Comparison of Two FSCW PM Machines for Integrated Traction Motor/Generator Gurakuq Dajaku, Sachar Spas, Xhevat Dajaku, and Dieter Gerling, IEEE s concentrated windings offers the advantage of short and less complex end-winding, high slot filling factor, low cogging torque, greater fault tolerance, and low manufacturing costs [1, 2]. Further, FSCW offers also different possible combinations of numbers of rotor poles and stator slots [3]. Thus, depending on the slot/pole combination, there exist several winding topologies with high winding factor for the fundamental wave (up to 97%), that is a necessary and a desired parameter for high torque capability machines. On the other side, FSCW are characterized with high space harmonic contents in their magneto motive force (MMF) distribution. Except the fundamental harmonic which is responsible for machine torque and effective power, the rest of sub- and high MMF winding harmonics induce negative effect on the machine such as, significant rotor losses (rotor core and permanent magnets) [4-6], rotor heating, noise and vibrations problems [7-9], and so on. Therefore, as results of space MMF harmonic problems, the all manufacturer until now are Abstract- This paper presents a comparative study of two different FSCW PM machines for application as integrated motor-generator in hybrid vehicles. The first machine design contains the conventional concentrated winding with q=0.5 that is recently used in many hybrid systems for commercial vehicles, whereas the second machine use the new 18-teeth/10poles concentrated winding with the optimized magneto motive force. Design and analysis of considered machines is based on their performances which included evaluation of electromagnetic torque and torque ripples, Ohmic losses, magnet losses, field weakening capability, noise analysis, and temperature behaviour. Using 2D and 3D finite elements the both machine types are investigated and compared under the same geometrical and electromagnetic constrains. Considering the main electromagnetic and thermal aspects, the new machine show high power capability and efficiency, low torque ripple, low magnet losses, noiseless design, and thermally robust. Index Terms-- Concentrated winding, permanent magnet machines, MMF harmonics, magnet losses, optimization. I I. INTRODUCTION N THE last time, many automobile manufacturer and also some automotive suppliers have developed different hybrid systems based on integrated motor/generator principle, where depending on the application and the mode of operation, calling them as Integrated Starter Generator (ISG), Integrated Motor Assist (IMA), or Integrated Motor Generator (IMG). Fig. 1 show different actual traction machines provided from different manufactures that already exists in the marked. In hybrid electric vehicle (HEV) applications they perform several important functions, such as, start-stop, recuperation, power boosting, and power generation. In order to save space, the electric machine is integrated into the drivetrain between clutch and transmission. Usually it is a short axis, large diameter permanent magnet (PM) synchronous motor with fractional slots concentrated winding (FSCW). The use of G. Dajaku is Senior Scientist with FEAAM GmbH, Germany (e-mail: gurakuq.dajaku@unibw.de). S. Spas is with FEAAM GmbH (e-mail: sachar.spas@unibw.de). Xh. Dajaku is with Universitaet der Bundeswehr Muenchen, Institute for Electrical Drives, Germany (e-mail: xhevat.dajaku@unibw.de). D. Gerling is Full Professor at the Universitaet der Bundeswehr Muenchen, Institute for Electrical Drives, Germany (e-mail: dieter.gerling@unibw.de). 978-1-4799-7940-0/15/$31.00 ©2015 IEEE a) b) c) d) Fig.1. Different FSCW traction PM machine [21, 22], a). Integrated Motor Generator (IMG) from Bosch, b). DynaStart from ZF-Sachs, c)Integrated Motor Assist (IMA) from Honda, d). PM generator from Toyota Prius 2010. 