IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO.
B, OCTOBER 2019
Finite Element Analysis and Experimental Study of
Computationally Efficient Lumped Parameter
Thermal Model for Field Excited Linear Flux
Switching Machine
Noman Ullah, Member, IEEE, Faisal Khan, Member, IEEE, Abdul Basit, Osama Waheed, Amir Khan, Ali Usman,
and Wasiq Ullah,
Abstract—In recent years, Double Sided Field Excited Linear
Flux Switching Machine with Segmented Secondary (DSFELF-
SMSS) have been the object of increasing attention for long stroke
applications due to; (a) elimination of mechanical conversion sys-
tem when compared with corresponding rotary designs, (b) low
manufacturing cost and variable air-gap magnetic flux density
when compared with Permanent Magnet Linear Flux Switching
Machines (PMLFSMs), (c) segmented secondary reduces volume
and cost of long stator when compared with uniform secondary,
and (d) double sided design diminishes high normal force prob-
lem when compared with single sided linear designs. However,
suitable thermal analysis model is important to monitor tem-
perature levels, improve their performance by varying current
loadings, and avoid undue damage. In this paper, results of
proposed computationally efficient Lumped Parameter Thermal
Model (LPTM) based on first order differential equations are
verified by 3-D Thermal Finite Element Analysis (3DTFEA) for
novel DSFELFSMSS, followed by a large range of experimental
validations utilizing thermographic analysis. Armature and field
winding copper and core iron losses are considered as heat gen-
eration sources, all three heat flow mechanisms i.e. conduction,
convection, and radiation are accounted. Firstly, thermal analysis
results up to maximum bearing temperature of Class B insulation
(120◦ C) under 100% duty cycle are investigated in order to define
hottest part and continuous operation duty time of the proposed
machine. Secondly, 75% and 50% duty cycles solutions for the
hottest part of proposed machine are investigated by LPTM
and 3DTFEA, validated by full scale prototype results. Authors
are confident to recommend proposed approach for applications
where fast and efficient modelling is necessary, as the proposed
approach takes few seconds to solve for temperature distribution.
Index Terms—Field excited flux switching machine, finite
element analysis, linear motor, lumped parameter thermal model,
thermal network.
I. I NTRODUCTION
EOMETRIC structure of Double Sided Field Excited
G Linear Flux Switching Machine with Segmented Sec-
ondary (DSFELFSMSS) possesses an inherent property of
Noman Ullah, Faisal Khan, Osama Waheed, Amir Khan, Ali Usman,
and Wasiq Ullah are with the Department of Electrical and Computer
Engineering, COMSATS University Islamabad, Abbottabad Campus, 22060
Pakistan e-mail: (nomanullah@cuiatd.edu.pk; faisalkhan@cuiatd.edu.pk;
osamawaheed14@hotmail.com; amirkhan9678.ak@gmail.com;
aliusmandar2@gmail.com; and wasiqullah1@gmail.com).
Abdul Basit is with Department of Electrical Energy System Engineering,
University of Engineering and Technology, Peshawar, 25000 Pakistan e-mail:
(abdul.basit@uetpeshawar.edu.pk).
Manuscript received October 12, 2019; revised 0000000.
1
confining all excitation sources (AC+FE) to short moving pri-
mary, leaving secondary part completely passive. This unique
feature allows a better temperature control [1] and machine
can be excited to high current densities for higher average
thrust force [2]. Higher current densities increase copper losses
that ultimately results in temperature rise of electrical machine
components. Excess temperature levels may cause deformation
of structure and can damage inter turn insulation resulting in
incipient faults and also insulation medium installed between
winding and core [3].
For safe and appropriate thrust force generation operation,
two possible solutions can be; (a) special cooling arrangements
influencing cost and volume of electrical machine, and (b)
limit electrical and magnetic loadings after detailed thermal
analysis of machine’s performance designed for specific ap-
plication [4]. The latter is preferred to reduce manufacturing
cost and avoid additional cooling facilities failures.
Thermal and electromagnetic phenomena are two different
aspects of electrical machine design. In literature thermal
models of machines are not addressed extensively compared
to its electromagnetic designs. Thermal modelling plays an
important role regarding operation limits and choice of insu-
lation class [5]. Thermal modelling results can be obtained by;
(a) numerical methods e.g. Finite Element (FE) Analysis and
Computational Fluid Dynamics (CFD) [6], and (b) Lumped
Parameter (LP) [7] by utilizing analogy between thermal
and electrical circuits [8]. Although FE Analysis and CFD
are universally accepted accurate techniques. However, re-
quirement regarding model formation and computational time,
compatible hardware, and high license cost compel designers
to adopt alternate modelling techniques [9].
In the limited literature regarding thermal analysis of flux
switching machines, thermal equivalent circuit model pre-
dicting transient and steady state performance of PM flux
switching machine using Schwarz-Christoffel mapping is de-
veloped and presented in [10]. However, the model is for
rotary machines and may not predict accurate results for linear
machine topology. Reasons behind poor documentation for
thermal analysis of linear flux switching machines are; (a)
special open structure, (b) large modelling area, and complex
working patterns. Furthermore, LP Thermal Model (LPTM)
for linear machines cannot be created by using commercial
software, whereas it can be done for rotating machines by
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 2

