Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve

Hossein Parivar; Ahmad Darabi

doi:doi:10.11648/j.eas.20220702.12

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Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve

Hossein Parivar, Ahmad Darabi

Published in Engineering and Applied Sciences (Volume 7, Issue 2)

Received: 22 April 2022 Accepted: 23 May 2022 Published: 31 May 2022

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Abstract

High-speed permanent magnet synchronous generators (HS-PMSGs) suffer from mechanical stresses due to high speeds. With the predicted mechanical stresses that may occur in the rotor of the HS-PMSGs, the design of these machines should be very accurate. So, for the HS-PMSGs, a proper electromagnetic coupled with mechanical design is a critical issue. This paper presents a novel method for the electromagnetic and mechanical design of an HS-PMSG by finding an appropriate dimension of the retention sleeve and permanent magnets (PMs) based on the well-known Taguchi optimization method. A 40-kW, 60-krpm, 2-poles and 18-slots HS-PMSG is designed at the first step, and next, it has been optimized by the proposed optimization method, and finally modeled and analyzed through Finite-Element Method (FEM). Results obtained from the electromagnetic and mechanical simulations of the HS-PMSG show that in the optimized design of the HS-PMSG some parameters changed and the HS-PMSG has a better performance compared to the initial design. For example, The effective air gap has been reduced which leads to the better electromagnetic and mechanical performance of HS-PMSG compared to the initial design. By the reduction in the thicknesses of the retention sleeve and the PM, it can be concluded that the total size and dimensions of the HS-PMSG have been reduced. The weight of the PM and the retention sleeve are reduced by about 16.31% and 29.28% responsively, and as a result, the total weight of the HS-PMSG is reduced by approximately 1.94%, The Joule loss is reduced by about 9.80%, the HS-PMSG efficiency has been improved by 0.02%, and finally, the cogging torque is reduced by 27.87%, comparing with the initially designed. The FEM results ensure the electromagnetic and mechanical performance of the machine around the predicted speed of 60-krpm.

Published in	Engineering and Applied Sciences (Volume 7, Issue 2)
DOI	10.11648/j.eas.20220702.12
Page(s)	21-28
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2022. Published by Science Publishing Group

Keywords

High-Speed Permanent Magnet Synchronous Machine, Retention Sleeve, Taguchi Optimization Method, Finite-Element Method, Titanium

