Others

Multiphysics Design of a High-Speed Permanent Magnet Machine for a Micro Gas Turbine Application

  • ZHENG Mengzi ,
  • HUANG Weiguang ,
  • GAO Chuang ,
  • WU Fuxian
Expand
  • 1. Shanghai Advanced Research Institute, Chinese Academy of Sciences, Shanghai 201210, China
    2. School of Chemical Engineering, University of Chinese Academy of Sciences, Beijing 100049, China
    3. Innovation Academy for Light-duty Gas Turbine, Chinese Academy of Sciences, Beijing 100190, China
    4. Helan Turbines Co., Ltd, Shanghai 210815, China

Online published: 2023-11-30

Supported by

This work is supported in part by the Key Programs of Chinese Academy of Sciences (No. ZDRW-CN-2017-2), in part the Innovation Academy of Light-duty Gas Turbine (No. E0210E1231), in part by the Natural Science Foundation of Shanghai (No. 19ZR1423500).

Copyright

Science Press, Institute of Engineering Thermophysics, CAS and Springer-Verlag GmbH Germany, part of Springer Nature 2022

Abstract

This paper presents a detailed and comprehensive multiphysics design process of an 80 kW, 60 000 r/min high-speed permanent magnet machine (HSPMM) for a micro gas turbine application. First, the preliminary design of the HSPMM is carried out according to the mechanical and electromagnetic theory. Afterwards, the influence of carbon fiber sleeve (CFS) thickness, rotor diameter and core length on rotor stress and rotor dynamics is carefully analyzed to obtain the optimal range of rotor diameter and core length. On this basis, the electromagnetic and power loss characteristics are analyzed in detail to obtain the final design scheme. Fluid-solid coupling model is used to calculate the temperature field of the HSPMM to verify the rationality of the scheme. The rotor thermal stress analysis considering the multi-layer and multi-angle winding of CFS is carried out to obtain the rotor models suitable for prototype and mass production, respectively. Finally, the prototypes are manufactured and tested to verify the reliability of the multiphysics design process.

Cite this article

ZHENG Mengzi , HUANG Weiguang , GAO Chuang , WU Fuxian . Multiphysics Design of a High-Speed Permanent Magnet Machine for a Micro Gas Turbine Application[J]. Journal of Thermal Science, 2022 , 31(1) : 251 -260 . DOI: 10.1007/s11630-022-1540-x

