摘要 I Abstract II 誌謝 IV Contents V List of Figures VII List of Tables XI Chapter 1. Introduction 1 1.1 Motor industry 1 1.2 Advantages of synchronous reluctance motor 2 1.3 Purpose and motivation 6 1.4 Thesis structure 7 Chapter 2. Literature Review 8 2.1 Introduction of SynRM 8 2.2 Evolution of SynRM rotor structure 10 Chapter 3. Basic Theory of SynRM 14 3.1 Equivalent circuit of SynRM 14 3.2 Design of SynRM 19 3.2.1 Design of stator 19 3.2.2 Analysis of slotless stator and separated-segment-rotor 20 3.2.3 Stator with slot with distributed anisotropy structure rotor 22 3.3 Summary 24 Chapter 4. Design Process of SynRM 25 4.1 Analysis process 25 4.1.1 Study of maximum flux density limit 26 4.1.2 Study of d- and q-axis current limit 27 4.1.3 Improvement of saliency ratio 27 4.1.4 Principle for flux-barrier design 27 4.1.5 Effect of ribs 28 4.1.6 Effects and principle of applying low iron loss material 28 4.1.7 Coupling effect under loaded condition 29 4.2 Structure design process 29 4.2.1 Air gap between stator and rotor 30 4.2.2 Pole number 30 4.2.3 Rotor scale 30 4.2.4 Shape, value, distribution of flux-barrier 31 4.2.5 Excitation current angle 31 4.2.6 Ribs on d-q-axis of rotor 32 4.2.7 Torque ripple 32 4.2.8 Analysis of applying distinct materials 32 4.3 Manufacture process 33 4.3.1 Scale and performance of motor 33 4.3.2 Driver restrictions 34 4.3.3 Equivalent circuit and phasor diagram 34 4.3.4 Structure and winding design 34 4.3.5 Flux density saturation 35 4.3.6 Increase of saliency ratio 35 4.3.7 Testing design result through FEM 36 4.3.8 Manufacture 36 4.3.9 Test and verify the motor prototype with simulation result 36 Chapter 5. Analysis and Design of Rotor 37 5.1 Design of flux barriers 37 5.2 Number of flux barriers 37 5.3 Shape of flux barrier 38 5.4 Pitch angle between adjacent flux barriers 47 5.5 Depth design of FBs 51 5.6 Design of distribution and width of FBs 54 5.7 Characteristics and application of different materials 57 5.7.1 Amorphous electric steel lamination 62 5.7.2 Electric steel lamination of high saturation flux density 64 5.8 Iron loss analysis 66 5.9 Operating range and maximum efficiency 67 5.10 Major important characteristic of SynRM 75 5.11 Manufacture and verification 77 Chapter 6. Manufacture and Verification of SynRM 85 6.1 Prototypes 85 6.2 Measurement with autotransformer 89 6.3 Measurement of phase inductance 90 6.4 Test with AC controller 91 Chapter 7. Conclusion and Recommendation 97 Reference 99 List of Figures Fig 1.1 IEC motor efficiency class [3] 2 Fig 1.2 Schematic diagram of BLDC [7] 5 Fig 1.3 (a) SPMM (b) inset permanent magnet motor (c) IPMM [8] 5 Fig 1.4 Schematic diagram of induction motor [9] 5 Fig 2.1 Principle of reluctance force (assuming that the material can only move along Z-axis) [1] 8 Fig 2.2 Principle of reluctance torque [13] (τ: torque, δ: angle between magnetic field and d-axis) 9 Fig 2.3 Schematic diagram of d- and q-axis of SynRM 10 Fig 2.4 Earliest design of TLA SynRM [16] 11 Fig 2.5 SP rotor [14] 12 Fig 2.6 Punched TLA rotor structure combined with squirrel cage winding design [14] 12 Fig 2.7 Distinct rotor structure (a) SRM rotor (b) ALA rotor (c) TLA rotor [13] 13 Fig 3.1 Equivalent circuit model of SynRM [13] 14 Fig 3.2 Equivalent circuit (a) d-axis part (b) q-axis part [13] 16 Fig 3.3 Equivalent phasor diagram of SynRM 17 Fig 3.4 Schematic diagram of distributed anisotropy structure rotor [17] 20 Fig 3.5 Schematic diagram of q-axis flux distribution [17] 21 Fig 3.6 q-axis flux distribution with stator with slots. (a) slots aligned, (b) slots not aligned [17] 23 Fig 3.7 Flux distribution on kth segment of rotor [17] 24 Fig 4.1 Analysis process for SynRM 26 Fig 4.2 Structure design process of SynRM 30 Fig 4.3 Manufacture process of SynRM 33 Fig 5.1 Defining number of FBs 38 Fig 5.2 Definition of design variables of FBs (where first set of FB is the one closest to q-axis) 39 Fig 5.3 Different shape of FB 40 Fig 5.4 Schematic diagram of difference between U and C-type FB [22]. (whereΔx is the variation between the two types) 41 Fig 5.5 Simulation results of U-shape and C-shape flux-barrier design 43 Fig 5.6 U-shape and C-shape flux-barrier design 44 Fig 5.7 Simulation results for analyzing the relationship between torque and ribs in C and U-type FB designs 46 Fig 5.8 Comparison of the primary design of C and U type FB design 47 Fig 5.9 Distribution of flux density 48 Fig 5.10 Schematic diagram of ideal flux distribution along d-axis 49 Fig 5.11 Analysis of distribution of flux density on air gap and rotor 50 Fig 5.12 Primary C-type sinusoidal distribution FBs design (a) sinusoidal design I (b) sinusoidal design II 50 Fig 5.13 Schematic diagram of design of pitch angles of FBs [22] 52 Fig 5.14 Schematic diagram of design of pitch angles of FBs [27] 53 Fig 5.15 Discussion of first set of FBs 54 Fig 5.16 Design and analysis of width and distribution