References

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[2]	A. Binder and T. Schneider, “High-speed inverter-fed AC drives,” Int. Aegean Conf. Electr. Mach. Power Electron. Electro motion ACEMP’07Electromotion’07 Jt. Conf., pp. 9–16, 2007. DOI: 10.1109/ACEMP.2007.4510476.
[3]	D. Gerada, A. Mebarki, N. L. Brown, C. Gerada, A. Cavagnino, and A. Boglietti, “High-speed electrical machines: Technologies, trends, and developments,” IEEE Trans. Ind. Electron., vol. 61, no. 6, pp. 2946–959, 2014Z. DOI: 10.1109/TIE.2013.2286777.
[4]	R. Hasegawa, “Applications of amorphous magnetic alloys,” Mater. Sci. Eng. A, Struct., vols. 375—377, pp. 90—97, Jul. 2004, DOI: 10.1007/1-4020-2965-9_17.
[5]	J. B. Bartolo, H. Zhang, D. Gerada, L. De Lillo, and C. Gerada, “High speed electrical generators, application, materials and design,” Proc. -2013 IEEE Work. Electr. Mach. Des. Control Diagnosis, WEMDCD 2013, pp. 47–59, 2013. DOI: 10.1109/WEMDCD.2013.6525164.
[6]	H. A. Khan, F. Khan, S. Khan, N. Ahmad, J. B. Soomro and I. Sami, "Design and Performance Investigation of 3-Slot/2-Pole High-Speed Permanent Magnet Machine," in IEEE Access, vol. 9, pp. 41603-41614, 2021. DOI: 10.1109/ACCESS.2021.3065265.
[7]	Y. Hu, S. Zhu, L. Xu and B. Jiang, "Reduction of Torque Ripple and Rotor Eddy Current Losses by Closed Slots Design in a High-speed PMSM for EHA Applications," in IEEE Transactions on Magnetics, DOI: 10.1109/TMAG.2021.3083664.
[8]	K. J. Binns, M. S. N. Al-Din, and P. J. G. Lisboa, “Use of canned rotors in high field permanent magnet machines,” Electr. Power Appl. IEEE Proc. B, vol. 139, no. 5, pp. 471–477, 1992. DOI: 10.1049/ip-b.1992.0058.
[9]	H. Parivar, A. Darabi, “Design and Modeling of a High-Speed Permanent Magnet Synchronous Generator with a Retention Sleeve of Rotor” in International Journal of Engineering, vol. 34, no. 11, pp. 2433–2441, 2021. DOI: 10.5829/ije.2021.34.11b.07.
[10]	Wang Z, Li Y, Du J, Yu Z. Analytical Calculation for Multilayer Rotor Eddy Current Losses of High-Speed Permanent Magnet Machines. IEEJ Transactions on Electrical and Electronic Engineering. 2022 Apr; 17 (4): 601-10.
[11]	Song SW, Jeong MJ, Kim KS, Lee J, Kim WH. A study on reducing eddy current loss of sleeve and improving torque density using ferrofluid of a surface permanent magnet synchronous motor. IET Electric Power Applications. 2022 Apr; 16 (4): 463-71.
[12]	Wang Y, Zhu ZQ, Feng J, Guo S, Li Y. Rotor stress analysis of high-speed permanent magnet machines with segmented magnets retained by carbon-fibre sleeve. IEEE Transactions on Energy Conversion. 2020 Sep 8; 36 (2): 971-83.
[13]	Chen LL, Zhu CS, Zhong Z, Liu B, Wan A. Rotor strength analysis for high-speed segmented surface-mounted permanent magnet synchronous machines. IET Electric Power Applications. 2018 Aug 16; 12 (7): 979-90.
[14]	Lee TW, Hong DK. Rotor Design, Analysis and Experimental Validation of a High-Speed Permanent Magnet Synchronous Motor for Electric Turbocharger. IEEE Access. 2022 Feb 17; 10: 21955-69.
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[16]	Andriushchenko E, Kallaste A, Belahcen A, Vaimann T, Rassõlkin A, Heidari H, Tiismus H. Optimization of a 3d-printed permanent magnet coupling using genetic algorithm and taguchi method. Electronics. 2021 Jan; 10 (4): 494.
[17]	Naseh M, Hasanzadeh S, Dehghan SM, Rezaei H, Al-Sumaiti AS. Optimized design of rotor barriers in pm-assisted synchronous reluctance machines with taguchi method. IEEE Access. 2022 Apr 7; 10: 38165-73.

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APA Style

Hossein Parivar, Ahmad Darabi. (2022). Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve. Engineering and Applied Sciences, 7(2), 21-28. https://doi.org/10.11648/j.eas.20220702.12

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ACS Style

Hossein Parivar; Ahmad Darabi. Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve. Eng. Appl. Sci. 2022, 7(2), 21-28. doi: 10.11648/j.eas.20220702.12

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AMA Style

Hossein Parivar, Ahmad Darabi. Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve. Eng Appl Sci. 2022;7(2):21-28. doi: 10.11648/j.eas.20220702.12

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@article{10.11648/j.eas.20220702.12,
  author = {Hossein Parivar and Ahmad Darabi},
  title = {Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve},
  journal = {Engineering and Applied Sciences},
  volume = {7},
  number = {2},
  pages = {21-28},
  doi = {10.11648/j.eas.20220702.12},
  url = {https://doi.org/10.11648/j.eas.20220702.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.eas.20220702.12},
  abstract = {High-speed permanent magnet synchronous generators (HS-PMSGs) suffer from mechanical stresses due to high speeds. With the predicted mechanical stresses that may occur in the rotor of the HS-PMSGs, the design of these machines should be very accurate. So, for the HS-PMSGs, a proper electromagnetic coupled with mechanical design is a critical issue. This paper presents a novel method for the electromagnetic and mechanical design of an HS-PMSG by finding an appropriate dimension of the retention sleeve and permanent magnets (PMs) based on the well-known Taguchi optimization method. A 40-kW, 60-krpm, 2-poles and 18-slots HS-PMSG is designed at the first step, and next, it has been optimized by the proposed optimization method, and finally modeled and analyzed through Finite-Element Method (FEM). Results obtained from the electromagnetic and mechanical simulations of the HS-PMSG show that in the optimized design of the HS-PMSG some parameters changed and the HS-PMSG has a better performance compared to the initial design. For example, The effective air gap has been reduced which leads to the better electromagnetic and mechanical performance of HS-PMSG compared to the initial design. By the reduction in the thicknesses of the retention sleeve and the PM, it can be concluded that the total size and dimensions of the HS-PMSG have been reduced. The weight of the PM and the retention sleeve are reduced by about 16.31% and 29.28% responsively, and as a result, the total weight of the HS-PMSG is reduced by approximately 1.94%, The Joule loss is reduced by about 9.80%, the HS-PMSG efficiency has been improved by 0.02%, and finally, the cogging torque is reduced by 27.87%, comparing with the initially designed. The FEM results ensure the electromagnetic and mechanical performance of the machine around the predicted speed of 60-krpm.},
 year = {2022}
}

