q axis
• Measurements under actual running conditions
• No load; motor driven at constant speed; Iq = 0; Id is varied; load angle is
considered 0; determine Ld
• Full load; Lq; Id = 0; load angle = power factor angle; determine Lq
Source: H. B. Ertan and İ Şahin, "Evaluation of inductance measurement methods for PM machines," International
Conference on Electrical Machines (ICEM), 2012 XXth, Marseille, 2012, pp. 1672-1678.
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Non-linearity of Flux Linkages and Cross Coupling Effects
Flux linkages for a dq model considering saturation and cross
coupling:
• Ψdd(id) – d-axis flux linkage due to d-axis current
• Ψdq(iq) – d-axis flux linkage due to q-axis current.
Source: D. M. Ionel, M. J. Balchin, J. F. Eastham and E. Demeter, "Finite element analysis of brushless DC motors for flux
weakening operation“, IEEE Transactions on Magnetics, vol. 32, no. 5, pp. 5040-5042, Sep 1996.
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Non-linearity of Flux Linkages and Cross Coupling Effects
• d –axis flux linkage:
• The PM flux:
• Both Ψdd(id) and Ψdq(iq) include contributions from the PM flux, which is
subtracted, yielding two possible models:
Source: D. M. Ionel, J. F. Eastham, E. Demeter, M. J. Balchin, D.Stoia and C. Apetrei, “Different Rotor Configurations for
BLDC Motors Operating in Flux Weakening Mode" in International Conference on Electric Machines, 1996
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Laboratory
Non-linearity of Flux Linkages and Inductances
• Run FEA with Id = 0 and non-zero Iq and calculate the three phase
flux linkages. The PM flux is obtained as:
• Run FEA with both Id and Iq non zero, and three phase flux linkages
are calculated. Ld and Lq are obtained as:
Source: Peng Zang, “A Novel Design Optimization of a Fault-Tolerant AC Permanent Magnet Machine-Drive System”,
PhD Dissertation, Marquette University, 2013.
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Separation of Losses
Residuals
Loss at the
test points
Coefficients
Determination of β provides information about the different loss components of loss.
Source: G. Heins, D. M. Ionel, D. Patterson, S. Stretz and M. Thiele, "Combined Experimental and Numerical Method for Loss
Separation in Permanent-Magnet Brushless Machines," in IEEE Transactions on Industry Applications, vol. 52, no. 2, pp.
1405-1412, March-April 2016.
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Separation of Losses
Philosophy – loss components have different relationships with
current and speed, based on which the separation (segregation) can
be performed.
Source: G. Heins, D. M. Ionel, D. Patterson, S. Stretz and M. Thiele, "Combined Experimental and Numerical Method for
Loss Separation in Permanent-Magnet Brushless Machines," in IEEE Transactions on Industry Applications, vol. 52, no. 2,
pp. 1405-1412, March-April 2016.
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Outline
• IEEE 1812 “IEEE Trial-Use Guide for Testing Permanent Magnet
Machines”
• Status review, based on WG reports and published Guide
• WG Past Chair, Dr. H. Karmaker; MSC Chair, Dr. Dan M. Ionel
• Special thanks to Dr. Karmaker for his contributions to the first section of
this presentation
• Developments for equivalent circuit parameters and losses
• PE converter controls
• DQ inductances
• Separation of losses
• Related developments - “Virtual testing”
• High fidelity models and reduced order models
• Hardware in the Loop (HIL) and Real Time Digital Simulation (RTDS).
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HIL Principles
• Real time machine model (and power electronics) for real time digital
(RTDS) / hardware in the loop (HIL) simulator
• Reduced order machine models minimize the requirements for
computational resources
• The controller physically exists; other combinations are also possible.
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RTDS – Real Time Digital Simulator
• IEC 61850 communication standard for
electrical substation automation systems
• GOOSE (Generic Object Oriented Substation
Event) and SMV (Sampled Measured Values).
