Vibration analysis of permanent magnet synchronous motor using coupled finite element analysis and optimized meshless method

This paper deals with theoretical analysis and design of permanent magnet (PM) synchronous motors (PMSMs) with minimized cogging force. Recently, many optimal designs for the PMSMs have been done by finite element (FE) analysis, but such analysis generally is time consuming. In this study, the equation of magnetic flux lines existing between PMs and iron cores is expressed geometrically and the cogging force is calculated theoretically without FE analysis. The form of equation is assumed to be the second-order polynomial and the virtual core is used to express the cogging force in analytical model. The cogging force can be calculated by applying the solved flux line equation and the flux density equation to the Lorentz force equation by using the Maxwell stress tensor. The theoretical analysis of minimized cogging force is applied to several prototypes such as synchronous PM planar motor (SPMPM), 2-DOF PMSM with screw motion, and axial flux PM (AFPM) brushless dc motor in this paper, and the analytical results are validated by FE analyses and experiments.

PowerSynth is a multiobjective optimization tool for rapid design and verification of power semiconductor modules. By using reduced order models for the calculation of electrical parasitics of the layout and thermal coupling between devices, optimal trace layout and die placement can be simultaneously achieved orders of magnitude faster than conventional finite element analysis (FEA) techniques. An overview of the tool, its modeling methods, model validation, and module layout optimization are presented. The electrical and thermal models are validated against FEA simulations and physical measurements of built modules generated from the tool. The FEA comparisons are performed with FastHenry and ANSYS Icepak to evaluate electrical parasitics and thermal behavior, respectively. A sample hardware prototype based on a half-bridge circuit topology is chosen for testing. Excellent agreement between the FEA simulations, experimental measurements, and PowerSynth predictions are demonstrated. Additionally, when compared with conventional simulation runtime and workflow, PowerSynth takes considerably less computation and user time to produce several candidate layout solutions from which a designer may easily balance selected tradeoffs.

The warpage of individual IC panel/package or whole molded strips keeps changing with temperature during the assembly processes from die bonding, wire bonding, molding, post-mold cure to soldering reflow. How to optimize package design and properties of all assembly materials to obtain acceptable warpage level both at room temperature and reflow temperature becomes more challenging. In this study, finite element analysis (FEA) simulation was performed in warpage prediction of three types of advanced laminated IC packages (PBGA, CSP BGA and PoP BGA). Shadow Morie system was used in monitoring warpage deviation under temperature profile from -55degC to 260degC. Calibration or correction of FEA results can be performed by introducing experimental results from Shadow Morie measurement to fine-tune the modeling so as to obtain more accurate prediction

The temperature rise inside permanent magnet synchronous motors (PMSMs) caused by losses can lead to potential irreversible demagnetisation of magnets, insulation failure between windings, etc. This paper presents an analytical model to predict the PMSM temperature based on the electrical and thermal characteristics. The temperature relationship between motor windings and permanent magnets is addressed through the electrical modelling. Meanwhile, one lumped-parameter based thermal model is developed and combined with the electrical model, which will avoid processing the complicated aspects of thermal analysis and picture the thermal distribution inside PMSM conveniently. Furthermore, the thermal circuit encompasses the eddy current loss in the magnets, which provides high accuracy. The predicted temperature through the proposed model is validated by finite element analysis (FEA) simulation when the motor is operated under a three-phase sinusoidal power supply.

Although a compliant gripper is a type of compliant mechanism, existing analytical models rarely account for the real mechanical behavior of the flexible parts within the gripper. In this work, an in-plane motion flexure-based compliant gripper is presented, modeled, and analyzed. An analytical methodology based on the Compliance Matrix Method (CMM) is proposed to compute the relationship between input and output forces and displacements in two different coordinate frames using a single unified expression that represents the real mechanical behavior of the system. The analytical model is validated through Finite Element Analysis (FEA) simulations and experimental tests performed on additively manufactured prototypes. Additionally, the model is used to analyze output displacements resulting from variations in geometric parameters, with results validated through FEA simulations. This demonstrates the method’s utility in optimizing gripper design during early development stages prior to fabrication. The proposed analytical model accurately estimates the compliant gripper’s kinetostatic behavior, achieving less than 5% difference compared to FEA and experimental results. Furthermore, the model is adaptable and can be extended for the kinetostatic analysis of other compliant grippers with similar flexure-based architectures.