187 using the conventional 3-teeth/2-poles concentrated winding with q=0.5 for their PM traction machines. This assumption can be confirmed also from the different machines types presented in Fig. 1. All these machines are designed with the same 3-teeth/2-poles FSCW, while the main difference exists only on the number of pole pairs, as well as, on the rotor topology and design. The MMF analysis presented in [4] show low winding factor (about 86%) for the conventional 3-teeth/2-poles winding compared with the others FSCWs (up to 97%). On the other side, it is the single winding type that operates with the first MMF harmonics, while the rest use the high harmonics as operating wave. Thus, referred to the fundamental wave, the conventional winding has only high harmonics in the MMF spectrum, while the others FSCW includes the both sub- and high harmonics. Concerning the rotor losses and also the noise problems, many investigations show that, the amount of sub- and high harmonics contents, and also their location with respect to fundamental wave are the main responsible factors for the machine performances [2 to 9]. It is important to point out that, for low rotor losses and noiseless machines it is required to have a stator windings with low harmonic contents, none sub harmonics, and also with high harmonics located far away from the working wave. Thus, considering all these conditions, the conventional 3-teeth/2poles winding overcomes the rest of the FSCW, and at the moment it is the only one winding type that until now is being used for different traction PM machines. The actual traction machines with the conventional winding even already are in application in different hybrid systems, they still to have several problems concerning the rotor losses and rotor heating, especially in the high power and high speed region. Fig. 2 illustrates the torque-speed requirements for a standard traction machine, and also the area related with existing problems in the conventional designs. Thus, to overcome the existing problems, this paper propose a new integrated motor/generator design as an alternative solution. The new PM machine use an optimized 18-teeth/10-poles FSCW which is characterized with low winding factor for the fundamental wave, however, also with low harmonic contents compared with the conventional 3-teeth/2-poles winding. The main motivation of this work was to show the opportunity and potentials of the new winding for traction PM machines as integrated motor/generator. Thus, during the following analysis two machine types with the conventional and also the new winding are designed and investigated under the same electromagnetic and geometrical constrains. From the analysis and comparison of the electromagnetic and thermal results, valuable and positive conclusions are obtained, which wake up the interests to consider the new winding type as an alternative solution for the actual problems on the conventional designs! II. CONSIDERED CONCENTRATED WINDING TYPES A. Conventional 3-teeth/2-poles Winding Fig. 3a) illustrate the winding layout for the conventional 3-teeth/2-poles concentrated winding, where each phase comprises one coil, and with “+A+B+C” coil (phase) sequence. For high poles machine, the standard phase sequence is repeated p-time. In many literatures this winding type is called often also as FSCW with q=0.5 (with q is the number of coils/phase/pole). For the “+A+B+C” basic winding version, the MMF distribution and also its space harmonics are given in Fig. 3b), however eq. (1) describe the MMF using the Fourier series function. ∞ 2N w ⋅ ˆi ν Θ 3T / 2P (φS , t) = ∑ ξ w ⋅ cos ( ωt − νφS ) πν ν =1,2,4,5,... (1) ⎛ π⎞ ν ξ w , = sin ⎜ ν ⎟ ⎝ 3⎠ In the above eq.