EMCW 2015 Conference
Wisconsin Convention Center
400 W. Avenue, Milwaukee, WI 53203
Wednesday, May 13, 2015
9:00am – 4:00pm
Chair
Dan M. Ionel, Regal Beloit Corp., and Marquette
University
Co-Chairs
Gennadi Sizov, Rockwell Automation
Nathan Weise, Marquette University
Conference, Milwaukee, WI, Wednesday, May 13, 2015
9:00 am
Electromagnetic and Thermal Design Considerations
for High Performance Servo Permanent
Magnet Synchronous Motors
Gennadi Sizov, Rockwell Automation
In this presentation aspects related to electromagnetic and
thermal design of servo permanent magnet synchronous motor
design will be discussed. Servo motors are designed at the
thermal limits of the materials used in the construction of the
electromagnetic core. This presents additional design challenges.
Practical issues related to thermal-EM motor design and motordrive system design will be highlighted. Detailed FEA-based
motor-drive system simulation including the effects of PWM will
be used to analyze the motor-drive interaction and its effects on
thermal performance.
Gennadi Sizov received the B.S., M.S., and Ph.D. degrees in electrical
engineering from Marquette University, Milwaukee, WI, in 2005, 2007, and
2013, respectively. He is currently working as a Senior Motor Development
Engineer at Rockwell Automation, Mequon. He had previously worked with
R&D departments of A. O. Smith, ABB Low Voltage Drives, and Bucyrus
International (Caterpillar Mining). His areas of interest include the analysis,
modeling, design, and condition monitoring of electric machines and
adjustable-speed drives. Dr. Sizov is Co-Chair of the 2015 EMCW Conference.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
9:30 am
Simulation of Efficiency Maps for Synchronous
Permanent Magnet and Induction Machines
Mark Solveson and Emad Dlala, ANSYS
Accurate calculation of electric machine efficiency over a torquespeed range is a valuable tool for machine engineers. It allows
them to better determine design trade-offs, such as reducing
magnet size and cost versus a potential reduction in efficiency or
increase in torque ripple throughout the operating speed. A
description of the simulation approach using magnetic Finite
Element Analysis will be presented for a Synchronous Permanent
Magnet machine and includes validation with a measured
efficiency map. In addition, methods for calculating efficiency
maps for induction machines will also be presented.
Mark Solveson is Lead Application Engineer with ANSYS, Inc., where he
specializes in simulation using electromagnetic finite-element analysis and
multi-domain system simulation software for power distribution, automotive,
off-road vehicle, healthcare, aerospace and renewable energy industries. Prior
joining ANSYS, he acquired eleven patents with the Research and Development
group at Eaton Corporation as well as an M.S.E.E from Marquette University.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
10:00 am
Rotational Cutting as an Alternative in the
Processing of Electrical Steel Strip
Markus Hubert and Jörg Franke, Friedrich-AlexanderUniversität Erlangen-Nürnberg (FAU)
Improving the efficiency in production is always the aim. In many
applications where progressive stamping approaches the
technological limits, rotational cutting is successful. Relevant
applications to name are the processing of paper, card boxes,
packaging and simple perforated steel profiles. The main limiting
factors of the stamping technology are the accelerations and
decelerations in sheet feed and stamping motion. In contrast
rotational cutting is a continuous process that leads to greater
speeds and higher output. While performing the electrical steel
strip between two cylindrical tools in stamp and die arrangement,
the laminations are cut out. Rotational cutting in the manufacture
of laminations is a great challenge and researched at the Bavarian
Technology Center for Electric Drives at the FAU. This
presentation provides the main technological differences
between progressive stamping and rotational cutting regarding
the process structure. Furthermore the geometric and technical
parameters of the rotational cutting process are described
mathematically. Finally, a sophisticated device for the tooling
setup is introduced and the first cutting results of laminations are
presented.
Markus Hubert received a diploma in Mechanical Engineering from the Georg
Simon Ohm University of Applied Sciences Nuremberg. Since 2012 he is
working at the Institute for Factory Automation and Production Systems (FAPS)
of the Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Germany.