TABLE I II. P ROTOTYPE M OTOR S TRUCTURE AND

D ESIGN PARAMETERS OF DSFELFSMSS E LECTROMAGNETIC P ERFORMANCE
Symbol Parameter (Unit) Value A. Design Methodology
τm Mover pole pitch (mm) 17.5
τs Stator pole pitch (mm) 30 While considering applications’ requirements, proposed DS-
hs Stator height (mm) 21 FELFSMSS having two unique inherent properties i.e. field
hm Mover height (mm) 89 coils to replace PMs and segmented secondary in place of long
wt Mover tooth width (mm) 9.5
wslot Slot width (mm) 8 uniform secondary helps to reduce overall manufacturing cost
hslot Slot height (mm) 43.75 with additional benefits of LFSMs defined earlier in Section ??
hy Mover yoke height (mm) 1.5 is designed and simulated utilizing JMAG Commercial FEA
g Air-gap (mm) 1.5
wsst Stator segment tip width (mm) 26.25 Package v. 18 (as shown in Figure 1). Design of proposed
wssb Stator segment base width (mm) 2 machine is complementary in nature and following equations
hss Stator segment height (mm) 10.5 are utilized to determine number of mover teeth (Nmt ),
L Stack length (mm) (z-direction) 100
Aslot Slot area (mm2 ) 350 number of DC coil pairs (NDC ), number of AC coil pairs
v Mover velocity (m/s) 0.5 (NAC ), and stator to mover pole pitch (τs /τm ) [14]:
NAC Number of AC coil turns 40
NDC Number of DC coil turns 40 Nmt = 4jm + 1 (1)
kf AC and DC winding fill factor 0.5
IAC AC current (A) 3.5 NDC = 2jm + 1 (2)
JAC AC current density (A/mm2 ) 0.55 NAC = 2jm (3)
IAC DC current (A) 5
JDC DC current density (A/mm2 ) 0.80 τs /τm = 4jm/(2jm + 2) (4)
hwm Whole machine height (mm) 111
S.R Split ratio 0.20 Where m is number of phases, j is a positive integer and
represents each AC phase winding pair repetition in the
machine, τs is the stator pole pitch, and τm is mover pole
pitch. DSFELFSMSS having single side specifications of
utilizing geometric parameters and material properties [11].
m = 3, j = 2, Nmt = 25, NDC = 13, and NAC = 12 leading
Although numerous LP modelling methodologies [11-13] for
to τs /τm = 24/14 is investigated in this paper. Additional
other classes of linear electrical machines are proposed and
teeth on all four corners are attached to balance magnetic
validated in literature. However, no thermal modelling refer-
circuit. Design variables and parameters are shown in Figure
ence regarding linear field excited flux switching machine is
2 and Table I, respectively.
available till date.
Authors of [11] performed thermal resistance-network anal-
ysis (TRA) for PM linear motor and validated its results by B. Operating Principle
prototype. However, the model is for water cooled single sided Operating principle of DSFELFSMSS is based on no-load
linear machine with elimination of heat transfer by radiation. flux (only due to DC excitation) flow directions obtained by
Linear generator, to be used in marine environment is also 2D planar Finite Element (FE) Analysis. As the proposed
investigated by LPTM in [12], however the model is for tubular machine shows bi-polar flux linkage, Figure 3 is utilized to
PM machine and requires measurement based model calibra- explore no-load flux paths and explain operating principle. For
tions. Authors of [13] developed one dimensional transient simplicity, two DC coils effect is accounted and flux linkage
temperature field model for linear induction motor to study within corresponding AC coil is investigated. Mover tooth
main factors that impact stator temperature decay rate. Con- with AC winding is termed as TAC , DC winding tooth on
sequently, thermal analytical model with sufficient accuracy, the left side of TAC is referred as TDC1 and its flux lines are
less convergence time durations, and free from measurement presented with red colour, whereas DC coil tooth on the right
based model calibrations is essential need of present time. In side of TAC is referred as TDC2 and its flux lines are shown
this paper, computationally efficient 1-D Lumped Parameter in green colour. It is understood that AC coil will only show
Thermal Model (1DLPTM) based on first order differential flux linkage when DC generated flux flows through TAC .
equations for novel DSFELFSMSS is proposed and validated Considering motion of short mover in x-direction, when
by 3-D thermal Finite Element Analysis (3DTFEA) and exper- relative position of stator segment is aligned with TAC and
imental results. Design variables and methodology, operating TDC2 , electrical angle θe is assumed as zero degree. DC flux
principle, and electromagnetic performance of proposed DS- flow for the particular position is shown in Figure 3a and is
FELFSMSS utilizing JMAG Commercial FEA Package v.18 considered as the point where positive maximum magnitude
is presented in Section II. Computationally efficient 1DLPTM of Coil A flux linkage occurs. After quarter of electrical cycle
of proposed machine, its solution methodology and its 3DTFE movement (θe = 90◦ ), DC flux generated in both TDC1 and
Analysis is done in Section III. Full scale hardware validation TDC2 completed its circle without flowing through TAC , as
using thermographic analysis utilizing ”Fluke VT04 Visual IR shown in Figure 3b. Hence magnitude of Coil A flux linkage
Thermometer” for duty cycles of 100%, 75%, and 50% limited is zero. When movement of half electrical cycle occurs i.e.
by Class B insulation maximum bearing temperature is done θe = 180◦ , stator segment provides short path for DC flux
in Section IV. Finally, some conclusions are drawn in Section (generated in TDC1 ) to flow through TAC , as shown in Figure
V. 3c. It can be clearly seen that direction of DC flux through
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 3