References

[1] Bianchi N., Bolognani S., Luise F., Potentials and limits of high-speed PM motors. IEEE Transactions on Industry Applications, 2004, 40(6): 1570–1578.
[2] Borisavljevic A., Polinder H., Ferreira J.A., On the speed limits of permanent-magnet machines. IEEE Transactions on Industrial Electronics, 2009, 57(1): 220–227.
[3] Gerada D., Mebarki A., Brown N.L., et al., High-speed electrical machines: Technologies, trends, and developments. IEEE Transactions on Industrial Electronics, 2013, 61(6): 2946–2959.
[4] Uzhegov N., Kurvinen E., Nerg J., et al., Multidisciplinary design process of a 6-slot 2-pole high-speed permanent-magnet synchronous machine. IEEE Transactions on Industrial Electronics, 2016, 63(2): 784–795.
[5] Du G., Xu W., Zhu J., Huang N., Effects of design parameters on the multiphysics performance of high-speed permanent magnet machines. IEEE Transactions on Industrial Electronics, 2019, 67(5): 3472–3483.
[6] Uzhegov N., Smirnov A., Park C.H., et al., Design aspects of high-speed electrical machines with active magnetic bearings for compressor applications. IEEE Transactions on Industrial Electronics, 2017, 64(11): 8427–8436.
[7] Tenconi A., Vaschetto S., Vigliani A., Electrical machines for high-speed applications: Design considerations and tradeoffs. IEEE Transactions on Industrial Electronics, 2014, 61(6): 3022–3029.
[8] Zhang F., Du G., Wang T., et al., Electromagnetic design and loss calculations of a 1.12-MW high-speed permanent-magnet motor for compressor applications. IEEE Transactions on Energy Conversion, 2015, 31(1): 132–140.
[9] Ede J. D., Zhu Z., Howe D., Rotor resonances of high-speed permanent-magnet brushless machines. IEEE Transactions on Industry Applications, 2002, 38(6): 1542–1548.
[10] Huang Z., Fang J., Multiphysics design and optimization of high-speed permanent-magnet electrical machines for air blower applications. IEEE Transactions on Industrial Electronics, 2016, 63(5): 2766–2774.
[11] Fang H., Qu R., Li J., et al., Rotor design for high-speed high-power permanent-magnet synchronous machines. IEEE Transactions on Industry Applications, 2017, 53(4): 3411–3419.
[12] Wang Y., Zhu Z., Feng J., et al., Rotor stress analysis of high-speed permanent magnet machines with segmented magnets retained by carbon-fibre sleeve. IEEE Transactions on Energy Conversion, 2020, 36(2): 971–983.
[13] Li W., Qiu H., Zhang X., et al., Influence of rotor-sleeve electromagnetic characteristics on high-speed permanent-magnet generator. IEEE Transactions on Industrial Electronics, 2013, 61(6): 3030–3037.
[14] Hong D.K., Woo B.C., Koo D.H., Rotordynamics of 120 000 r/min 15 kW ultra high speed motor. IEEE transactions on magnetics, 2009, 45(6): 2831–2834.
[15] Zhang Y., McLoone S., Cao W., et al., Power loss and thermal analysis of a MW high-speed permanent magnet synchronous machine. IEEE Transactions on Energy Conversion, 2017, 32(4): 1468–1478.
[16] Li W., Zhang X., Cheng S., Cao J., Thermal optimization for a HSPMG used for distributed generation systems. IEEE Transactions on Industrial Electronics, 2012, 60(2): 474–482.
[17] Huang Z., Fang J., Liu X., Han B., Loss calculation and thermal analysis of rotors supported by active magnetic bearings for high-speed permanent-magnet electrical machines. IEEE Transactions on Industrial Electronics, 2015, 63(4): 2027–2035.
[18] Du G., Xu W., Zhu J., Huang N., Power loss and thermal analysis for high-power high-speed permanent magnet machines. IEEE Transactions on Industrial Electronics, 2020, 67(4): 2722–2733.
[19] Ismagilov F.R., Uzhegov N., Vavilov V.E., et al., Multidisciplinary design of ultra-high-speed electrical machines. IEEE Transactions on Energy Conversion, 2018, 33(3): 1203–1212.
[20] Yang J., Liu P., Ye C., et al., Multidisciplinary design of high-speed solid rotor homopolar inductor machine for flywheel energy storage system. IEEE Transactions on Transportation Electrification, 2020, 7(2): 485–496.
[21] Zheng M., Huang W., Gao C., Rotor stress and dynamics analysis of a high-speed permanent magnet machine for a micro gas turbine considering multiphysics factors. IEEE Access, 2020, 8: 152523–152531.
[22] Pyrhonen J., Jokinen T., Hrabovcova V., Design of rotating electrical machines, second ed., Chichester: Wiley, U.K., 2013.
[23] Vrancik J.E., Prediction of windage power loss in alternators. National Aeronautics and Space Administration, 1968.
[24] Bilgen E., Boulos R., Functional dependence of torque coefficient of coaxial cylinders on gap width and Reynolds numbers. Journal of Fluids Engineering, Transactions of the ASME, 1973, 95: 122–126.
[25] Gieras J.F., Design of permanent magnet brushless motors for high speed applications. 17th International Conference on Electrical Machines and Systems (ICEMS), Hangzhou, China, 2014, pp: 1–16.

Outlines

/