(1), ν ξ w is the winding factor, i the phase current, ω the angular frequency, Nw the number of turns per phase, and ν the MMF harmonic order. From the Fig. 3b), the conventional winding contains all harmonic order except the multiple of 3rd, e.g. the 1st, 2nd, 4th, 5th, and so on. For the PM machines, usually the first harmonic is used as working wave (torque component), whereas the rest of all high space harmonics induce parasitic effects in the machine, such as torque ripple, losses, noises, and thermal problems. Torque [Nm] required torque B. New 18-teeth/10-poles Winding Several new techniques and methods are developed in the past to improve the MMF winding characteristics, or to reduce their effects on the machine parameters. These techniques are based, either on the winding design such as using, 1. multi-layer FSCW [10, 11], 2. coils with different turns per coil side [12], delivered torque Area characterized with high rotor losses and temperature problems nb nmax Fig. 2. Requirements for torque-speed. and regions characterized with high rotor losses and temperature problems in the actual PM traction machine. 188 a) MMF [ p.u. ] MMF [ p.u. ] a) 1 0 -1 0 1 2 3 4 theta [rad. degree] b) 5 6 -1 1 2 3 4 theta [rad. degree] 5 6 1 MMF [ p.u. ] MMF [ p.u. ] 0 0 b) 1 0.5 0 0 1 0.5 0 0 2 4 6 8 10 harmonic order Fig. 3. a). Conventional 3-teeth/2-poles FSCW, b). MMF-characteristics. 5 10 15 20 harmonic order Fig. 4. a). New 18-teeth/10-poles FSCW, b). MMF-characteristics. combination, the resulting (total) MMF winding distribution can be calculated from the sum of the corresponding MMFs for the first and the second winding system, as is described in eqs. (2) to (4). 3. stator shifting concept [13-15], or 4. dual multiphase FSCW [16], or, on the modification of the stator core structure by applying (2) Θ18T /10P (φS , t) = Θ1 (φS , t) + Θ 2 (φS , t) m 2N w1 ⋅ ˆi ν ⋅ ξ w1 ⋅ cos ( ωt − νφS + δ1 ) (3) Θ1 (φS , t) = ∑ ⋅ πν ν 2 m 2N ⋅ ˆi Θ2 (φS ,t) = ∑ ⋅ w2 ⋅ ν ξw2 ⋅ cos ( ωt −ν( φS +αw ) +δ2 ) (4) πν ν 2 1. magnetic flux-barriers in stator yoke [17], or 2. magnetic flux-barriers in teeth locations [18]. Fig. 4a) illustrate the winding layout for the new 18-teeth/10-poles concentrated winding that is developed according to the dual multiphase FSCW concept [16]. It consists of two different winding systems which are integrated in the same stator core and are shifted in space and time to each other. The winding layout for the first winding system is similar with the 12-teeth/10-poles single-layer winding (yellow winding), whereas for the second system, it is similar with the 12-teeth/10-poles double-layer winding (index 1 and 2 denotes the first and the second winding system, respectively). Further, concerning the machine supply, it offers several options for connecting the phase windings to the power source device. The six-phase windings can be fed by a six-phase inverter, or alternatively, using the star&delta winding combination it can be supplied also with a three-phase conventional inverter. The MMF distribution and the corresponding space harmonics for the new winding type are presented in Fig. 4b), that shows high quality MMF distribution and also low harmonic contents. According to the dual winding with the corresponding winding factors, ⎛ π⎞ ⎛ 7 ⎞ ⎛ 1 ⎞ ν ξw1 = sin ⎜ ν ⎟ , ν ξw2 = cos ⎜ ν π ⎟ ⋅ sin ⎜ ν π ⎟ 18 18 ⎝ ⎠ ⎝ ⎠ ⎝ 18 ⎠ (5) In the above equation. (3) to (4), with α w is denoted the mechanical shift angle between the two winding systems, and Nw1, Nw2 are the number of turns per phase for the first and the second winding, respectively. C. Comparison of MMF Characterisitcs In following, the MMF characteristics for the both winding types are analyzed for the five pole-pairs machine case (same operating wave condition). For the conventional winding, to achieve the corresponding number of poles, the basic winding layout shown in Fig. 3a) is repeated five-time in the circumferential direction. Thus, 189 for the five-poles condition, the conventional and the new winding are called as 5*(3T/2P) and 18T/10P, respectively. The following Fig. 5 and also Table-1 compares the respective results for the MMF distribution, space harmonics, and the winding factors. From these results it can be concluded here that, with the new winding, the harmonic contents is reduced for the factor two, and also the existing high harmonics are locate far away from the fundamental wave compared with the conventional design. As well discussed earlier, these two specifics are very important for rotor loss and also noise problems reduction. On the other side, the winding factor for the fundamental wave is for about 