TABLE II
Mover K EY P ERFORMANCE I NDICATORS OF DSFELFSMSS
Additional Key Performance Indicator (Unit) Value
Teeth
F lux − Linkagep−p (mW b) 96.08
Detent − F orcep−p (N ) 6.74
C4 T hrust − F orceAvg (N ) 19.91
N ormal − F orcep−p (N ) 0.02
B4

A4
(F lux − Linkagep−p ), peak-to-peak detent force (Detent −
C3
DC
Windings
F orcep−p ), average thrust force (T hrust − F orceAvg ), peak-
to-peak normal force (N ormal − F orcep−p ), and their cor-
B3 responding waveforms are considered for detailed analysis of
proposed machine [15]. FE Analysis results are tabulated in
A3
Table II, whereas waveforms are presented in Figure 5-8.
C2
Left Right
Stator Stator III. T HERMAL M ODELLING
B2
A. 1DLPT Model
A2
AC
Thermal resistances and heat transfer coefficients are two
Windings important parameters to be calculated for thermal modelling
C1
[16]. All three mediums of heat transfer transfer i.e. conduc-
B1
tion, convection, and radiation are accounted to obtain accurate
x results. Machine parts having direct contact through solid
z A1 material such as winding and core separated by epoxy and
insulation sheet is modelled as conduction. Heat transferred
y Additional to ambient from machine surfaces is studied as convection.
Teeth
Heat transfer in between two metal surfaces through air-gap
is considered as radiation. Nine nodes with twenty one thermal
Fig. 1. 2D cross section of DSFELFSMSS resistances are defined for proposed thermal model (as shown
in Figure 9 and 10). In order to simplify LPTM, following
assumptions are made;
g 1) Heat flow is assumed in the yz-direction because ma-
wssb

chine’s structure is periodic in nature and same heat

hy wt generation in the x-direction is observed due to uniform
τs

wslot periodic current excitation,

2) Initial and ambient temperature are maintained at 30◦ C
τm

wsst

hslot hss in the solution process,

hs/2 3) Equivalent square winding structure is utilized to model
copper, epoxy, and insulation sheet of excitation sources
hm
(as shown in Figure 11),
4) As the model is developed for worst case scenario i.e.
Fig. 2. Design variables of DSFELFSMSS locked mover case hence forced convection is neglected.
1) Calculation of Thermal Resistances: Thermal conduc-
tion resistance is calculated utilizing (5) [16];
TAC in Figure 3a and Figure 3c is opposite to each other.
Hence with relative position of θe = 180◦ , negative maximum l
Rcond = (5)
magnitude of Coil A flux linkage is observed. When θe = 270◦ λA
(Figure 3d), DC flux flow through TAC is again zero and Where, l is length of the block, λ is thermal conductivity,
results in zero magnitude of Coil A flux linkage. Explained and A is the surface area of the block. Thermal convection
operating principle is repetitive in nature and is verified for all resistance is calculated utilizing (6) [17];
DC and AC coils. No-load magnetic flux density nephogram
obtained from FE Analysis is shown in Figure 4. 1
Rconv = (6)
hconv A

