The slender shape of the driving machine leads to a low rigidity and large axial thermal elongation of the motorized spindle, which deteriorates the machining precision. To solve these problems and pursue a more compact size, this paper investigates the feasibility of using a tooth-coil permanent magnet synchronous machine in a high-speed spindle, replacing the original motor that has the conventional distributed winding. Comprehensive performance and behavior of machines with distributed and tooth-coil windings are comparatively analyzed, in terms of the essential torque ripples, winding inductances, electromagnetic losses, rotor integrity, and heat dissipation of the spindle. Thorough numerical simulation results indicate that the newly designed tooth-coil winding solution shows significant advantages over the original design, regarding high rotor rigidity, low torque ripples, reduced electromagnetic losses, and reduced shaft thermal elongation. Prototypes and test setups for the high-speed tooth-coil machine are built, where preliminary measurements are carried out to validate the analysis results and system design.

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In this article, an efficient multi-objective optimization strategy for the Halbach array permanent magnet synchronous machine (PMSM) is developed by taking into consideration the nonlinear B-H behavior of soft magnetic materials. Based on the harmonic modeling (HM) technology, the electromagnetic performances (EPs) of the Halbach array PMSM can be computed. To specifically model the local magnetic saturation, the stator teeth are separated into several annular layers, and each tooth is further divided into several regions along the tangential direction. Then, the parameters of the Halbach array PMSM are optimized utilizing combined nonlinear semi-analytical model (SAM) and non-dominated sorting genetic algorithm II (NSGA-II). To validate the effectiveness and accuracy of the developed optimization scheme, a Halbach array prototype is then manufactured in accordance with the optimization results. The multi-objective rapid optimization strategy developed in this article, which includes but is not limited to Halbach array permanent magnet (PM) machines, serves as a reference for the design and optimization of various PM machines.

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This article proposes a compensation method of position estimation error for high-speed surface-mounted permanent magnet synchronous motors based on robust inductance estimation. The proposed method relies on the variation of the estimated δ-axis back back-electromotive force when a small current is injected into the γ axis. The inductance estimation error is limited within pm !5% when the nominal resistance and inductance vary bf pm 30% of their real values. With the estimated inductance, the position estimation error can be well compensated. Compared with the conventional current-injection method, the proposed method has enhanced robustness against the system noises. Benefiting from this, it is effective to estimate the inductance with a small injected current ( bf 0.5% of the rated current), where the conventional methods fail. Finally, the effectiveness of the proposed method is validated by simulation and experiment results on a 100 kr/min (1.67 kHz) high-speed permanent magnet synchronous machines accurately with 10-kHz sampling frequency.

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This letter proposes a general single-sensor active damping framework for LCL-equipped high-speed permanent magnet synchronous machines. By the proposed method, arbitrary damping assignment and stability for the LCL resonance within the Nyquist frequency are achieved with only the inverter-current feedback or motor-current feedback. Moreover, the simplified analytical expression between the physical parameters and the damping performance enables automatic tuning for different drive systems.@en

In this article, a novel dynamic-decoupled active damping current controller is proposed for an LCL-equipped high-speed permanent magnet synchronous machine. Compared with the conventional stationary current-control method for the LCL-type system, the proposed method is established in the synchronous rotating frame for improving the current transient performance. When taking the controller into the synchronous coordinate, there are two following challenges: first, the synchronous resonance frequency varying in a wide range because of the synchronous coordinate transformation, and second, eliminating the coupling between the dq coordinate. To address these issues, an improved synchronous capacitor-current-feedback active damping method is designed based on arbitrary pole assignment and is significantly effective for the LCL resonance within the Nyquist frequency. Moreover, a novel dynamic-decoupled motor-current controller is proposed to eliminate the coupling between the dq-axis motor current. The gain selection method is discussed to acquire sufficient phase margin and gain margin. Finally, the effectiveness of the proposed method is verified by driving the tested motor to 72 kr/min.