12% lower. Since, by the electric machines the lower winding factor is directly related with the Ohmic losses, at the first point of view, the new winding design shows to represent drawbacks concerning the winding losses. But, as will be shown from this analysis, considering only the winding factor parameter isn’t always the right way for selection or rejection any FSCW for a specific application. However, depending on the requirements and also on the operation conditions of the machine, for a proper decision, the all machine parameters should be considered and analyzed carefully, such as the winding factor (Ohmic losses), rotor losses, thermal and also the noise aspect. Thus, the main motivation of this work was to investigate in details the main performances of the new FSCW considering the all aspects mentioned above, and to show its chances and potentials for traction PM machine applications. III. TRACTION MACHINE DESIGNS Two different PM machines for application as an integrated motor/generator are designed and their main performances are investigated and compared. For the first design, the conventional 3-teeth/2-poles winding shown in Fig. 3a) is used, while for the second machine, the new 18teeth/10-poles winding presented in Fig. 4b) is considered. The requirements for the electric motor concerning to the machine geometry data, materials, as well as, the maximum power and speed, continuous power, and the battery DC voltage, are summarized in Table II. For a proper comparison, the both machines are designed and investigated under the same electrical and geometrical constrains (voltage, current and volume). Further, the same materials for the machine components, same rotor dimensions, and also the same magnet volume is selected for the both machines; The main difference is only on the stator core geometry and in the winding type. Additionally, since the studied machines have different winding types, the number of turns per phase for the both winding configuration is defined under the condition that the both machines should generate the same torque for the same excitation load current. Fig. 6 shows the geometries of the investigated machines. Two dimensional (2D) and three-dimensional (3D) finite elements (FE) tools are used to determine the main machine parameters and performances. The simulation results presented in following are performed for 250Arms maximal load current. For simplicity, the 20-poles conventional and the new machines are called as 30T/20P and 36T/20P, respectively. MMF [ p.u. ] 5*(3T/2P) 1 0 -1 0 1 MMF [ p.u. ] a) 2 3 4 theta [rad. degree] 5 2 3 4 theta [rad. degree] 5 6 18T/10P 1 0 -1 0 1 6 5*(3T/2P) 18T/10P MMF [ p.u. ] 1 0.8 TABLE II: MAIN ELECTROMECHANICAL AND GEOMETRY DATA Active length 63 mm Outer stator diameter 300 mm Outer rotor diameter 240 mm Gap length 1 mm Number of rotor poles 20 Fig. 5: MMF distribution and the corresponding MMF spectrum for the conventional and the new winding topology. Iron Core material STEEL 330-35AP Magnet material VACODYM 854 AP TABLE-I: Winding factors Maximal Torque 270 Nm b) 0.6 0.4 0.2 0 0 5 10 15 Harmonic Order 20 ν ξw 5th 10th 13th 20th Maximal current 250A ν ξw ,3T / 2P 86.6% 86.6% 0% 86.6% Maximal speed 6000 rpm ν ξ w ,18T /10P 76% 0% 76% 0% DC Voltage 300V 190 IV. COMPARISON OF RESULTS 320 A. Electromagnetic Torque a) T [Nm] 240 The torque results vs. rotor position presented in Fig. 7a) shows high torque ripples for the conventional design (16%). Thus, for reducing the torque ripples under the 5% limit, the first machine design need to be skewed, that increase the manufacturing costs of the machine, and also reduce the effective torque. In contrast, due to low torque ripples for the proposed 36T/20P design, none skewing is required. Furthermore, the new machine overcomes the conventional design also on the field weakening region, Fig. 7b). As results of low MMF harmonic contents, the harmonic inductance amount for the new winding is lower compared with the conventional winding, and according to analysis performed in [20], this leads to field weakening improvement for