C. Electromagnetic Performance Where, hconv is convective heat transfer coefficient and A is

the surface area. Also,
Four important key performance indicators termed as
peak-to-peak open circuit flux linkage of centre phase hconv = f (N u, P r, Gr, Re) (7)
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 4

TDC1 TAC TDC2 TDC1 TAC TDC2 TDC1 TAC TDC2 TDC1 TAC TDC2

A+ A- A+ A- A+ A- A+ A-

DC+ DC- DC- DC+ DC+ DC- DC- DC+ DC+ DC- DC- DC+ DC+ DC- DC- DC+

DC+ DC- DC- DC+ DC+ DC- DC- DC+ DC+ DC- DC- DC+ DC+ DC- DC- DC+

A+ A- A+ A- A+ A- A+ A-
y
z TDC1 TAC TDC2 TDC1 TAC TDC2 TDC1 TAC TDC2 TDC1 TAC TDC2

x
(a) (b) (c) (d)

Fig. 3. Operating principle; aθe = 0◦ , bθe = 90◦ , cθe = 180◦ , and dθe = 270◦

Fig. 4. Magnetic flux density nephogram at no-load

0.06 5
Detent-Force P-P = 6.74N
4
0.04
No-Load Flux Linkage (webber)

0.02 Phase A Phase B Phase C 2

Detent Force (N)

1
0
0

-0.02 -1

-2
-0.04
-3

-0.06 -4
0 50 100 150 200 250 300 350 0 50 100 150 200 250 300 350
Electrical degree (3) Electrical Degree (3)

Fig. 5. Three phase no-load flux linkage Fig. 6. Detent force

Here, N u is the Nusselt number, P r is Prandtl number, considered as 0.25 [18]. P r number can be obtained by (9);
Gr is Grashof number, and Re is Rayleigh number. All Momentum Diffusivity Cp .µ
aforementioned numbers are dimensionless quantities. Pr = = (9)
Heat Diffusivity k
Nusselt number for natural convection can be calculated as
(8) [4]; Where, Cp is specific heat capacity of air and is considered
as 1007 J/kg.◦ C, µ is air kinematic viscosity and its value at
N u = a.(GrP r)b (8) 30◦ C is 1.608 × 10−5 Kg/m.s, and k is thermal conductivity
of air and its value at 30◦ C is 0.02588 W/m.◦ C.
Gr number can be calculated as (10);
Where, a and b are constants and depends on the geometry of
surface and heat flow. Constant a for vertical and horizontal buoyancy forces β.g.∆T.L3
plate is 0.59 and 0.54, respectively. Whereas, constant b is Gr = = (10)
viscous forces µ2
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 5

25 TABLE III
Thrust-ForceAvg = 19.91N
T HERMAL R ESISTANCES

Symbol Definition Value (Ω)

Rw Thermal resistance between winding 0.0142
and mover teeth by conduction
20 Rww Thermal resistance between armature 0.0283
Thrust Force (N)

and field windings by conduction

Rs Thermal resistance between stator and 294.30
ambient by convection
Rp Thermal resistance between mover inner 104.97
tooth and ambient by convection
15 Rc Thermal resistance between mover upper 73.12
surface and ambient by convection
Rps Thermal resistance between mover inner 110.97
surface and stator segment by radiation
Rew Thermal resistance between end winding 259.05
10
and ambient by convection
0 50 100 150 200 250 300 350
Electrical Degree (3)

Fig. 7. Thrust force represents the air volume change that corresponds to tem-
perature change ∆T at constant pressure. g is gravitational
0.005
attraction force (m/s2 ) and L is characteristic length of the
Normal-Force P-P = 0.02N
surface.
Equation (9) results in P r number value of 0.6257.
0
Whereas, four Gr number values are obtained due to variation
of surface’s length and temperature difference, resulting in
-0.005
Normal Force (N)