Jörg Franke heads the Institute for Factory Automation and Production Systems
(FAPS) at the Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU) since
2009. In FAPS he focuses the research on manufacturing of mechatronic
products, starting from packaging of electronic circuits, structured metallization
of circuit carriers, surface mount technology, assembly of electric motors,
automation solutions and ending with engineering, planning and simulation of
complex mechatronic systems. Previously, Prof. Dr.-Ing. Franke held different
management positions with global responsibilities e.g. at McKinsey&Co, Robert
Bosch GmbH, ZF AG, Schaeffler AG and ABM Greiffenberger AG.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
10:30 am
Alternative Manufacturing Method for
Concentrated Wound Machines
Jason Kreidler, Regal Beloit Corp.
As the price and availability of rare earth materials came into
question an effort into maximizing the use of this material in a
PMAC machine became critical. In order to achieve power density
in the stator which matches the power density of rare earth
materials higher slot fills needed to be achieved. To meets these
criteria Regal Beloit embarked on a project to construct an
automated stator manufacturing line capable of maximum slot
fills. This paper will discuss the benefits and challenges of design,
and implementation of an automated stator line.
Jason Kreidler manages the Enabling Technology Team for Commercial and
Industrial Motors at Regal Beloit Corporation. Jason started his career in
electric motors 19 years ago working in various development engineering
roles. He received his degree in Mechanical Design form Lakeshore Technical
College and is currently enrolled at University of Wisconsin – Stout studying
Business Management.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
11:00 am
Unbalanced Magnetic Force and Vibration
Characteristics of Flux Switching Permanent Magnet
Machines with and without Eccentricity
Silong Li and Bulent Sarlioglu, University of Wisconsin Madison
The flux switching permanent magnet (FSPM) machine, which has
both magnet and armature winding on the stator, and has a
salient pole rotor similar to switched reluctance machine (SRM),
become very popular in recent years. The research on FSPM
machines is mainly focused on electromagnetic performances
analysis, but the mechanical and structural analyses are very
limited. However, the salient pole rotor structure of FSPM
machine is prone to produce high vibration and acoustic noise.
Additionally, manufacturing issues such as eccentricity and
bearing defect could also lead to unbalanced magnetic force
(UMF) and vibration in the FSPM machine. In order to fill this
knowledge gap, this presentation/paper will investigate the UMF
and vibration characteristics of FSPM machine both with and
without eccentricity. Simulations with 2D and 3D FEA 2 will be
presented.
Silong Li received the B.S. degree in electrical engineering & automation from
Xi’an Jiaotong University, Xi’an, China in 2011, and the M.S. degree from
University of Wisconsin Madison, in 2014. He is currently working toward the
Ph.D. degree in electrical and computer engineering at the University of
Wisconsin-Madison. His research interests include novel permanent magnet
machines design, and high performance electric machine drives.
Bulent Sarlioglu is a Professor at University of Wisconsin–Madison, and
Associate Director of Wisconsin Electric Machines and Power Electronics
Consortium (WEMPEC). He received the Ph.D. degree from University of
Wisconsin–Madison. Dr. Sarlioglu spent more than ten years at Honeywell’s
aerospace division, most recently as a staff systems engineer, earning
Honeywell’s technical achievement award in 2003 and an outstanding engineer
award in 2011. He contributed many internally or externally funded R&D
programs and realization of many technology development programs for many
platforms including Boeing 7E7 (787), Airbus A350 and A380. Dr. Sarlioglu is the
inventor or co-inventor of sixteen US patents. His current research interests
include novel electric machines, high-speed electric machines, and wide
bandgap device based power electronics.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
11:30 am
Rapid Estimation of Induction Machine Stator Core
Losses
Sreekanth Narayana Pillai and Ian P. Brown, Illinois
Institute of Technology
An induction machine finite element analysis technique for the
estimation of stator core losses using a series of magneto-static
simulations is presented. This technique unites two previously
proposed simulation procedures: one for determining the average
torque in the induction machine under field oriented conditions
and another for the rapid analysis of synchronous machine core
losses. Stator winding and sinusoidally distributed rotor bar
currents are imposed at discrete rotor positions where a
magneto-static finite element solution is computed. Electric and
magnetic symmetries are exploited to reconstruct or approximate
the stator flux density waveforms. From the reconstructed or
approximate waveforms the stator core loss is estimated.