Source: RTDS
Technical
Documentation, 2016.
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Example HIL from RTDS
Source: RTDS Technical
Documentation: State of Electric
Machine Models and their
Applications in RTDS Real-Time Digital
Simulator, 2016.
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RTDS Model for PMSM
• Model based on the model for synchronous machine
• Saturation, core loss, harmonics due to back emf are neglected
Source: RTDS technical documentation VSC Permanent Magnet Synchronous Machine (PMSM), 2016
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RTDS Input Parameters for PM Synchronous Machine
Electrical parameters
Mechanical parameters
Source: RTDS technical documentation VSC Permanent Magnet Synchronous Machine (PMSM), 2016.
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Simulink/Matlab Real Time
• Simscape blocks can be employed
• Input parameters for PM machine: Ld, Lq, moment of inertia,
number of poles, voltage, back emf constant, rated current.
M o to r M o d e l
Source: http://www.mathworks.com/products/simulink-real-time/
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High Fidelity Models - ANSYS Time-Decomposition-Method
• Transient
electromagnetic
FEA
• HPC for multiple
problems
• New approach
(TDM) - solve all
time steps for
one problem
simultaneously
• Patent pending
• 10x faster
simulations
reported.
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t0
t1
t2
t3
t4
… tn
Level 1 (MPI)
Distributed
Time Steps
Level 2 (MT)
Multithreading
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Reduced Order Models for HIL Controls
• Systematic FEA to calculate
a look-up table, e.g. phase
flux linkage vs. rotor position
and current
• Inputs
• currents
• rotor position
• Outputs
• flux linkages
• torque
Flux Linkage
[Wb]
𝜃𝑖 [deg]
Current [A]
• Lossless model example.
Source: ANSYS technical documentation
on ECE Model Creation and Applications,
2015.
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Models Including Core (Iron) Losses
Specific core losses components in an IPM over the entire torque speed range;
estimated by FEA
Source: R. Wrobel, P. H. Mellor, M. Popescu and D. A. Staton, "Power Loss Analysis in Thermal Design of PermanentMagnet Machines—A Review," in IEEE Transactions on Industry Applications, vol. 52, no. 2, pp. 1359-1368, MarchApril 2016.
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Laboratory
Permanent Magnet Losses
• PM loss (below base speed) α Iq2 and N2
• Loss due to stator slotting α N2 and loss due to armature reaction α N2 , Iq2
•
• Two FEA solutions used to determine d and α.
Source: X. Wu, R. Wrobel, P. H. Mellor and C. Zhang, "A computationally efficient PM power loss derivation for
surface-mounted brushless AC PM machines”, Electrical Machines (ICEM), 2014 International Conf., Berlin, 2014.
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AC Conductor Power Losses
• A function of frequency
and temperature and
given as
where Pdc – DC power loss,
PaceffE – power loss due to
AC excitation of the
windings and PaceffR –
winding power loss due to
rotation of the rotor
• Assumption of uniform
average loss distribution
may yield incorrect
temperature distribution.
Temperature distribution calculated from detailed loss
model (left) and averaged loss model (right).
Source: R. Wrobel, P. H. Mellor, M. Popescu and D. A. Staton, "Power Loss Analysis in Thermal Design of PermanentMagnet Machines—A Review," in IEEE Transactions on Industry Applications, vol. 52, no. 2, pp. 1359-1368, MarchApril 2016.
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Laboratory
Coupled Model in Motor-CAD and Motor-LAB
• Electromagnetic FE
analysis, including
losses
• Thermal
calculations with
equivalent circuit
networks
• Steady state,
transient, and
complex duty
cycles.
Motor-CAD EMag
Motor-LAB
Motor-CAD Therm
Source: MDL technical
documentation Modelling
the Nissan LEAF Electric
Motor, 2015.