N u number value of 21.8820 for stator, 13.8686 for mover

horizontal surface, 12.9160 for mover vertical surface, and
-0.01
4.6611 for winding.
Generalized equation for convection heat transfer coefficient
-0.015 can be written as;
N u.kair
-0.02 hconv = (11)
Lsurface
-0.025 Utilizing 0.02588 W/m.◦ C as value of Kair , aforementioned
0 50 100 150 200 250 300 350
N u values and corresponding surface lengths, hconv for
Electrical Degree (3)
stator, mover horizontal surface, mover vertical surface, and
Fig. 8. Normal force winding is concluded as 5.6631, 5.9325, 3.3427, and 8.5327
W/m2 .◦ C.
As mentioned before, heat transfer in between stator seg-
ment inner surface and mover tooth surface through air-gap
is accounted as radiation. Thermal radiation resistance is
calculated using (12);
A+ A- 1
Rrad = (12)
DC+ DC- DC- DC+ hrad Asurface
Where, hrad is radiation heat transfer coefficent and can be
represented as;
2 2


DC+ DC- DC- DC+ hrad = ksb .εss . Tstator + Tmover tooth . (Tstator + Tmover tooth )
(13)
A+ A-
Where, ksb is Stefan-Boltzmann constant, εss is emissivity of
silicon steel, Tstator is stator inner segment surface temperature,
and Tmover tooth is mover tooth surface temperature facing
towards stator. Aforementioned equation resulted in hrad of
6.3235 W/m2 .◦ C
Fig. 9. Node locations Twenty One thermal resistances shown in Figure 10 are
explained in Table III and are obtained by using (5), (6), and
(12).
Where, β is cubical expansion coefficient and ∆T is difference Under transient condition, capacitor is utilized to represent
between surface and air temperature. Product of β and ∆T heat storage in the core and windings. whereas, under steady-
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 6

Rps1 C1 P1 Rs1 Rs2 C2

P2 Rps2

Raw1 Rew1 Rew3 Rfw1

Rww1

Rp1 C5 P5 C6
P6 C9
Primary Mover

Rc

Rp2 C7 P7 P8 C8
P9

Rew2 Rew4
Rww2
Raw2 Rfw2

Rps3 C3 P3 P4 C4
Rs3 Rs4 Rps4

Fig. 10. 1DLPT Model for DSFELFSMSS

 
dθ̇3 1 (θ3 − Tamb ) (θ3 − θ9 )
= P3 − − (17)
dT C3 Rs Rps
 
Insulation Sheet dθ̇4 1 (θ4 − Tamb ) (θ4 − θ9 )
= P4 − − (18)
Epoxy dT C4 Rs Rps
h
dθ̇5 1 (θ5 −Tamb )
dT = C5 P5 − i Rew −
Copper (θ5 −θ6 ) (θ5 −θ9 )
(19)
Rww − Rw
h
dθ̇6 1 (θ6 −Tamb )
dT = C6 P6 − i Rew −
(θ6 −θ5 ) (θ6 −θ9 )
(20)
Rww − Rw
h
Fig. 11. Equivalent square winding structure dθ̇7 1 (θ7 −Tamb )
dT = C7 P7 − i Rew −
(θ7 −θ8 ) (θ7 −θ9 )
(21)
Rww − Rw
state condition the capacitor is assumed as fully charged.
Capacitance under transient condition can be calculated as;
h
dθ̇8 1 (θ8 −Tamb )
dT = C8 P8 − i Rew −
(22)
X
Ci = mi .ci (14) (θ8 −θ7 ) (θ8 −θ9 )
i Rww − Rw

Where, mi represents mass of stator segment for i = 1, 2, 3,

h
dθ˙9 (θ9 −Tamb ) (θ9 −θ1 )
1
dT = C9 P9 − RC +2Rp − Rps − (θ9R−θ 5)
−
and 4, mass of AC windings for i = 5 and 7, mass of DC w
(θ9 −θ6 )
windings for i = 6 and 8, and mass of mover yoke for i = 9. Rw − (θ9 −θ2 ) − (θ9 −θ3 )
− (θ9 −θ4 )
− (θ9 −θ7 )
Rw − (23)
i Rps Rps Rps
ci is specific heat capacity of aforementioned machine parts. (θ9 −θ8 )
Rw
ci is considered as 450 J/Kg.◦ C for silicon steel and 385
J/Kg.◦ C for windings. Where, θ̇i , Pi , θi , and Tamb represents temperature rise,
2) Solution Methodology: In order to calculate temperature combination of iron and copper loss, temperature level, and
rise of nodes illustrated in Figure 9, following first order dif- ambient temperature, respectively.
ferential equations are deduced from Figure 10 and processed
using MATLAB-SIMULINK software;
B. 3D Thermal FE Analysis Model
dθ˙1
 