Optimal parameter selection is a crucial step in improving the quality of electronic packaging processes. Traditional approaches usually start with a set of physical experiments and then employ Design of Experiment (DOE) based response surface methodology (RSM) to find the parameter settings that will optimize a desired system response. Nowadays deterministic computer simulations such as Finite Element Analysis (FEA) are often used to replace physical experiments when evaluating a system response, e.g., the stress level in an electronic packaging. However, FEA simulations are usually computationally expensive due to their inherent complexity. In order to find the optimal parameters, it is not practical to use FEA simulations to calculate system responses over a large number of parameter combinations. Nor will it be effective to blindly use DOE-based response surface methodology to analyze the deterministic FEA outputs. In this paper, we will utilize a spatial statistical method (i.e., the Kriging model) for analyzing deterministic FEA outputs from an electronic packaging process. We suggest a sequential method when using the Kriging model to search for the optimal parameter values that minimize the stress level in the electronic packaging. Compared with the traditional RSM, our sequential parameter selection method entertains several advantages: it can remarkably reduce the total number of FEA simulations required for optimization, it makes the optimal solution insensitive to the choice of the initial simulation setting, and it can also depict the response surface and the associated uncertainty over the entire parameter space.

Permanent magnet (PM) synchronous motors (PMSMs) have been used to drive a number of vehicles. They have high torque density, high efficiency, and a wide speed range. However, the high cost of PMs is disadvantageous. This paper presents a technique for increasing the torque density by modifying the shape of the PMs and minimizing the magnet volume. The PM characteristics such as flux density, demagnetizing force, PM energy product, and the air-gap flux density are represented by a lumped magnetic equivalent circuit when the thickness and width of the PM are increased for the same volume but with different shapes. The torque, torque ripple, core loss, magnet loss, and efficiency of three interior (IPMSM) models designed by the proposed method are compared by finite element analysis. In addition, the demagnetization of the PM due to high temperature, maximum torque load angle, and an adverse field is analyzed. Finally, the analysis result is compared with that of the experiment to verify the proposed model.

Real-time finite element structural analysis in augmented reality

Acoustic emission (AE) testing and Lamb wave inspection techniques have been widely used in non-destructive testing and structural health monitoring. For thin plates, the AEs arising from structural defect development (e.g., fatigue crack propagation) propagate as Lamb waves, and Lamb wave modes can be used to provide important information about the growth and localisation of defects. However, few sensors can be used to achieve the in situ wavenumber–frequency modal decomposition of AEs. This study explores the ability of a new multi-element piezoelectric sensor array to decompose AEs excited by pencil lead breaks (PLBs) on a thin isotropic plate. In this study, AEs were generated by out-of-plane (transverse) and in-plane (longitudinal) PLBs applied at the edge of the plate, and waveforms were recorded by both the new sensor array and a commercial AE sensor. Finite element analysis (FEA) simulations of PLBs were also conducted and the results were compared with the experimental results. To identify the wave modes present, the longitudinal and transverse PLB test results recorded by the new sensor array at five different plate locations were compared with FEA simulations using the same arrangement. Two-dimensional fast Fourier Transforms were then applied to the AE wavefields. It was found that the AE modal composition was dependent on the orientation of the PLB direction. The results suggest that this new sensor array can be used to identify the AE wave modes excited by PLBs in both in-plane and out-of-plane directions.

Enhancing power density and reliability of power electronics is extremely important in power electronics applications. One of the key challenges in the design process is to design the optimum heat sink. In this paper, an algorithm is proposed to design air-cooled heat sinks using genetic algorithm (GA) and finite element analysis (FEA) simulations. While the GA generates a population of candidate heat sinks in each iteration, FEA simulations are used to evaluate the fitness function of each. The fitness function considered in this paper is the maximum junction temperature of the semiconductor devices. With an approach that prefers “survival of the fittest”, a heat sink providing better performance than the conventional heat sinks is obtained. The simulation and experimental evaluations of the optimized air-cooled heat sink are also included in the paper.

Recent developments in Generative AI enable creators to stylize 3D models based on text prompts. These methods change the 3D model geometry, which can compromise the model’s structural integrity once fabricated. We present MechStyle, a system that enables creators to stylize 3D printable models while preserving their structural integrity. MechStyle accomplishes this by augmenting the Generative AI-based stylization process with feedback from a Finite Element Analysis (FEA) simulation. As the stylization process modifies the geometry to approximate the desired style, feedback from the FEA simulation reduces modifications to regions with increased stress. We evaluate the effectiveness of FEA simulation feedback in the augmented stylization process by comparing three stylization control strategies. We also investigate the time efficiency of our approach by comparing three adaptive scheduling strategies. Finally, we demonstrate MechStyle’s user interface that allows users to generate stylized and structurally viable 3D models and provide five example applications.

Compact RBF meshless methods for photonic crystal modelling

The rotor position is a key state in the closed-loop control system of the permanent magnet synchronous motor (PMSM). Its measurement accuracy has a significant effect on steady accuracy, dynamic response, and torque ripple. The magnetoresistance (MR) sensor is widely used in the rotor position detection due to its distinct advantages, such as simple structure, high sensitivity, and strong robustness. In this paper, a solution using the giant magnetoresistance (GMR) sensor in TLE5309D chip for angle measurement is introduced, and its feasibility is verified by finite element analysis (FEA) simulation and bench test. In the simulation, two schemes different in the sensor location and the number of permanent magnet poles, are evaluated according to the higher harmonic content and field direction stability near the sensor. The experiment from 1 rpm to 1000 rpm is implemented, and the measurement results after calibration based on discrete Fourier series (DFS) show that the GMR sensor has a good performance in the test.