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Reduced Node Thermal Model
• Very useful for complex (full) system simulation… provided satisfactory accuracy
• Matrix reduction method to calculate a smaller R-C network that gives same
transient thermal response
• Keep enough nodes to give good indication of temperatures across entire model
• Full model of 65 nodes versus 7 nodes in reduced model
• Accuracy within 1% and 7 times reduction in computational time.
Source: MDL technical documentation Modelling the Nissan LEAF Electric Motor, 2015.
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Summary and Acknowledgments
• IEEE 1812 “Trial-Use Guide for Testing Permanent Magnet
Machines” is now available for use
• On-going IEEE Working Group activities focus on developments for
• Equivalent circuit parameters measurements
• Separation of losses
• Other related topics include
• High fidelity models and reduced order models
• Hardware in the Loop (HIL) and Real Time Digital Simulation (RTDS)
• Special thanks to Drs. Haran Karmaker and Vandana Rallabandi for
their contributions in the preparation of this presentation
• The continued support of our group’s academic research by Motor
Design Ltd. and ANSYS, Inc. is gratefully acknowledged.
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Main References
• IEEE 1812 Trial-Use Guide for Testing Permanent Magnet Machines, Dec. 2014.
• H. B. Ertan and İ Şahin, "Evaluation of inductance measurement methods for PM machines,"
Electrical Machines (ICEM), 2012 XXth International Conference on, Marseille, 2012, pp. 1672-1678.
• D. M. Ionel, M. J. Balchin, J. F. Eastham and E. Demeter, "Finite element analysis of brushless DC
motors for flux weakening operation," in IEEE Transactions on Magnetics, vol. 32, no. 5, pp. 50405042, Sep 1996.
• D. M. Ionel, J. F. Eastham, E. Demeter, M. J. Balchin, D.Stoia and C. Apetrei, “Different Rotor
Configurations for BLDC Motors Operating in Flux Weakening Mode“, in International Conference on
Electric Machines, 1996.
• Peng Zhang, “A Novel Design Optimization of a Fault-Tolerant AC Permanent Magnet Machine-Drive
System”, PhD Dissertation, 2013.
• G. Heins, D. M. Ionel, D. Patterson, S. Stretz and M. Thiele, "Combined Experimental and Numerical
Method for Loss Separation in Permanent-Magnet Brushless Machines," in IEEE Transactions on
Industry Applications, vol. 52, no. 2, pp. 1405-1412, March-April 2016.
• R. Wrobel, P. H. Mellor, M. Popescu and D. A. Staton, "Power Loss Analysis in Thermal Design of
Permanent-Magnet Machines—A Review," in IEEE Transactions on Industry Applications, vol. 52, no.
2, pp. 1359-1368, March-April 2016.
• X. Wu, R. Wrobel, P. H. Mellor and C. Zhang, "A computationally efficient PM power loss derivation
for surface-mounted brushless AC PM machines," Electrical Machines (ICEM), 2014 International
Conference on, Berlin, 2014, pp. 17-23.
• ANSYS technical documentation on ECE Model Creation and Applications, 2015.
• RTDS technical documentation: State of Electric Machine Models and Their Applications in RTDS
Real-Time Digital Simulator, 2016.
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Invitation for Participation
• IEEE 1812 Test Guide WG
• In-person formal meetings at IEEE PES Jul 2016 and IEEE IEMDC May 2017
• Update planned for Coil and Winding Expo, Chicago, Oct 2016
• “Virtual testing” initiative
• Forum for discussion and collaboration
• SPARK Lab at University of Kentucky serves as main sponsor
• Current supporters include ANSYS and Motor Design Ltd. with others, such
as RTDS, Toshiba expressing interest
• Inaugural in-person meeting proposed for the Coil and Winding Expo in
Chicago, IL in October 2016
• Contact
Dan M. Ionel, PhD, FIEEE, Professor and L. Stanley Pigman Chair in Power
Director, SPARK Laboratory – University of Kentucky
Chair, IEEE Power and Energy Society – Electric Motor Subcommittee
dan.ionel@uky.edu; dan.Ionel@ieee.org
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