Optimization Design of a 300kW High-speed Permanent Magnet Synchronous Machine for Aviation Aircraft

doi:10.12382/bgxb.2023.0049

Abstract

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

CLC Number:

TM351

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.

Figures/Tables 21

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

Fig.1 90°-Halbach array magnet

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

Fig.2 Principle of field-circuit coupled simulation

Fig.3 Changes of loss and temperature with flux density

Fig.4 Changes of loss and temperature with split ratio

Fig.5 Flowchart of 2D Nelder-Mead algorithm

Fig.6 Process of Nelder-Mead-based optimization

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

Fig.7 Distribution of magnetic flux lines in PMSM

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

Fig.9 Demagnetization caused by armature reaction

Fig.10 Magnetization patterns

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

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

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

Fig.13 Measured no-load back-EMF waveform

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

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

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

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

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