This paper presents a detailed analysis of stator winding inter-turn Short Circuit (ITSC) faults, taking the cross effects in the three phases of a permanent magnet synchronous motor (PMSM) into account by considering insulation degradation resistances. A PMSM with series coils in each phase winding is selected as a case study.The ITSC in one coil of each phase winding is modelled based on deformed fluxes or inductance variations caused by flux linkages, depending on the distribution of the coils in the same phase winding. Different fault ratios are investigated to evaluate different fault severity and scenarios. Therefore, three-phase faulty coils within three-phase winding analysis dynamics will constitute sixth-order assessments. The proposed faulty PMSM model is verified by a 2-D finite element analysis (FEA), showing show a good agreement between the proposed model and FEA.

The spoke type permanent magnet synchronous motor (PMSM), which is a general ferrite magnetic flux concentrated motor, has a low portion of reluctance torque at the total torque magnitude. Therefore, as a way to increase the reluctance torque, there is a double-layer spoke type PMSM that can maximize the difference in inductance between the d-axis and the q-axis. However, in the double-layer spoke type PMSM, cogging torque, torque ripple, and total harmonic distortion (THD) increase as reluctance torque is maximized, which is the main cause of vibration and noise. In this paper, a method is proposed that provides the same effect as skew without dividing stages of the permanent magnet by dividing the core of the rotor into two types so that it is easy to manufacture according to the number of stages unlike extant skew methods. Based on the method, the reduction of cogging torque and THD was verified by Finite Element Analysis (FEA).1. IntroductionThe general interior permanent magnet synchronous motor (IPMSM) uses NdFeB magnets to take advantage of the high airgap magnetic flux density. However, it had an adverse impact on cost of the motor because there are fluctuation of the cost from limited sources of heavy rare earth. Therefore, for stable supply of permanent magnets, a lot of development of a spoke type permanent magnet synchronous motor (PMSM), which is a structure capable of concentrating magnetic flux by using a ferrite magnet having a low magnetic flux density, has been conducting. The spoke type PMSM concentrates the magnetic flux density and can replace the NdFeB magnet used in the extant PMSM with a ferrite magnet.However, in general spoke type PMSM, the portion of reluctance torque is low because the difference in inductance between the d-axis and the q-axis is not large. In order to further utilize this reluctance torque, a double-layer spoke type shape that can maximize the difference in inductance between the d-axis and the q-axis can be used to bigger reluctance torque to improve motor performance.However, increasing the reluctance torque increases cogging torque, torque ripple, and total harmonic distortion (THD), which in turn leads to vibration and noise problems. Therefore, the double-layer spoke type PMSM needs a design that can reduce cogging torque and THD. As a representative method, it can be solved by applying skew to the rotor, but the conventional method of applying skew is not a good method in terms of productivity because it is difficult to manufacture because it divides the stages of the permanent magnet. For ameliorate of the limitation, the shape of the rotor core is divided and cross-stacked into stack1 and stack2 so that the permanent magnet can be inserted in one shape as the conventional shape.Therefore, the shape of the rotor core is divided into stack1 and stack2 so that the permanent magnet can be inserted in one shape as before and cross-stacked. The stack1 cuts the left part fixing the permanent magnet, and the stack2 cuts the right part fixing the permanent magnet to apply the same effect as skew. In this paper, this is expressed as a core skew, and through this core skew, the design to reduce cogging torque, torque ripple, and THD is conducted while considering productivity.2. Concept of Core SkewThe core skew represents the stacking of only cores of opposite shapes when stacking the rotor cores of the motor. The contents of the basic theory are as follows.Fig. 1 shows stack No. 1 and stack No. 2, respectively. Due to the shape of the rotor core, the phases of the airgap magnetic flux density of stack No.1 and stack No.2 are shifted, and when the two stacks are synthesized due to the phase of the shifted airgap magnetic flux density. As shown in Fig. 2, the cogging torque decreases.Also Fig. 1 shows the shape of applying core skew to the conventional model by intersecting and stacking stack No. 1 and stack No. 2 .Through this core skew structure, research to reduce cogging torque, torque ripple, and THD is conducted. Most of the original skew research is conducted in 3D FEA, but since 3D FEA requires a lot of time, first calculate the optimal model using 2D FEA and then proceed with 3D FEA according to the number of steps considering 3D effect. The final result will be revealed on full paper.AcknowledgmentThis work was supported by the Technology Innovation Program (No. 20011495) funded By the Ministry of Trade, Industry & Energy(MOTIE, Korea), in part by the National Research Foundation of Korea (NRF) Grant funded by the Korean government. (No. 2020R1A2C1013724). **