The slender shape of the driving machine leads to a low rigidity and large axial thermal elongation of the motorized spindle, which deteriorates the machining precision. To solve these problems and pursue a more compact size, this paper investigates the feasibility of using a tooth-coil permanent magnet synchronous machine in a high-speed spindle, replacing the original motor that has the conventional distributed winding. Comprehensive performance and behavior of machines with distributed and tooth-coil windings are comparatively analyzed, in terms of the essential torque ripples, winding inductances, electromagnetic losses, rotor integrity, and heat dissipation of the spindle. Thorough numerical simulation results indicate that the newly designed tooth-coil winding solution shows significant advantages over the original design, regarding high rotor rigidity, low torque ripples, reduced electromagnetic losses, and reduced shaft thermal elongation. Prototypes and test setups for the high-speed tooth-coil machine are built, where preliminary measurements are carried out to validate the analysis results and system design.@en

In this article, a nonlinear semianalytical model (SAM) is presented to predict the magnetic field distribution (MFD) and electromagnetic performances (EPs) in the cubic spoke-type permanent magnet (PM) machine. To model the rectangular PMs, the rectangular PM is simplified as a combination of fan-shaped regions with different arc angles. Then, the MFD and EPs of the cubic spoke-type machines can be obtained by the harmonic modeling technique. Particularly, the saturation of the magnetic bridges is considered by the nonlinear iterative algorithm. The proposed nonlinear SAM is studied on a 12-slot/8-pole cubic PM prototype, and the nonlinear finite element model and experiment verify its correctness. The main contribution of this article is to present a general analytical modeling method for cubic spoke-type PM machines and consider the magnetic saturation of magnetic bridges.

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This paper studies the power density limits of propulsion motor for electric aircraft considering thermal aspects and breakdown voltage reduction of insulation. The study em-ploys multi-objective optimization (MOO) to explore various mo-tor cooling options and filter configurations. The results show that motors with direct winding heat exchanger (DWHE) can reach higher specific power, while those equipped with water jacket cooling (WJC) offer a moderate design with simpler structure. Furthermore, the impact of sine wave and dv/dt filters on electric motors design is studied. The findings demonstrate that dv/dt filters enable designs with higher overall specific power compared to sine wave filters. Through simulations, this study identify the challenge faced by aviation motor design in significantly increased insulation thickness, necessitating advanced insulation materials with a minimum thermal conductivity of 5 W/(m.K) to facilitate a high specific power design. Based on this assumption, a preliminary design of 9.6 kW/kg with an efficiency of 98% is presented.

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This article presents an optimal multivariable control (OMC) strategy for the LCC-LCC compensated wireless power transfer systems. To mitigate reactive power and achieve higher efficiency, the proposed OMC method incorporates dual-side hybrid modulation and primary-side switch-controlled-capacitor (SCC) tuning into the triple-phase-shift (TPS) control. First, the impact of hybrid modulation and SCC tuning on the system characteristics is investigated. The inverter and rectifier zero-voltage-switching (ZVS) conditions are then analyzed to achieve dual-side ZVS with minimal reactive power. Furthermore, a multivariable optimization problem is established based on the power loss analysis. The solution to this problem provides optimal control variables that minimize the overall system loss. Through collaborative modulation and control of the inverter, rectifier, and SCC, the proposed method reduces the rms values of the currents and lowers the turn-off currents for the converters. As a result, this approach improves efficiency in both light- and heavy-load conditions, enabling wide output regulation and full-range efficiency optimization simultaneously. Finally, the proposed method is benchmarked with the existing TPS method. Experimental results demonstrate that the proposed method achieves higher dc-to-dc efficiency in the power range of 0.2-2.2 kW, with a maximum efficiency improvement of up to 6.3%.

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Triangular current mode (TCM) zero-voltage switching (ZVS) modulation method is widely adopted in power electronic converters to achieve acceptable efficiency in high switching frequency operations. For bidirectional dc-dc converters, in order to realize ZVS turn-on, a reverse inductor current can be utilized for this purpose through variable frequency control. In this article, this reverse switched current is revisited considering the parasitic resistances presented in the mosfet switches and the inductor for three common types of dc-dc converters, i.e., buck, boost, and buck-boost converters, which study was normally neglected in the previous research. Universal closed-form equations of the modified duty cycle and switched current are derived, which can be utilized to calculate the reverse current under different operating conditions. It is found that the parasitic resistances can have a negative impact on the switched current value, and this may lead to an unexpected loss of ZVS turn-on. A laboratory prototype of a four-switch buck+boost converter featuring TCM-ZVS buck, boost, and buck-boost operation capability was built to investigate and verify the proposed concepts. The operating voltage and power range are from 100 V to 400 V, and 300 W to 1 kW, respectively.