Sreekanth Narayana Pillai graduated with a Bachelor in Technology in Electrical
and Electronics Engineering degree from Mahatma Gandhi University,
Kottayam, Kerala, India in 2008.
Ian P. Brown received the B.S. degree in engineering from Swarthmore College,
Swarthmore, PA, USA, in 1999 and the M.S. and the Ph.D. degrees in electrical
engineering from the University of Wisconsin, Madison, WI, USA, in 2003 and
2009, respectively. Since 2012, he has been with the Illinois Institute of
Technology, Chicago, IL, USA. Previously, he was with the Corporate
Technology Center, A. O. Smith Corporation, Milwaukee, WI, USA. His main
research interests are high-performance electrical drives and the design of
electric machines.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
1:00 pm
High-Frequency “Airgap” Windings for High-Power
Density Electrical Machines
Jonathan Martin and Kiruba Haran, University of Illinois Urbana Champaign
The University of Illinois is currently working on high-power
density megawatt-scale electrical machines for aerospace
applications. One key feature is the use of very high-frequency
armature windings ranging from 3 kHz to 10 kHz. The high
frequency currents, especially in an “airgap”-winding
configuration pose significant AC loss challenges, and thereby
require highly stranded Litz conductors. This presentation will
discuss detailed AC loss calculations that have been performed, as
well as review results from manufacturing trials and bench tests
carried out to refine the machine design.
Jonathan Martin graduated with a B.A. in Physics from Colgate University in
2014. He is currently pursuing a M.S. degree in electrical engineering under
Professor Kiruba Haran with focus on electric machines at the University of
Illinois, Urbana-Champaign.
Kiruba Haran obtained a BS in Electrical Engineering from OAU, Nigeria, in
1994, and a PhD in Electric Power Engineering from RPI, Troy, NY in 2000. He is
currently an Associate Professor and Associate Director of the Grainger Center
for Electric Machinery at the University of Illinois at Urbana-Champaign. He
moved to UIUC in 2014 after 13 years at GE Research. At GE, Dr. Haran was the
manager of the research group developing advanced electrical machine
technology for all of GE’s industrial businesses, including Wind, Oil & Gas,
Aviation, Transportation and Energy Services. Dr. Haran has 35 US patents,
several more global patents, and has published 20 journal papers and given
dozens of conference presentations. He is a registered PE in NY, and is a fellow
of the IEEE.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
1:30 pm
Linear actuators: A Very Diverse Landscape
Bruno Lequesne, E-Motors Consulting, LLC
Many mechanisms ultimately require linear motion, from fuel
injection to aircraft launches. The presentation will provide an
overview of the many technical solutions developed for such
applications. An important distinction will be made between
devices where the motive force is perpendicular to the airgap, as
opposed to parallel. This distinction exists in the rotary world as
well but is seen much less frequently. For linear actuation it
generally separates shorter from longer motions. For longer
travels, the option of retaining a rotary machine, paired with a
rotary-to-linear mechanism has many advantages in a number of
cases. Ultimately, choosing one approach over another involves
both a deep understanding of electromagnetic force generation
as well as a system approach.
Bruno Lequesne received the Certified-Engineer degree from the Ecole
Supérieure d'Electricité (CentraleSupélec), France, in 1978, and the PhD degree
in electrical engineering from the Missouri University of Science and
Technology, Rolla, MO, USA, in 1984. He worked for 30 years in the automotive
industry with General Motors, Delphi, and Eaton on transportation
electrification research before starting his own consultancy, E-Motors
Consulting, LLC, in 2014. Dr. Lequesne holds 49 patents with 4 more pending,
primarily on sensors, linear actuators, and automotive applications. He is the
recipient of ten Best Paper Awards, seven from the IEEE Industry Applications
Society (IAS), and three from the Society of Automotive Engineers. He was
elected an IEEE Fellow in 1997. He is also past president (2011-2012) of the
IEEE IAS and is currently on the steering committee of the IEEE Transportation
Electrification Community.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
2:00 pm
Modern Heat Extraction Systems for Electrical
Machines – A Review
Mircea Popescu, Motor Design, Ltd.