the 36T/20P machine. Conv. 30T/20P New 36T/20P 160 80 0 0 60 120 180 240 300 rotor position [ el. degree ] 300 Conv. 30T/20P New 36T/20P 250 B. Magnet Losses 200 T [Nm] b) 360 150 100 The high harmonics in the air-gap MMF distribution rotate at different speeds to that of the rotor magnets and induce significant eddy currents in the magnets. To take into account the correct path of the eddy currents in the magnet regions, the loss calculations is performed using 3D FE analysis. Fig. 8 compares the losses distribution for one operation point (maximal rotor speed), while Fig. 9 shows the magnet losses vs. rotor speed for the maximal load current and non-segmented magnets. From the both results it can be concluded that, with the new motor design the magnet losses are reduced significantly compared with the reference machine (factor ten). Thus, none magnet segmentation is required for the new machine. On the other side, for the 30T/20P machine, the magnet segmentation with very short magnet pieces (5mm) is required to reduce the magnet losses at the same level with the proposed design, Fig. 10. 50 0 0 2000 4000 6000 8000 speed [rpm] Fig. 7: a).Electromagnetic torque vs. rotor position, b). Field weakening capability. 30T/20P Design [W/m³] 3.81e+8 36T/20P Design a) 4.30e+3 b) Fig. 6: Investigated PM machines, a). Conventional 30-teeth/20-poles design (30T/20P), b). New 36-teeth/20-poles design (36T/20P). Fig. 8: Magnet loss distribution for 250Arms and 6000rpm. 191 10 30T/20P Design Magnet losses [kW] Conv. 30T/20P 8 36T/20P Design New 36T/20P 6 4 2 0 0 2000 4000 6000 8000 speed [rpm] Fig. 9: Magnet losses vs. rotor speed for non-segmented magnets. Fig. 11: Geometrical coil shape approach. TABLE-III: Winding resistances and Joule losses for 250Arms current Machine type 30-teeth/20-poles Phase resistance RWinding = 11,8mΩ Joule losses 36-teeth/20-poles RWinding ,I = 5, 2mΩ RWinding ,II = 22,5mΩ 2,21 kW 2,38 kW 2 30T20P 36T20P B [T] 1 Fig. 10: Segmentation effect on the eddy current losses in permanent magnets for the 30T/20P machine. 0 -1 -2 0 50 a) C. Ohmic Losses 100 theta [degree] 150 1.5 B [T] Fig. 11 illustrate the geometrical approach used for determination of winding resistances, while Table III presents the derived results for the phase resistances and also the corresponding Joule losses. Thus, even the winding factor for the 36T/20P design is for 12% lower than for the 30T/20P design (76% vs. 86.6%), the Ohmic losses are only for 7.5% higher. This effect can be justified considering the shorter end-winding length and also the low saturation due to low harmonic contents in the new machine. Further, for the same active length for the both machines, the total length for the 36T/20P design is reduced for about 6% as results of shorter end-winding. 30T20P 36T20P 1 0.5 0 F [ N/m² ] 10 D. Noise Excitation Magnetic Forces The radial force density distribution on the stator bore, which results from the air-gap magnetic field under no-load (open-circuit), as well as on-load conditions, is the main cause of electromagnetically induced noise and vibrations. Fig. 12 gives the simulation results for the air-gap fluxdensity and the resulting magnetic radial forces for the maximal excitation load current. Considering the radial force harmonics (modes) in Fig. 12.b), it can be shown that except the mode zero (m = 0) the lowest mode for the 0 x 10 5 25 30 35 30T20P 36T20P 5 0 3 F [ N/m² ] 15 20 Space Harmonics 5 -5 0 b) 10 50 x 10 100 theta [degree] 150 5 30T20P 36T20P 2 1 0 0 5 10 15 20 Space Harmonics 25 30 35 Fig. 12: a). Air-gap flux density, b). Radial force density. 