1 (θ1 − Tamb ) (θ1 − θ9 )
= P1 − − (15) 3D Thermal FE Analysis divides the machine into many
dT C1 Rs Rps small segments, each with appropriately specified thermal
properties, and solves heat flow equations to calculate tem-
 
dθ̇2 1 (θ2 − Tamb ) (θ2 − θ9 )
= P2 − − (16) perature distribution over the whole system. The properties
dT C2 Rs Rps
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019
Fig. 12. Spatial temperature distribution in degree Celsius
TABLE IV
M ATERIAL PROPERTIES
Material Thermal Conductivity Density
(W/m.◦ C) (Kg/m3 )
Copper 380 8900
Epoxy 0.4 1800
Insulation sheet 0.18 930
Silicon steel 45 7800
Air 0.02588 1.205
of different materials used in proposed machine are listed in
Table IV.
Although 3D Thermal FE Analysis predict accurate temper-
ature distribution compared with other analytical techniques,
however it is computationally complex and expensive in
terms of hardware/software requirements. In order to reduce
computational complexity, geometric simplification such as
conversion of winding part into three distinct homogeneous
material regions i.e. copper, epoxy, and insulation sheet (as
shown in Figure 11) can be done. Intrinsic material and
excitation symmetry over a length of one mover pole pitch
can further reduce the problem with assumption of periodic
nature in x-direction (as shown in Figure 9). In the 3D Thermal
FE Analysis model, a heat generation of 94W is assigned to
the copper and core losses part, which is the same value as
in experimental work. 3D Thermal FE Analysis temperature
distribution results of proposed machine is shown in Figure
12.
Boundary conditions must be formulated and used in the
model to accurately predict temperature distribution. Con-
vection boundary conditions are difficult to estimate as they
depend upon geometric structure and also show variation
with the temperature. Boundary conditions (hconv and hrad )
established in subsection III-A are also considered here.
IV. E XPERIMENTAL VALIDATIONS
In order to fully validate the 1DLPTM and 3D Thermal FE
Analysis results, numerous duty cycles test were performed by
injecting known current into the proposed machine. Tempera-
ture levels of worst case scenario (locked-mover condition) of
full scale prototype (as shown in Figure 13) were measured
utilizing Fluke VT04 Visual IR Thermometer and also time
7
to reach maximum bearing temperature of Class B insulation
(120◦ C) was investigated. Utilized IR Thermometer has tem-
Specific Heat perature measurement range of −10◦ C to +250◦ C with an
Capacity expected error of ±1.0%.
(J/Kg.◦ C)
All three AC phases are connected in series and supplied
385
900 with a single source. Series connection is chosen to obtain
1340 an overall null air-gap force on the mover and maintain
450 standstill condition. Also, series connection guarantees that
1007
all connections are intact, and same heat is generated through
out the winding. Due to geometric and electrical excitation
symmetry (as shown in Figure 9), nodes 1,2,3, and 4 are
assumed at same temperature level and is termed as stator
temperature level, node 5 and 7 are also at same temperature
level and is termed as field winding temperature level, node 6
and 8 belongs to same assumption and is termed as armature
winding temperature level. Similarly, node 9 is termed as
mover yoke temperature level.
A. 100% Duty Cycle
100% duty cycle with locked-mover condition is investi-
gated with continuous monitoring of machine parts’ temper-
ature levels after specified interval. Purpose of this test is to
define maximum continuous duty cycle operation time that
machine insulation class can bear and also the hottest part of
the machine. All machine’s parts are investigated as shown
in Figure 14 and graphical representation is done in Figure
15-18.
It can be seen that all three i.e. 1DLPTM, 3D Thermal
FE Analysis, and experimental test results shows reasonable
agreements. Difference among predicted and measured values
is due the fact that 1DLPTM predicts temperature levels
subject to assumptions defined in subsection III-A. Apparently,
mover yoke and field winding reach maximum temperature
levels in a continuous duty cycle time of seventy minutes.
Reason behind this temperature rise is that these parts are
sandwiched in between the whole structure and most of the
heat is stored instead of wiping out by convection or radiation.
Detailed comparison of mover yoke and field winding
measured temperature reveals that after continuous duty of
seventy minutes, mover yoke temperature is 123.9◦ C and field
winding is 124.8◦ C. Hence, field winding part is considered as
hottest part of the machine and is subjected to further analysis.
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 8