The thermal stress on the electrical machines is created by the
losses dissipated in the system which will heat different
components of the machine, like windings, rotor cages, magnets,
and needs to be dissipated. One can thermally protect the
electrical machines by reducing the local losses, i.e., the induced
eddy-current losses in the electrical conducting regions, iron
cores, magnets, retaining sleeves, and/or using an efficient
cooling system. Depending on the application, cooling systems
can be employed with natural convection (totally enclosed nonventilated), forced convection (air or liquid cooling), or radiation
cooling (in the case of electrical machines, operating in vacuum
environment). Heat can be extracted through conduction,
convection (natural and forced) and radiation. The thermal
management of electrical machines is a 3-dimensional problem
which requires complex heat extraction phenomena to be
addressed; e.g., heat transfer through complex composite
components such as the wound slot, temperature drop across
interfaces between components and complex turbulent air flow
within the end-caps. This study presents modern various solutions
for an efficient heat extraction or thermal management of the
electrical machines.
Mircea Popescu is the Engineering Director of Motor Design, Ltd., a software
and consultancy company headquartered in the UK and with offices in the US,
and has more than thirty years of engineering experience. Earlier in his career,
he was with Helsinki University of Technology (now Aalto University) in Finland
and with the SPEED Lab at University of Glasgow, UK. Dr. Popescu published
more than one hundred papers and his publications have received three IEEE
best paper awards. His consultancy contributions for industry are incorporated
in many state-of-the-art products. Current major projects include electrical
machines and drives for hybrid/electrical vehicles, and formula-e racing cars.
An IEEE Fellow, Dr. Popescu is the Chair of the IEEE Industry Application Society
(IAS) Electrical Machines Committee and a Distinguished Lecturer for IEEE IAS
Region 8.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
2:30 pm
Synchronous Reluctance and PM Assisted Motors
Steven J. Stretz, Regal Beloit Corp.
Synchronous reluctance machines and their PM assisted varieties,
which incorporate magnets in the flux barriers, are being
considered for variable speed power electronic converter -fed
applications. The presentation will cover fundamental concepts,
optimal computer-aided design, and practical demonstrations of
the technology. The advantages of employing PM assisted rotor
topologies with cost competitive ferrites will be quantified in
terms of improved power factor, specific power, and efficiency.
Numerical and experimental results for a 10hp 1,800rpm typical
rating will be discussed.
Steven J. Stretz is Chief Engineer with Regal Beloit Corporation and is based in
Grafton, WI. He received the B.S. degree in electrical engineering from the
University of Wisconsin Milwaukee followed by post graduate studies in
Engineering Management. Mr. Stretz has more than 40 years of experience in
various engineering and management roles in the electric machine industry and
introduced to manufacturing many new products. He has been a working
member of IEEE and NEMA involved in the development of standards for
electric machines.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
3:00 pm
Permanent Magnets for Electric Machines: Current
Performance and Research Trends
Melania Jasinski, Heeju Choi, and Jinfang Liu, Electron
Energy Corp.
In this presentation we will review the performance of permanent
magnets for electric machine applications and discuss the tradeoff between the performance and cost, density of magnetic flux
and thermal stability, etc. We will also present lesser known
magnet grades, such as ultra-high temperature Sm-Co magnets,
temperature compensated Sm-Co magnets, sequentially
laminated magnets, and new grades of Nd-Fe-B magnets. The
latest research activities in the US, recently funded by the
Advanced Research Projects Agency-Energy, as well as worldwide
major research programs on rare earth and non- rare earth
magnets and their objective-accomplishment status, will be
discussed in the context of preparing the engineering community
for possible new generations of permanent magnets.
