L1 Intro

Industrial Electrical Engineering and Automation
L1 Introduction
Design
of electrical machines
Avo Reinap
Industrial Electrical Engineering and
Automation, LTH
Lund University, Sweden
Power of understanding
energy conversion
material properties
machine construction
Creativity
Power of imagination
integration
production
Machine Design
Avo R
Design of Electrical Machines
Design process
EIEN20 Design of Electrical Machines, IEA, 2016
Avo R
Component and system thinking

Performance and controllability
Cost and manufacturability
Loading and reliability
Dimensioning and modelling

Multi-dimensional multi-physics
Supply, electronics, application, drive cycle,
Optimizing
Objective vs design parameters
Visibility vs sensitivity analysis
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L1 Introduction
Need for electrical actuator

Electrical machine design at Lund
Material and
production
development
Machine design
and evaluation
Direct air-cooled
windings
Unconventional
actuators
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Electrified traction drive

Integrated pump and fan drives
Wind generators
Mechatronics, robotics
Maintenance
As long we going to have electricity there is
always an electrical machine around
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L1: Introduction
Course overview
Machine construction overview

Lund University, Sweden
Course (?)
Design of electrical
machines (EIEN20)
Construction + production
Energy conversion
processes + analysis tools
Materials + properties
From component
towards application and
system
Avo R
L1 Introduction
About the course

Other courses (@IEA)

Power electronics (and
electrical drives)
(EIEN15)
Hybrid Vehicle Drives
(MIE100)
Wind Power Systems
(EIEN10)
Mechatronics: Industrial
Product Design (EIEN01)
Avo R
Assessment
Approved design report
grants the grade 3. For
higher grade a written
exam is required.
Learning process
16x2 lectures (LP3)
5 weekly home
assignments (LP3)
Course project (LP4)
Avo R
Motivation (U): 7.5

credits + knowledge (as
bonus)
Borrowed from Ice Age I
Requirements (R):
32 hours of lectures
>50 hours of project
>90 hours of self-studies
Easiness (I): I=U/R

Tools: own pc with
Resources: http://iea.lth.se/emk/
Avo R
10
Motivation
11
About the course
Employed by being creative engineering

challenges to think creatively
Improve your power of understanding and
power of imagination
Actual trends integrability, manufacturability,
sustainability,
Design challenges new technology, new
materials, computational power,
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12
L1 Introduction
Course Plan
Course goal
objective of this course is to gain experience
covering the overall design process: design,
actual construction and testing of an
electromagnetic device
Understand the electromechanical design
behind the classical electromagnetic devices
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13
Preliminary course plan for

lectures and project
workshops
Every second lecture an
assignment is given that
suppose to be solved and
reported within 2 weeks
Project assignments and
groups are formed during LP3
and solved LP4
Article and presentation is
expected from the project
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Previous projects
Introduction to computational techniques and

software optimization of a transformer
Magnetic analysis and characteristics of
transformer
Thermal analysis of PMSM
Magnetic analysis and characteristics of PMSM
Machine types, models and characteristics
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14
15
Home assignments
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16
L1 Introduction
What is electrical machine,

where do I find it?
Design Task 2016

Traction machines
Induction
Reluctance
PM assisted
Components for ESS

application
HV Chokes
HV Transformer
One of the electrical machines

that you study/control at
power electronics
Your own interest
Machine
Energy converter
used to perform some

useful work or to provide
transportation
Generation
Transformation
Consumption
ELECTROMAGNETISM
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17
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Cause-effect, action-reaction
Understanding observation (physics) expression
(maths) creation (innovation)
Classification based on magnet origin (?)

Excitation vs armature
Understanding energy conversion

Thermodynamic arguments (conservation of
energy)
Field analysis (Maxwell stress tensor)
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18
Prior/Parallel knowledge
Electrical machine in a nutshell
19
Ohms Law
1 / 3
Cause of electromagnetic force (torque)
Magnetic flux vs.
electromotive force,
electric current vs.
magnetomotive force
Maxwells equations
Power electronic control
Avo R
20
L1 Introduction
What is design for electromagnetics,

where to start?
Construction, calculation and dimensioning of

electromechanical devices
d
g on
Goo standin ic
r
t
unde omagne sion
r
r
t
elec y conve
g
Computer aided design

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Developed knowledge
Parametric change
Rough sizing
Operation point sweep
Sensitivity study
2D FE electromagnetics
2D FE heat transfer
Temperature distribution
2D FE fluid flow
u t u u
p 2u F
Cooling power q=uc
c cu
k q
C-coals
Calculations
completed?
Early estimation of machine pe rformance vs manufacturability
Peak operation, visibility vs vulnerability, subjective analysis of production
Structure modeling (3D)
Draw complete component or a structure in the machine,
3D FE multiphysics
CAD for prototype
Voltage across terminals

cooling conditions along
cooling surfaces
etc
Technical drawings
Engineering drawings
for production and
assembling
mathematical model of
the device
modelling
Electromagnetic
techniques
measurement
computer simulation
theory
design
experimental data
computed data
theoretical prediction
Thermal design
Manufacturing
tolerances
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comparison
comparison
verification of the
model by simulation
verification of the
model by theory
22
Analyze, Synthesize, Design
V-Goals
Geometric modeling (2D)
Visible solution?
Draw cross-sections, model initialization, analytic/empiric models, realisation visibility
1 B A
J j A V
Heating power q=J2
real device
Production
Parameterization
Geometry (W, H, proportions)
Material properties (coil, core, )
Loads (duty, current, flow)
Material
engineering
Cooling
Design process:
from simple to more complex
Materials ability and formability
Coils and conceivable ideas
Manufacturability
Functionality
techniques
21
Topology generation
Reliability
R-Goals
Realizable
solution?
Theoretical specification of machine performance and production
Detailed construction vs functionality estimation, production methods, cost, tolerances
Assembly modeling (2D and 3D)
Complete evaluation of the design vs detailed study on manufacturing issues
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23
Avo R
24
L1 Introduction
(Controlled)
Geometry
Materials
electric power
Main parts
Actuator
Motion
Force
Electro-mechanical energy converter