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TY  - JOUR
T1  - Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve
AU  - Hossein Parivar
AU  - Ahmad Darabi
Y1  - 2022/05/31
PY  - 2022
N1  - https://doi.org/10.11648/j.eas.20220702.12
DO  - 10.11648/j.eas.20220702.12
T2  - Engineering and Applied Sciences
JF  - Engineering and Applied Sciences
JO  - Engineering and Applied Sciences
SP  - 21
EP  - 28
PB  - Science Publishing Group
SN  - 2575-1468
UR  - https://doi.org/10.11648/j.eas.20220702.12
AB  - High-speed permanent magnet synchronous generators (HS-PMSGs) suffer from mechanical stresses due to high speeds. With the predicted mechanical stresses that may occur in the rotor of the HS-PMSGs, the design of these machines should be very accurate. So, for the HS-PMSGs, a proper electromagnetic coupled with mechanical design is a critical issue. This paper presents a novel method for the electromagnetic and mechanical design of an HS-PMSG by finding an appropriate dimension of the retention sleeve and permanent magnets (PMs) based on the well-known Taguchi optimization method. A 40-kW, 60-krpm, 2-poles and 18-slots HS-PMSG is designed at the first step, and next, it has been optimized by the proposed optimization method, and finally modeled and analyzed through Finite-Element Method (FEM). Results obtained from the electromagnetic and mechanical simulations of the HS-PMSG show that in the optimized design of the HS-PMSG some parameters changed and the HS-PMSG has a better performance compared to the initial design. For example, The effective air gap has been reduced which leads to the better electromagnetic and mechanical performance of HS-PMSG compared to the initial design. By the reduction in the thicknesses of the retention sleeve and the PM, it can be concluded that the total size and dimensions of the HS-PMSG have been reduced. The weight of the PM and the retention sleeve are reduced by about 16.31% and 29.28% responsively, and as a result, the total weight of the HS-PMSG is reduced by approximately 1.94%, The Joule loss is reduced by about 9.80%, the HS-PMSG efficiency has been improved by 0.02%, and finally, the cogging torque is reduced by 27.87%, comparing with the initially designed. The FEM results ensure the electromagnetic and mechanical performance of the machine around the predicted speed of 60-krpm.
VL  - 7
IS  - 2
ER  -

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Author Information

Hossein Parivar

Department of Electrical Engineering, Shahrood University of Technology, Shahrood, Iran
Ahmad Darabi

Department of Electrical Engineering, Shahrood University of Technology, Shahrood, Iran

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APA Style

Hossein Parivar, Ahmad Darabi. (2022). Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve. Engineering and Applied Sciences, 7(2), 21-28. https://doi.org/10.11648/j.eas.20220702.12

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ACS Style

Hossein Parivar; Ahmad Darabi. Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve. Eng. Appl. Sci. 2022, 7(2), 21-28. doi: 10.11648/j.eas.20220702.12

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AMA Style

Hossein Parivar, Ahmad Darabi. Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve. Eng Appl Sci. 2022;7(2):21-28. doi: 10.11648/j.eas.20220702.12