of flux paths that have: 55 Fig 5.17 Distinct materials characteristics 57 Fig 5.18 Model of simulation (3kW SynRM) 59 Fig 5.19 Simulation results of distinct materials combination 60 Fig 5.20 Simulation results of distinct materials combination 61 Fig 5.21 Simulation results of distinct materials combination 61 Fig 5.22 Simulation results of distinct materials combination 61 Fig 5.23 Hysteresis curve of 2605SA1 62 Fig 5.24 Iron loss characteristic of 2605SA1 63 Fig 5.25 Simulation result of motor applying amorphous electric steel lamination 63 Fig 5.26 Simulation result of motor applying amorphous electric steel lamination 63 Fig 5.27 Characteristic of Vacoflux50 64 Fig 5.28 Simulation result of motor applying high-flux-density steel lamination 64 Fig 5.29 Simulation result of motor applying high-flux-density steel lamination 65 Fig 5.30 Comparison of motors using different materials 66 Fig 5.31 Simulation model of 3kW SynRM 69 Fig 5.32 Effects of current changing on d-axis inductance under constant operating speed (model: 3kW SynRM) 70 Fig 5.33 Effects of current changing on q-axis inductance under constant operating speed (model: 3kW SynRM) 71 Fig 5.34 Effects of current changing on torque performance under constant operating speed (model: 3kW SynRM) 71 Fig 5.35 Effects of current changing on efficiency under constant operating speed (model: 3kW SynRM) 72 Fig 5.36 Effects of operating speed changing on iron loss under constant excitation current (model: 3kW SynRM) 73 Fig 5.37 Speed to efficiency curve under constant excitation current (model: 3kW SynRM) 74 Fig 5.38 Torque to Iq/Id curve 74 Fig 5.39 Effects of current density to efficiency and torque density 75 Fig 5.40 T-N curve of rated and max power output (model: 3kW SynRM) 76 Fig 5.41 Efficiency curve of rated and max power output (model: 3kW SynRM) 77 Fig 5.42 Iron loss curve of rated and max power output (model: 3kW SynRM) 77 Fig 5.43 Simulation model of 1kW SynRM 78 Fig 5.44 Effects of current changing on d-axis inductance under constant operating speed (model: 1kW SynRM) 79 Fig 5.45 Effects of current changing on q-axis inductance under constant operating speed (model: 1kW SynRM) 80 Fig 5.46 Effects of current changing on torque under constant operating speed (model: 1kW SynRM) 80 Fig 5.47 Effects of current changing on efficiency under constant operating speed (model: 1kW SynRM) 81 Fig 5.48 Effects of operating speed changing on iron loss under constant excitation current (model: 1kW SynRM) 81 Fig 5.49 Torque to Iq/Id curve 82 Fig 5.50 Effects of current density to efficiency and torque density 82 Fig 5.51 T-N curve of rated and max power output (model: 1kW SynRM) 83 Fig 5.52 Efficiency curve of rated and max power output (model: 1kW SynRM) 83 Fig 5.53 Iron loss curve of rated and max power output (model: 1kW SynRM) 84 Fig 6.1 Stator using 50CS1300 (1kW SynRM model) 86 Fig 6.2 Winding layout 86 Fig 6.3 Stator winding (1kW SynRM model): (a) side view (b) front view 87 Fig 6.4 Rotor product using 50CS1300 (1kW SynRM model) 87 Fig 6.5 Rotor product using 20CS1500HF (1kW SynRM model) 88 Fig 6.6 Final assembly (1kW SynRM model) 88 Fig 6.7 autotransformer 89 Fig 6.8 Comparison of simulation and measured results (10 V) 90 Fig 6.9 Measurement of inductance with 20CS1500HF (both stator and rotor) 91 Fig 6.10 Measurement of inductance with 50CS1300 (both stator and rotor) 91 Fig 6.11 AC motor controller 92 Fig 6.12 Passive load and test motor 92 Fig 6.13 Test setup 93 Fig 6.14 Phase angle of current and voltage in simulation 94 Fig 6.15 Phase angle of current and voltage in testing (blue curve: U phase voltage, pink line: U phase current, light blue curve: V phase current, green line: W phase current) 94 Fig 6.16 Simulation vs testing results 95 Fig 6.17 Speed and voltage curve 95 List of Tables Table 5.1 Torque performances with different shape of FB 40 Table 5.2 Parameters for two FB types of the SynRM 42 Table 5.3 Characteristic comparison of U-shape and C-shape flux-barrier design 44 Table 5.4 Simulation results for analyzing the relationship between torque and ribs in C and U-type FB designs 45 Table 5.5 Pitch angle of sinusoidal distribution for FB design 48 Table 5.6 Pitch angle of sinusoidal distribution for FB design (a1 is included) 49 Table 5.7 Sinusoidal distribution of pitch angles 51 Table 5.8 Comparison of simulation results 51 Table 5.9 Simulation results of designs of FB (model: 3 kW SynRM) 53 Table 5.10 Analysis results of distinct design of width and distribution of FBs 56 Table 5.11 Settings of simulation 59 Table 5.12 Effects of using different materials on stator and rotor separately under different operating speed (model: 3 kW SynRM) 67 Table 5.13 Operating condition 69 Table 5.14 Simulation condition 78 Table 6.1 Design parameters of 1kW SynRM model 85 Table 6.2 Prototypes and materials 89 Table 6.3 Parameters of self-coupling transformer 90