Electromagnetism intermediates energy conversion
Electric side: DC, AC, pulsed
Mechanic side: linear, rotary motion
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25
Avo R
26
Magnetic interaction vs attraction
The traditional five

senses of a human being
exclude ability to achieve
a direct response from
magnetic field that
intermediates the
electromechanical
energy conversion in an
electrical machines
Soft magnetic core to provide an easy path

for the flux in order to facilitate flux linkage or
magnetic coupling between sources and
loads
27
The energy conversion

between the electric and
mechanic energy takes
place in presence of the
magnetic field
Permanent magnet to produce invariable

magnetic flux
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Introduction to magnetism
Before we control or
construct an electrical
machine we play with
permanent magnets
Coil or winding to produce variable magnetic

flux
N40 NdFeB magnets
5x20x20 mm
F
M
Attraction or repulsion ca
40 N
M F
Shear ca 27 N including ca
7 N attraction/repulsion
F
M
F
F
M
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Attraction ca 8 N
Shear 4 N attraction 3 N
28
L1 Introduction
Maxwells Stress Tensor
Force components
Bn
Magnetic force on a
surface according to
magnetic pressure
1
tn
Bn2 Bt2
2 0
B B
tt n t
tn
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Bt t t
29
Attraction between ferrous material and exciting

magnetic fields due to permanent magnet(s) or coil(s)
resulting in reluctance force/torque
Interaction between electromagnet(s) or/and
permanent magnet(s) cause magnetic force/torque
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A+
A-
A+
I
Magnetic field around

current carrying coil
A+
I
F
M
A+
A+
A-
A-
I
F
A+
A-
F
M
Avo R
The principle of operation

of any rotating electric
motor is derived from
Lorenz force.
F
A+
F
A-
30
How machines work
Replace PM by EM
NI=Hl= ca 5kA
Electromagnet vs PM
Electrical machines exploit magnetic interaction

Two magnets one in stator the other with the rotor
displacement of these two magnets will create a torque
The magnets can be created directly or induced
The bigger the torque the bigger the machine
No new topology
The principles of machine design are more than 100 years old
M
31
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32
L1 Introduction
Control of machines
Types of machines
According to excitation
EM and PM
Reluctance and inductance
According to supply
According to geometrical arrangement
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33
Field oriented control

Maximise torque product
Consider the limits
And keep losses down
The goal for the design is

quite the same as for the
control
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Torque is proportional to size and weight

Power is proportional to torque and speed
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34
Machine=Generator&Motor
Can you figure out
when the animation
machine operates as
a generator and
when as a motor?
Size of machines
35
T
w
Avo R
Pe
iu=
=
w
=T
Pm
36
L1 Introduction
Home exercise
1. Find and download FEMM,
start using it!
2. Find and download
Notepad++ , start using it!
3. Experiment with femm
1. Learn to draw and define
model
A+
A+
I
A-
2. Field around conductor and

skin depth
3. Forces between conductors
and proximity effect
Avo R
37
10

L1 Intro

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Industrial Electrical Engineering and Automation

Design of Electrical Machines

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2016

Industrial Electrical Engineering and Automation

Industrial Electrical Engineering and Automation

Component and system thinking

Dimensioning and modelling

Design of Electrical Machines

Need for electrical actuator

Industrial Electrical Engineering and Automation

Electrical machine design at Lund

Design of Electrical Machines

Electrified traction drive

Design of Electrical Machines

Industrial Electrical Engineering and Automation

EIEN20 Design of Electrical Machines, IEA, 2016

Industrial Electrical Engineering and Automation

Design of Electrical Machines

About the course

Industrial Electrical Engineering and Automation

Other courses (@IEA)

Design of Electrical Machines

Motivation (U): 7.5

Borrowed from Ice Age I

Easiness (I): I=U/R

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2016

Industrial Electrical Engineering and Automation

Industrial Electrical Engineering and Automation

About the course

Design of Electrical Machines

Employed by being creative engineering

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Design of Electrical Machines

Preliminary course plan for

Introduction to computational techniques and

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2016

Industrial Electrical Engineering and Automation

Industrial Electrical Engineering and Automation

Design of Electrical Machines

Design of Electrical Machines

What is electrical machine,

Industrial Electrical Engineering and Automation

Design Task 2016

Components for ESS

One of the electrical machines

used to perform some

Design of Electrical Machines

Classification based on magnet origin (?)

Understanding energy conversion

Design of Electrical Machines

Industrial Electrical Engineering and Automation

Electrical machine in a nutshell

Design of Electrical Machines

EIEN20 Design of Electrical Machines, IEA, 2016

Design of Electrical Machines

What is design for electromagnetics,

Construction, calculation and dimensioning of

Computer aided design

Design of Electrical Machines