Fig. 13. Physical layout used for thermal tests

140 140
3D FE Analysis 1DLPTM Experimental

120 120

Stator Temperature (Deg Centigrade)

100 100

80 80

60 60

40 40

20 20
0 3 6 9 121518 242730333639424548 55 60 65 70 85 98
Time (Minutes)

Fig. 15. Stator temperature levels and corresponding time in minutes

150 150
3D FE Analysis 1DLPTM Experimental
Armature Winding Temperature (Deg Centigrade)

100 100

50 50

Fig. 14. IR thermometer results 0

0 3 6 9 12 15 18 24 27 30 33 36 39 42 45 48 55 60 65 70 85
0

Time (Minutes)

Fig. 16. Armature winding temperature levels and corresponding time in

B. 75% Duty Cycle minutes

Total time period of 16 minutes and on-time (Ton ) of 12

minutes is selected for 75% duty cycle. Only field winding
temperature levels are predicted and measured to validate
proposed approach and find operation time to reach maximum
bearing temperature level of used insulation class. Detailed
comparison of field winding temperature levels under 75%
duty cycle obtained by 1DLPTM, 3D Thermal FE Analysis,
and experiment is shown in Figure 19.
It can be seen that operation time can be extended from 70 to
105 minutes. Also, a reasonable comparison among 1DLPTM,
3D Thermal FE Analysis, and experiment is observed.
C. 50% Duty Cycle
Total time period of 12 minutes and on-time (Ton ) of 6
minutes is selected for subject test. Detailed comparison of
field winding temperature levels under 50% duty cycle ob-
tained by 1DLPTM, 3D Thermal FE Analysis, and experiment
is shown in Figure 20. It can be observed that operation time
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 9

150 150
3D FE Analysis 1DLPTM Experimental
Mover Temperature (Deg Centigrade)

100 100

50 50

Fig. 20. Field winding temperature levels and corresponding time in minutes
for 50% duty cycle

0 0
0 3 6 9 12 15 18 24 27 30 33 36 39 42 45 48 55 60 65 70
Time (Minutes)
can be extended to 135 minutes with out any undue damage
to insulation medium.
Fig. 17. Mover yoke temperature levels and corresponding time in minutes October 12, 2019

V. C ONCLUSION
Double Sided Field Excited Linear Flux Switching Machine
with Segmented Secondary (DSFELFSMSS) is a very inter-
150 150
esting solution for direct-drive long stroke applications such as
3D FE Analysis 1DLPTM Experimental
electric train, elevator system, and loads traditionally driven by
Field Winding Temperature (Deg Centigrade)

rotary motors through mechanical conversion system. Firstly,

this paper presents principles for electromagnetic design of
100 100 DSFELFSMSS. Operating principle and electromagnetic de-
sign key performance indicators are explained in detail. Sec-
ondly, computationally efficient Lumped Parameter Thermal
Model (LPTM) based on first order differential equations
50 50 is proposed. All three types of heat flows i.e. conduction,
convection, and radiation are accounted. The approach is de-
veloped for worst case scenario (locked-mover), hence forced
convection is neglected. Thirdly, 3-D Thermal Finite Element
0 0 Analysis (3DTFEA) followed by a large range of experiments
0 3 6 9 12 15 18 24 27 30 33 36 39 42 45 48 55 60 65 70
Time (Minutes)
utilizing thermographic analysis are conducted to validate
proposed approach accuracy.
Fig. 18. Field winding temperature levels and corresponding time in minutes Comparison among LPTM, 3DTFEA, and experiment re-
sults has highlighted a satisfactory accuracy for the proposed
approach. All experimental measurements are done through
IR thermometer i.e. without disturbing machine’s geometry or
setting sensors. Detailed thermal analysis revealed that field
winding installed adjacent to mover yoke is the hottest part of
machine, reason is reduced heat escape caused by convection
and radiation. Also, safe operational time can be increased by
reducing operation duty cycle. Regarding the computational
performance, it has been proved that use of proposed approach
can be done at initial design stages instead of time-consuming
Thermal FE Analysis that typically require several hours to
produce almost same results.

