航空飞行器用300kW高速永磁同步电机优化设计

doi:10.12382/bgxb.2023.0049

摘要/Abstract

摘要：

航空飞行器用高速永磁同步电机损耗密度高、散热条件差,脉宽调制电压供电产生的损耗可能会导致显著的温升,加剧Halbach磁体的退磁风险,影响电机的安全运行。针对上述问题,提出基于Nelder-Mead法的高速永磁同步电机多目标优化设计方法,以电机损耗和温升为优化目标,使用场路耦合有限元分析法和解析法计算电机在T型三电平变流器供电下的损耗,进而计算电机温升。根据寻优算法搜索最优设计区域,获得优化设计方案。分析Halbach磁体内的磁密分布和涡流损耗,对磁体进行优化设计,从而抑制退磁和损耗。设计并制造一台300kW、30000r/min高速永磁同步电机,仿真和实验结果表明,新提出的设计方法能够快速实现多目标寻优,并有效抑制退磁。

关键词: 航空飞行器, 高速永磁同步电机, Halbach磁体, Nelder-Mead法, 多目标优化, 场路耦合

Abstract:

The temperature rise of the high-speed permanent magnet synchronous machine (PMSM) for aviation aircraft supplied by PWM voltage might be significant because of its high loss density and poor heat dissipation condition. What’s worse, high temperature increases the demagnetization risk of Halbach-array magnets, which impairs the reliability of operation. In allusion to above problems, a multi-objective optimization method of high-speed PMSM based on Nelder-Mead algorithm is proposed. The loss and temperature rise are selected as optimization objectives. Field-circuit coupled finite element analysis method is used to calculate the loss of the machine powered by T-type three-level converter, thus calculating the temperature rise. The optimal design areas are searched by using the optimization algorithm, and the optimal solution is achieved. The flux density distribution and eddy current loss in the Halbach-array magnet are analyzed, and then the design of magnets is optimized to suppress eddy current loss and demagnetization. A 300kW, 30000r/min high-speed PMSM was designed and manufactured. Simulated and experimental results show that the proposed design method could realize multi-objective optimization and suppress demagnetization effectively.

Key words: aviation aircraft, high-speed PMSM, Halbach-array magnet, Nelder-Mead method, multi-objective optimization, field-circuit coupling

中图分类号:

TM351

魏嘉麟, 王又珑, 温旭辉, 陈晨, 李文善. 航空飞行器用300kW高速永磁同步电机优化设计[J]. 兵工学报, 2024, 45(5): 1363-1373.

WEI Jialin, WANG Youlong, WEN Xuhui, CHEN Chen, LI Wenshan. Optimization Design of a 300kW High-speed Permanent Magnet Synchronous Machine for Aviation Aircraft[J]. Acta Armamentarii, 2024, 45(5): 1363-1373.

图/表 21

表1 PMSM技术指标

Table 1 Technical specifications of high-speed PMSM

参数	数值
额定功率/kW	300
额定转速/(r·min^-1)	30000
额定电压/V	380
相数	3
额定效率/%	≥94
直流电压/V	540

图1 90°-Halbach阵列磁体

Fig.1 90°-Halbach array magnet

表2 优化变量和约束条件

Table 2 Optimization variables and constraints

类型	参数	数值范围
	定子外径R_s/mm	230
约束条件	轴向有效长度L_e/mm	140
	齿部磁密/T	≤1.5
	轭部磁密/T	≤1.5
优化变量	气隙磁密B_m/T	0.40~0.85
	裂比	0.40~0.75

图2 场路耦合仿真原理

Fig.2 Principle of field-circuit coupled simulation

图3 电机损耗和温升随气隙磁密变化趋势

Fig.3 Changes of loss and temperature with flux density

图4 电机损耗和温升随裂比变化趋势

Fig.4 Changes of loss and temperature with split ratio

图5 二维Nelder-Mead算法流程

Fig.5 Flowchart of 2D Nelder-Mead algorithm

图6 基于Nelder-Mead优化过程

Fig.6 Process of Nelder-Mead-based optimization

表3 电机损耗和温度

Table 3 Loss and temperature of PMSM

方案	损耗/kW	定子最高温度/℃
X₁(0.5,0.45T)	>8.00	>200
X₂(0.6,0.6T)	6.25	156.7
X₃(0.7,0.5T)	7.45	174.8
X₅(0.725,0.6T)	7.91	186.6
X₆(0.7,0.583T)	7.34	183.4
X₇(0.6,0.7T)	6.09
X₈(0.575,0.75T)	6.01
X₉(0.53,0.72T)	5.84
X₁₀(0.575,0.67T)	5.79
X₁₁(0.53,0.64T)	5.76
Y₁(0.575,0.5T)	6.28	165.5
Y₂(0.475,0.6T)	6.77	173.8
Y₃(0.53,0.575T)	6.23	162.7
Y₄(0.555,0.675T)	5.76	153.4
X_final(0.54,0.68T)	5.80	154.1

图7 电机内部磁位线分布

Fig.7 Distribution of magnetic flux lines in PMSM

图8 低磁密区域的电枢反应磁密

Fig.8 Armature reaction magnetic flux density in low flux density parts of the magnet

图9 电枢反应退磁

Fig.9 Demagnetization caused by armature reaction

图10 磁化方式

Fig.10 Magnetization patterns

图11 分段磁体涡流三维有限元仿真

Fig.11 3D finite element simulation of eddy current in segmented magnets

表4 磁体涡流损耗计算结果

Table 4 Calculated results of eddy current losses in magnets

变流器及其频率	轴向长度/mm	涡流损耗/W
	5	200.8
两电平,10kHz	10	378.9
	15	457.4
	20	495.3
	5	156.8
两电平,16kHz	10	259.2
	15	290.4
	20	303.6
	5	79.5
三电平,10kHz	10	139.6
	15	162.7
	20	174.7

图12 PMSM样机及其实验平台

Fig.12 Prototype of high-speed PMSM and itstest bench

图13 样机空载反电势实测波形

Fig.13 Measured no-load back-EMF waveform

图14 空载反电动势随转速变化曲线

Fig.14 No-load back-EMF vs. rotating speed

表5 样机实验数据

Table 5 Experimental results of the prototype

参数	转速/(r·min^-1)
参数	25000	30000
转矩/(N·m)	99.5	105.8
发电功率/kW	253.0	321.0
相电流有效值/A	505.0	550.0
负载功率/kW	246.0	312.0
电机效率/%	97.1	96.6
系统效率/%	94.5	93.9

图15 样机25000r/min线电压和三相电流实验波形

Fig.15 Experimental results of the prototype at 25000r/min

图16 功率实验前后空载反电势波形

Fig.16 No-load back-EMF waveforms measured before and after full load experiments

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