Melania Jasinski is the Manager of Process Technology at Electron Energy
Corporation. She received her PhD in Physics in 2003, from A.I.Cuza University,
while also working as a researcher at the National Institute for Research and
Development, in Iasi, Romania. She joined EEC in 2007, leading the R&D group
in material research activities under more than a dozen government and
industry funded projects. Dr. Jasinski co-authored more than 50 peer-reviewed
papers and 8 patent applications and serves as a reviewer for several journals
and government research-funding agencies.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
3:30 pm
Common-Mode Voltage Mitigation in MultilevelInverter-based Adjustable Speed Motor Drives
Chad Somogyi and Nabeel A.O. Demerdash, Marquette
University
The three-level neutral-point-clamped (NPC) ASD is a popular
multilevel inverter topology used in low- and medium-voltage
regenerative/non-regenerative motor drive applications because
of its ability to produce lower levels of total harmonic distortion
(THD) and withstand higher voltages while preserving rated
output power compared to two-level ASDs. While multilevel PWM
schemes to mitigate or eliminate CMV have been proposed in
literature, many of these methods do not consider real-world
conditions and requirements, such as switch dead-time, polarity
reversals in the output line voltage, etc., for safe and efficient
operation of three-level ASDs and motor loads. This paper will
review the harmful effects of CMV and introduce several carrierbased multilevel PWM strategies that reduce and/or eliminate
CMV produced by three-level NPC motor drives. Simulation and
experimental results based on a laboratory scale 7.5 kVA threelevel NPC ASD will be presented to verify the introduced PWM
strategies for mitigating the CMV in ASDs.
Chad Somogyi received a B.S. in electrical engineering technology from
Milwaukee School of Engineering University, Milwaukee, Wisconsin in 2012. He
is currently working on his M.S. in electrical engineering at Marquette
University, with a research focus on common-mode voltage mitigation for
multilevel-inverter-based adjustable speed motor drives.
Nabeel A. O. Demerdash has pioneered since the 1970’s finite element
techniques for low frequency electromagnetics and their applications for
electric machines and drives. In the 1980’s as part of a NASA project he
designed and built one of the very first rare-earth brushless DC motor drives for
electric vehicles. He has published more than 100 IEEE Transactions papers,
and is the winner of the 1999 IEEE Nikola Tesla Technical Field Award, which
represents the highest IEEE recognition for work on electrical machine topics.
Professor Demerdash is an IEEE Life-Fellow, a member of the American Society
of Engineering Education, the Sigma Xi, and the Electromagnetics Academy.
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Conference, Milwaukee, WI, Wednesday, May 13, 2015
http://www.coilwinding.org/
http://electricalmanufacturing.org/
Dan M. Ionel, EMCW 2015 Conference Chair, is Chief Engineer with Regal
Beloit Corp. and Research Professor with Marquette University in Milwaukee,
WI. After completing postdoctoral research with the SPEED Laboratory,
University of Glasgow, he worked in industry and academia in the UK and the
US. An IEEE Fellow, Dr. Ionel was granted more than thirty patents and has
published more than one hundred papers, including two winners of IEEE IAS
best paper awards. He is the Editor-in-Chief of the Electric Power Components
and Systems Journal, the Chair of the IEEE PES Electric Motor Subcommittee
and of the IEEE Milwaukee Power Electronics Chapter.
Nathan Weise, EMCW 2015 Conference Co-Chair, is an Assistant Professor
with Marquette University in Milwaukee, WI. He received the Ph.D. from
University of Minnesota, Minneapolis, MN and worked in industry as an
electrical engineer at Cummins Power Generation and General Electric Global
Research. Before joining Marquette University in 2014, he was an Assistant
Professor at the University of Maine, Orono, ME. His current interests include
power electronics, electrification of transportation, control of renewable
energy sources, motor drive systems, wave energy converters, HVDC, and grid
connected converters.
Ver. 2015 0321
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