ACKNOWLEDGMENT
Authors are thankful to Pakistan Center for Advanced Stud-
ies in Energy for providing simulation platform. Authors are
Fig. 19. Field winding temperature levels and corresponding time in minutes
for 75% duty cycle also thankful to COMSATS University Islamabad (Abbottabad
Campus), Pakistan for providing assistance regarding hardware
test bed.
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019
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10
Noman Ullah was born in District Tank, Khyber
Pakhtunkhwa, Pakistan in 1990. He received the B.S.
and M.S. degrees in electrical (power) engineering
from the University of Engineering & Technology,
Peshawar, Pakistan, in 2012 and 2015, respectively.
He is currently pursuing the Ph.D. degree in elec-
trical energy system engineering at University of
Engineering & Technology, Peshawar, Pakistan.
From 2013 to 2015, he was a Research Assistant
with the Pakistan Engineering Council. Since 2015,
he has been Lecturer with the Electrical Engineering
Department, COMSATS University Islamabad (Abbottabad Campus), Pak-
istan. His research interests include design and optimization of linear flux-
switching machines and applications.
Faisal Khan was born in District Charsada, Khyber
Pakhtunkhwa, Pakistan in 1986. He received the
B.S. degree in electronics engineering from COM-
SATS University Islamabad (Abbottabad Campus),
Pakistan in 2009 and M.S. degree in electrical
engineering from COMSATS University Islamabad
(Abbottabad Campus), Pakistan in 2012. He received
the Ph.D. degree in electrical engineering from
Universiti Tun Hussein Onn Malaysia, Malaysia in
2017.
From 2010 to 2012, he was a Lecturer at Uni-
versity of Engineering & Technology, Abbottabad, Pakistan. Since 2017, he
has been Assistant Professor with the Electrical Engineering Department,
COMSATS University Islamabad (Abbottabad Campus), Pakistan. He is
author of more than twenty five publications, one patent, and received multiple
research awards. His research interests include design of flux-switching,
synchronous, and dc machines.
Abdul Basit was born in District Mardan, Khyber
Pakhtunkhwa, Pakistan. He received his B.S. degree
in electrical engineering from University of Engi-
neering & Technology, Peshawar, Pakistan in 2006,
M.S. degree in electrical (power) engineering from
Chalmers University of Technology, Sweden in 2011
and his PhD from the Department of Wind Energy
of the Technical University of Denmark (DTU) in
2015.
From 2007 to 2009, he was a Field Engineer with
the NEC Corporation, Pakistan. Since 2015, he has
been Assistant Professor with the Electrical Energy System Engineering, U.S.-
Pakistan Center for Advanced Studies in Energy, University of Engineering
& Technology, Peshawar, Pakistan. His research interests include modelling
and analysis of operation and control of wind generators.
Osama Waheed was born in District Charsadda,
Khyber Pakhtunkhwa, Pakistan in 1997. He is cur-
rently perusing BS degree in Electrical (Power) En-
gineering at COMSATS University Islamabad (Ab-
bottabad Campus). His research interests include
design and optimization of linear flux-switching
machines and Thermal modeling of linear machines.
IEEE TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, VOL. A, NO. B, OCTOBER 2019 11

Amir Khan was born in District Bannu, Khyber

Pakhtunkhwa, Pakistan in 1997. He is currently
perusing BS degree in Electrical (Power) Engineer-
ing at COMSATS University Islamabad (Abbottabad
Campus). His research interests include design and
optimization of linear flux-switching machines and
Thermal modeling of linear machines.

Ali Usman was born in Gilgit Baltistan, Pakistan in

1997. He is currently perusing BS degree in Elec-
trical (Power) Engineering at COMSATS University
Islamabad (Abbottabad Campus). His research inter-
ests include design and optimization of linear flux-
switching machines and Thermal modeling of linear
machines.

Wasiq Ullah was born in District Peshawar, Khyber

Pakhtunkhwa, Pakistan in 1995. He received the
B.S. degree in electrical (power) engineering from
the Electrical Engineering Department, COMSATS
University Islamabad (Abbottabad Campus), Pak-
istan. He is currently pursuing the M.S degree in
electrical (power) engineering at Electrical Engineer-
ing Department, COMSATS University Islamabad
(Abbottabad Campus), Pakistan.
Since 2017, he has been Research Assistant with
the Electrical Engineering Department, COMSATS
University Islamabad (Abbottabad Campus), Pakistan. His research interests
include analytical design and optimization of synchronous and flux-switching
machines.