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@article{10.11648/j.eas.20220702.12,
  author = {Hossein Parivar and Ahmad Darabi},
  title = {Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve},
  journal = {Engineering and Applied Sciences},
  volume = {7},
  number = {2},
  pages = {21-28},
  doi = {10.11648/j.eas.20220702.12},
  url = {https://doi.org/10.11648/j.eas.20220702.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.eas.20220702.12},
  abstract = {High-speed permanent magnet synchronous generators (HS-PMSGs) suffer from mechanical stresses due to high speeds. With the predicted mechanical stresses that may occur in the rotor of the HS-PMSGs, the design of these machines should be very accurate. So, for the HS-PMSGs, a proper electromagnetic coupled with mechanical design is a critical issue. This paper presents a novel method for the electromagnetic and mechanical design of an HS-PMSG by finding an appropriate dimension of the retention sleeve and permanent magnets (PMs) based on the well-known Taguchi optimization method. A 40-kW, 60-krpm, 2-poles and 18-slots HS-PMSG is designed at the first step, and next, it has been optimized by the proposed optimization method, and finally modeled and analyzed through Finite-Element Method (FEM). Results obtained from the electromagnetic and mechanical simulations of the HS-PMSG show that in the optimized design of the HS-PMSG some parameters changed and the HS-PMSG has a better performance compared to the initial design. For example, The effective air gap has been reduced which leads to the better electromagnetic and mechanical performance of HS-PMSG compared to the initial design. By the reduction in the thicknesses of the retention sleeve and the PM, it can be concluded that the total size and dimensions of the HS-PMSG have been reduced. The weight of the PM and the retention sleeve are reduced by about 16.31% and 29.28% responsively, and as a result, the total weight of the HS-PMSG is reduced by approximately 1.94%, The Joule loss is reduced by about 9.80%, the HS-PMSG efficiency has been improved by 0.02%, and finally, the cogging torque is reduced by 27.87%, comparing with the initially designed. The FEM results ensure the electromagnetic and mechanical performance of the machine around the predicted speed of 60-krpm.},
 year = {2022}
}

Copy | Download

TY  - JOUR
T1  - Taguchi Method for Design and Optimization of a High-Speed Permanent Magnet Synchronous Generator Protected by Retention Sleeve
AU  - Hossein Parivar
AU  - Ahmad Darabi
Y1  - 2022/05/31
PY  - 2022
N1  - https://doi.org/10.11648/j.eas.20220702.12
DO  - 10.11648/j.eas.20220702.12
T2  - Engineering and Applied Sciences
JF  - Engineering and Applied Sciences
JO  - Engineering and Applied Sciences
SP  - 21
EP  - 28
PB  - Science Publishing Group
SN  - 2575-1468
UR  - https://doi.org/10.11648/j.eas.20220702.12
AB  - High-speed permanent magnet synchronous generators (HS-PMSGs) suffer from mechanical stresses due to high speeds. With the predicted mechanical stresses that may occur in the rotor of the HS-PMSGs, the design of these machines should be very accurate. So, for the HS-PMSGs, a proper electromagnetic coupled with mechanical design is a critical issue. This paper presents a novel method for the electromagnetic and mechanical design of an HS-PMSG by finding an appropriate dimension of the retention sleeve and permanent magnets (PMs) based on the well-known Taguchi optimization method. A 40-kW, 60-krpm, 2-poles and 18-slots HS-PMSG is designed at the first step, and next, it has been optimized by the proposed optimization method, and finally modeled and analyzed through Finite-Element Method (FEM). Results obtained from the electromagnetic and mechanical simulations of the HS-PMSG show that in the optimized design of the HS-PMSG some parameters changed and the HS-PMSG has a better performance compared to the initial design. For example, The effective air gap has been reduced which leads to the better electromagnetic and mechanical performance of HS-PMSG compared to the initial design. By the reduction in the thicknesses of the retention sleeve and the PM, it can be concluded that the total size and dimensions of the HS-PMSG have been reduced. The weight of the PM and the retention sleeve are reduced by about 16.31% and 29.28% responsively, and as a result, the total weight of the HS-PMSG is reduced by approximately 1.94%, The Joule loss is reduced by about 9.80%, the HS-PMSG efficiency has been improved by 0.02%, and finally, the cogging torque is reduced by 27.87%, comparing with the initially designed. The FEM results ensure the electromagnetic and mechanical performance of the machine around the predicted speed of 60-krpm.
VL  - 7
IS  - 2
ER  -

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