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The pursuit of battery charging technology for electric vehicle (EV) has led to extensive research on the inductive-based wireless power transfer (WPT) systems. In this paper, the compensation component (including coils) stresses will be studied in two commonly adopted compensation topologies, namely S-S and LCC-S compensations. Due to the peak voltage calculation inaccuracy for certain components based on conventional fundamental frequency analysis, an improved peak voltage calculation method is introduced in closed form, which is proved to be more accurate by both simulation and experiments.@en

It is ideal for the wireless power transfer (WPT) systems to operate at the resonance state for better transmission performance. In practice, however, the parameters of the resonant circuits often deviate because of the capacitance drift and coil misalignment. To this end, this paper proposes a new parameter estimation method for the WPT systems, which is able to facilitate the power flow control and active impedance tuning of the WPT systems under parameter deviations. Distinct from the traditional parameter identification methods, the proposed method is implemented with an short-circuited rectifier, and therefore, the whole estimation process is independent of the load variations. Furthermore, to avoid severe system detuning during the frequency-sweeping process, a dynamic frequency sweeping method is proposed to efficiently and safely extract the data of the primary and secondary coil currents. Based on the extracted data, a mathematical model is established, and the JAYA algorithm is utilized to identify the unknown parameters. Experimental results are presented to verify the estimation accuracy of the proposed method.@en

In this article, an efficient multi-objective optimization strategy for the Halbach array permanent magnet synchronous machine (PMSM) is developed by taking into consideration the nonlinear B-H behavior of soft magnetic materials. Based on the harmonic modeling (HM) technology, the electromagnetic performances (EPs) of the Halbach array PMSM can be computed. To specifically model the local magnetic saturation, the stator teeth are separated into several annular layers, and each tooth is further divided into several regions along the tangential direction. Then, the parameters of the Halbach array PMSM are optimized utilizing combined nonlinear semi-analytical model (SAM) and non-dominated sorting genetic algorithm II (NSGA-II). To validate the effectiveness and accuracy of the developed optimization scheme, a Halbach array prototype is then manufactured in accordance with the optimization results. The multi-objective rapid optimization strategy developed in this article, which includes but is not limited to Halbach array permanent magnet (PM) machines, serves as a reference for the design and optimization of various PM machines.

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This article proposes a nonlinear semianalytical model (SAM) of the multiphase Halbach array axial flux permanent-magnet motor (AFPMM) to speed up the computation of its magnetic field. Compared to the existing analytical models, the proposed nonlinear SAM can directly consider magnetic saturation to obtain more accurate results. To this end, the multiphase Halbach array AFPMM is equivalent to several 2-D models by the quasi-3-D method under the Cartesian coordinate system. Then, the nonlinear SAM is developed by using the convolution theorem and the fast Fourier factorization. The proposed nonlinear SAM is studied on a five-phase Halbach array AFPMM with different rotors, and the nonlinear finite element (FE) model and experiment verify its effectiveness. The proposed SAM is computationally efficient and accurate, and it is also applicable to other types of multiphase Halbach array permanent magnet (PM) electrical motors in Cartesian coordinates.

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In this article, a new analytical model for predicting the magnetic field of the U-shaped interior permanent magnet motor (IPMM) is proposed. In the polar coordinates, rectangular permanent magnets are equivalent to the combination of consistent fan-shaped subdomains, and after that, the Laplace or Poisson equation of each solution domain can be obtained. Furthermore, based on the harmonic modeling (HM) technique, the saturation characteristics of the magnetic bridge are accurately considered, and then its magnetic field distribution (MFD) and electromagnetic performances (EPs) can be obtained. The approach proposed in this article includes but is not limited to U-shaped IPMMs, and it can also be applied to spoke-type or V-shaped IPMMs with a minor modification.

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Compensation capacitors are naturally susceptible to manufacturing defects and aging effects, leading to the degraded performance of a wireless power transfer (WPT) system. This article focuses on the compensation parameters optimization during the design stage and control strategy during the operation phase to improve the inherent capacitor error tolerance of the WPT system. The Sobol sensitivity method is applied to rank the importance of deviations of three capacitors on the transfer characteristics, and then the method of tracking the secondary resonance frequency is proposed. The numerical method is applied to find the optimal compensation parameters, with the constraint that the output voltage change caused by the shift of the designed compensation condition is limited to be less than ±5%. Experimental results show that with the proposed frequency tracking method and compensation parameter optimization, the deviation tolerance index is decreased from 0.485 to 0.363, showing an improvement of 25.2%, and the minimum power factor is increased from 0.78 to 0.89. Besides, the characteristics of constant primary coil current and voltage gain are almost not affected.

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This article presents a parameter recognition-based impedance tuning method for the impedance mismatch caused by capacitance drift and coil misalignment in series-series-compensated wireless power transfer (WPT) systems. First, a parameter recognition method is proposed to identify the unknown parameters of the resonant circuits by only measuring the rms values of the coil currents. No phase detection circuits and auxiliary measurement coils are required. Furthermore, according to the recognized parameters, the reactance on both sides are minimized simultaneously by regulating the system frequency and the phase shift angles of the active rectifier. Compared with the existing methods, the proposed parameter recognition method adopts a dynamic frequency approaching strategy to avoid severe system detuning due to the bifurcation phenomenon. Moreover, based on the recognized parameters, the proposed impedance tuning method can simultaneously cope with the parameter deviations caused by capacitance drift and coil misalignment on both sides without using extra circuits and switches. Experimental results show that the unknown parameters of the resonant circuits are recognized accurately, with the average relative errors all less than 3%. Additionally, by implementing the impedance tuning method, the dc to dc efficiency of the WPT prototype is improved by 4.3%-15% in the experiments.