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This article proposes a discrete-time dynamic-decoupled current controller for an LCL-equipped high-speed permanent magnet synchronous machine with only the motor currents measured. The controller is designed in the synchronous coordinate based on a complex z-domain transfer function. The main contribution of the proposed current controller is the robust dynamic decoupling performance to achieve better transient behavior. Moreover, an effective coefficient selection method is developed to acquire sufficient phase margin and gain margin, even with the system parameters varying ± 50%. Additionally, the stable region of the LCL resonance with the proposed method is discussed. Finally, the effectiveness of the proposed method is verified by driving the tested motor to 100 kr/min.

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The zero-sequence inductance is a vital parameter for the performance analysis of permanent magnet machines, especially under faulty conditions or in open-winding machines. This paper focuses on the zero-sequence inductance calculation of fractional slot concentrated winding permanent magnet synchronous machines (FSCW-PMSMs), and reveals the variation regularity of this kind of inductance and its various components against pole/slot combinations, using the winding function and finite element methods. Moreover, based on the analysis of 36-slot FSCW-PMSMs with different pole numbers, the dependency of each inductance component on the pole/slot combination is discussed in detail. To validate the regularities, experimental measurements of zero-sequence inductance are implemented in the prototype of the 36-slot stator. It is found that the regularities are independent of specific slot or pole numbers, which provide guidelines for optimum pole/slot combination selection, to mitigate the problems caused by zero-sequence current.

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This article presents a new rotor design to reduce rotor eddy current loss of a high-speed permanent magnet synchronous machine for flywheel energy storage system. Instead of using common nonmagnetic sleeves, the new rotor incorporates permeable retaining sleeves (PRSs) to fix permanent magnets on the rotor hub. The PRSs are made of permalloy that features high permeability and high electrical conductivity. Thus, skin depths for asynchronous harmonics are extremely small. On the other hand, the PRSs are electrically insulated along the circumferential direction. Owing to these two reasons, rotor eddy current loss at open circuit decreases by 64.2% without sacrificing torque output, compared with an original rotor with nonmagnetic retaining sleeve. In addition, thermal and structural finite element analyses are performed to calculate rotor temperature distribution and evaluate the structural integrity of the new rotor. Rotor eddy current loss reduction benefits lowering rotor temperature rise. Prototype machine with the new rotor is fabricated, and preliminary tests are carried out to confirm the analysis results.

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This paper presents a new rotor design with assembled permeable retaining sleeve (APRS) to improve performances of a high speed permanent magnet synchronous machine (PMSM). The APRS consists of equal number of permeable and nonmagnetic parts, which are alternately arranged and assembled together circumferentially via keyways. Electromagnetic and mechanical characteristics of the rotor applied to a high speed flywheel PMSM are analyzed using finite element method. Machine performances are compared to an original design with commonly used rotor structure. It shows that phase inductance of the high speed machine increases dramatically due to smaller effective air gap, which may benefit suppressing inverter current harmonics. Also, permanent magnet usage reduces by 9.4 % to obtain identical back electromotive force and torque constant. In addition, a smaller skin depth owing to high-permeability material and the circumferential segmentation of the retaining sleeve effectively reduce rotor eddy current. Associated loss decreases by 40.7 % under open-circuit condition. A prototype rotor is fabricated and preliminary experimental tests are performed to confirm the analysis results.@en

Fractional slot concentrated winding machines (FSCWMs) with the low operation speed and large diameter usually have a large number of poles and slots; thus, numerous pole/slot combinations are feasible. The common practice to choose pole/slot combinations by multiplying the basic combinations may neglect some competitive candidates. Taking 36-slot FSCWMs as examples, this paper investigates the influence of pole numbers on torque density and flux-weakening ability, the two most vital performances of wheel-hub machine. It is shown that the machines with pole number slightly less than the slot number have the highest torque densities. Each component of synchronous inductance is separately analyzed, and its variation against pole numbers shows obvious regularity. Machines with pole numbers larger than the slot numbers have an excellent flux-weakening ability due to the large inductance and small permanent magnet flux linkage. The measurements together with the finite element analysis results confirm that the stator leakage inductance contributes the most to the superior flux-weakening ability. The identical analysis is also performed on 54-slot and 81-slot FSCWMs, with similar regularities observed.

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