192 30T/20P design is the mode-10, while for the 36T/20P is the mode-16 (the amplitude of mode-4 is too low and it can be completely cancelled by a proper rotor design). According to [7 to 9], in relation to acoustic behavior of the electric machines, the significant radial force modes are those of low order, i. e m = 0, 1, 2, 3. Thus, for the both machine designs only mode-0 can be critical for the noise excitations, while the high order modes usually doesn’t meet the resonance frequency of the stator structure within the speed range of the machines. However, considering the mode-0 alone, it is well known that only the frequency components of this mode are responsible of the noise and vibrations. Therefore, to evaluate the frequency components for the mode-0, the both machines are investigated in time domain. From Fig. 13, the 30T/20P design contains several mode-0 time harmonics that can be responsible for the noise problems, while the proposed deign it has a very smooth mode-0 response. F [ N/m² ] 2.6 x 10 5 30T20P 36T20P 2.5 2.4 2.3 2.2 0 5 10 time [ms] 15 20 F [ N/m² ] 15000 30T20P 36T20P 10000 5000 0 10 20 30 xp f R 40 50 [ Hz ] Fig. 13: Mod -0 in time domain for 250Arms load current.. 350 E. Temperature Results 300 T [ °C ] During the thermal analysis, the both machines are assumed to be mounted inside the water cooled jacked with 80°C coolant temperature. In the FE model the coolant convention coefficient between the fluid and the stator frame is taken to be 2000 W/(Km²). Further, in order to simplify the FE model, the stator slot is modeled with a homogeneous copper section with a thin insolation area around it. The equivalent thermal conductivity for the insolation slot area is taken to be 0.08 W/(Km) [23]. Fig. 14 gives the temperature behaviors in the rotor magnets and also in the stator slot for the maximal speed and power condition. As results of rotor loss reduction, and also higher number of stator slots, the proposed machine is thermally robust also for the maximal load condition. Otherwise, the high rotor losses and the resulting high rotor temperature are the main factors that limit the operating capability of the conventional machine at high speed and power range. a) 250 200 Conv. 30T/20P 150 New 36T/20P 100 50 0 0 50 100 150 time [s] 200 250 300 200 250 300 600 Conv. 30T/20P b) V. CONCLUSIONS T [ °C ] 500 New 36T/20P 400 300 200 This paper deals with a detailed analysis of two different FSCW traction PM machines. From the obtained results, the following can be concluded: 30-Teeth/20-Poles Design; The conventional 30T/20P machine is characterized with high torque ripple, high magnet losses, noise and vibration excitation forces, and rotor temperature problems. As results of high MMF harmonic contents, at high power&speed region this machine type can’t fulfill the requirements. Stator/rotor skewing is required to reduce torque ripples. Additionally, magnet segmentation with very short magnet pieces (5mm) is needed to reduce the magnet losses and high rotor temperatures. On the other side, the existing time-harmonic components of mode-0 are critical for the noise and vibration problems. 36-Teeth/20-Poles Design; An alternative machine design with 36-teeth/20-poles is presented to solve the existing ISG problems. The new winding is characterized 100 0 0 50 100 150 time [s] Fig. 14: Temperature results for 250Arms and 6000rpm, a). Winding temperature, b). Magnet temperature. with low winding factor (76%), however with low harmonic contents (factor two). Even the lower winding factor, the Ohmic losses are only for 7% higher compared with the reference machine. This is as results of shorter end-winding length, low saturation due to high harmonics, and non-required skewing. Further, The total machine length is for 6%shorter, Smooth torque response => none skewing is required, Noiseless design => mode-0 is constant, and other modes are of the high order, 193 [13] G. Dajaku, D. Gerling, “A Novel 24-Slots/10-Poles Winding Topology for Electric Machines”, International Electric Machines and Drives Conference (IEMDC-2011), Niagara Falls (Ontario), Kanada, May 15-18, 2011, pp. 65-70. [14] P. B. Reddy, H. Kum-Kang, and A. El-Refaie, “Effect of stator shifting on harmonic cancellation and flux weakening performance of interior PM machines equipped with fractional-slot concentrated windings for hybrid traction applications,” Proc. of IEEE Energy Conversion Congress and Exposition (ECCE), pp. 525-533, Sep. 2012. [15] X. Chen, J. Wang, P. Lazari, and L. 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