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The health management of batteries is a key enabler for the adoption of Electric Vertical Take-off and Landing vehicles (eVTOLs). Currently, few studies consider the health management of eVTOL batteries. One distinct characteristic of batteries for eVTOLs is that the discharge rates are significantly larger during take-off and landing, compared with the battery discharge rates needed for automotives. Such discharge protocols are expected to impact the long-run health of batteries. This paper proposes a data-driven machine learning framework to estimate the state-of-health and remaining-useful-lifetime of eVTOL batteries under varying flight conditions and taking into account the entire flight profile of the eVTOLs. Three main features are considered for the assessment of the health of the batteries: charge, discharge and temperature. The importance of these features is also quantified. Considering battery charging before flight, a selection of missions for state-of-health and remaining-useful-lifetime prediction is performed. The results show that indeed, discharge-related features have the highest importance when predicting battery state-of-health and remaining-useful-lifetime. Using several machine learning algorithms, it is shown that the battery state-of-health and remaining-useful-life are well estimated using Random Forest regression and Extreme Gradient Boosting, respectively.@en

The ModHVDC concept is a modular permanent magnet generator which uses insulated stator segments with dedicated power electronic converters to produce HVDC. This could significantly reduce the number of required power conversion steps for HVDC-connected offshore wind parks. However, the concept poses structural challenges to the machine design, which are investigated in this paper. It is observed that segmentation of the stator has two major effects on the harmonic forces that occur inside in the machine: the addition of low spatial order harmonics, referred to as the segment harmonics, and an increase of the cogging torque. Furthermore, the structural integrity of the stator was found to be reduced. Based on these findings, design recommendations are put forward to mitigate the drawbacks of stator segmentation.@en

This article proposes a hybrid analytical model (HAM) for predicting ac copper losses in hairpin windings. The HAM combines the nonlinear semi-analytical model (SAM) and the 1-D ac copper loss computation model to solve the inaccurate boundary solutions of the 1-D ac copper loss computation model when magnetic saturation occurs in the stator teeth. The HAM is used to study the ac losses of the hairpin windings with four different conductor arrangements under different current excitation conditions, and the versatility of the HAM is verified. The HAM has high calculation accuracy, and the calculation speed is 66% faster than the finite element (FE) model. The primary contribution of this research is to present a quick and simple approach for accurately predicting ac copper losses in hairpin windings with arbitrary conductor arrangements.

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This paper introduces variable-frequency zero voltage switching (ZVS) modulation strategy for the four-switch buck+boost converter with one operating pattern for the inductor current, i.e., three-segment inductor current modulation control. The proposed modulation scheme guarantees a smooth transition from step-up to step-down or from step-down to step-up operating modes without abrupt duty cycle or switching frequency change. Triangular current mode (TCM) ZVS control could be derived from this three-segment inductor current modulation strategy. Moreover, the controller design can be simplified compared with other multi-mode control methods. Experimental results were given to validate the modulation control strategy based on a 300−600 V input, 400 V output, 3.3 kW prototype.@en

In this article, we propose a novel nonlinear semianalytical model (AM) for the magnetic field calculation of electric machines. The nonlinear properties and local saturation effect of the iron part are taken into consideration in Cartesian coordinates, which is the main contribution of the proposed model. Thus, high accuracy of electromagnetic field results can be obtained with the low computational time cost. The model is developed based on the harmonic modeling technique by solving Maxwell's equations. The detailed theoretical derivations, which use the complex Fourier series and the Cauchy product, are presented. To verify the proposed model, an axial flux permanent-magnet (PM) machine is selected to be investigated. Both finite-element model and experimental results agree well with that of the proposed model. Moreover, the nonlinear AM has potential application for other types of PM electrical motor in Cartesian coordinates, such as flat PM linear machines.

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This article proposes a compensation method of position estimation error for high-speed surface-mounted permanent magnet synchronous motors based on robust inductance estimation. The proposed method relies on the variation of the estimated δ-axis back back-electromotive force when a small current is injected into the γ axis. The inductance estimation error is limited within pm !5% when the nominal resistance and inductance vary bf pm 30% of their real values. With the estimated inductance, the position estimation error can be well compensated. Compared with the conventional current-injection method, the proposed method has enhanced robustness against the system noises. Benefiting from this, it is effective to estimate the inductance with a small injected current ( bf 0.5% of the rated current), where the conventional methods fail. Finally, the effectiveness of the proposed method is validated by simulation and experiment results on a 100 kr/min (1.67 kHz) high-speed permanent magnet synchronous machines accurately with 10-kHz sampling frequency.

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