车用高功率密度永磁同步电机的研究
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摘要
随着气候变暖和能源问题的日益严重，全球范围内掀起了新能源汽车开发热潮。永磁同步电机效率高、调速性能好等一系列优点受到广泛关注。作为新能源汽车的动力核心部件，其好坏直接决定整车性能。本文在辽宁省科技攻关计划项目—永磁交流牵引电动机的共性关键技术及产品研发的支持下，通过理论分析和实验对车用高效、高功率密度永磁同步牵引电机空载铁耗、负载杂散损耗、热管理以及电机设计计算等关键技术问题展开深入分析研究。
首先，对正弦波电压供电和变频器供电下的车用永磁同步电机磁场特性进行了详细分析。在此基础上，采用有限元方法对永磁同步电机在正弦波电压供电和变频器供电下的空载铁耗进行了分析计算和实验测试。给出了采用有限元方法计算的铁耗修正系数。通过实验测试得到了变频器供电后空载铁耗增加率与供电电压调制比的关系。在计算和实验的基础上，提出了一种综合考虑气隙磁密谐波幅值、电机极槽配合的电机空载铁耗最小化的气隙磁密优化判据ironloss_index。运用该优化判据，对不同极槽配合的极弧因数和转子外圆进行了详细分析，给出了不同极槽配合下的最优极弧因数和8极48槽结构转子外圆最优辅助槽位置。
其次，针对负载杂散损耗分布复杂，难于准确计算的问题，从定子、转子和永磁体三方面对车用永磁同步电机的负载杂散损耗进行了理论分析和有限元求解，并通过实验给出了计算结果的修正系数。从定子磁动势着手，给出了定子负载杂散损耗和转子涡流损耗解析表达式。重点分析了定子磁动势各次时间谐波和空间谐波对转子损耗的影响。直接从麦克斯韦方程出发推导了永磁体涡流损耗解析计算表达式，为永磁体涡流损耗的抑制提供了依据。通过负载杂散损耗的实验测试，给出了有限元计算的修正系数和负载杂散损耗与电机输入功率的比例关系以及时间谐波电流所产生的杂散损耗随负载的变化关系。采用推导的永磁体涡流损耗解析表达式结合有限元方法对分段法抑制永磁体涡流损耗进行了详细分析，给出了普遍适用的分段规律。设计了一种永磁体涡流损耗测试装置，对不同尺寸的永磁体测试结果验证了所得结论的正确性。
再次，在损耗计算基础上，采用流体场和温度场相结合的方式对车用永磁同步电机冷却系统和热管理进行详细分析。根据车用电机的安装和尺寸特点，确定了周向螺旋结构最适合车用永磁同步电机。运用流体场软件分析得到了水道散热系数与水流速度的关系。同时采用流体场对机内空气流动特性进行了详细分析，得到了空气流速分布。在此基础上，对20kW样机进行了稳态和瞬态温度场分析计算，给出了一种实时修正电机损耗的瞬态温度场计算流程图和损耗修正公式。测试结果验证了温度场计算结果的正确性。给出了允许短时过载时间随热负荷的变化关系。
最后，结合车用永磁同步电机的控制方法对永磁同步电机的电磁设计计算方法以及参数配合对高效区范围、弱磁性能的影响进行了详细分析。对车用永磁同步电机的转子结构形式、极槽配合和空载反电动势的选择进行了研究，最终设计制造了转子结构为“V一”型和“V”型，额定功率20kW，4500r/min，峰值功率40kW，功率密度大于1.5kW/kg，高效区比例>80%的两台车用永磁同步电机样机，并进行了全面的实验测试。测试结果与计算结果误差较小，验证了分析和计算方法的正确性。
With global climate warming and energy issue becoming increasingly severe, a globalupsurge of new energy vehicles development has emerged. Because of the high efficiency,good speed control performance and other advantages, the permanent magnet synchronousmotors (PMSM) is concerned widespread. As the key component of the power of newenergy vehicles, the PMSM directly determines the vehicle performance. The researchwork of this thesis is supported by the Liaoning province Engineering Research Centerfunded projects permanent magnet AC traction motor common key technologies andproduct development. Through theoretical analysis and experiment test, the no load ironloss, stray load loss, thermal management, motor design and calculation technologies andsome other key technical issues of high efficiency, high power density PMSM for electricvehicles(EVs) application are analyzed in-depth.
Firstly, the magnetic field characteristics of PMSM when fed from sine voltage andconverters are analyzed in details. On this basis, the finite element method (FEM) isadopted to calculate and analyze the no load iron loss when fed from sinusoidal voltageand converters, and then the experimental test is carried out. The iron loss correction factorof FEM calculation result is presented. The relationship between the no load iron lossincremental ratio and supply voltage modulation ratio is obtained by experiment. Based onthe calculation and test results, an optimization criterion which minimize the no load ironloss named ironloss_index and comprehensive consider the harmonic amplitude of air-gapflux density, pole slot combinations is proposed. Using this optimization criterion, the pole arc factor and rotor cylindrical of different pole slot combination is analyzed in details, andthen the optimal pole arc factor of different pole slot combination and the optimal groovesposition on rotor cylindrical of 8 poles 48 slots structure is given.
Secondly, because of distribution complexand difficult to accurately calculation, thetheoretical analysis and FEM calculation of the stray load loss of the PMSM for EVsapplication is presented from the stator, rotor and magnets. The correction factor of thecalculated results is obtained based on the test results. Commence from the stator magneticmotive force (MMF), the analytical expression of stator stray load loss and rotor eddycurrent loss is presented. The influence of the time and spatial harmonics of stator MMF onrotor loss are mainly analyzed. An magnets eddy current loss analytical expression isderived directly from the basic equation of electromagnetic field，and it provides thetheoretical basis for loss reduction. Through the stray load loss test results, the correctionfactor of stray load loss FEM calculation results is obtained, the proportional relationshipof stray load loss to motor input power and the relationship between the stray load lossgenerated by current time harmonics and load torque are also given. Combination with theanalytical expression and FEM, The magnet eddy current loss suppression technology ---magnet segmentation is investigated, and then a common segmentation law is obtained. Atest device is designed for magnet eddy current loss test, the eddy current loss test resultsof different size magnets verified the validity of the results.
Thirdly, based on the iron loss calculated results, the cooling system and thermalmanagement are analyzed in details combination the fluid field and temperature field.According to motor installation environment and size characteristics, the spiral structure isdetermined as the suitable cooling structure. The relationship between the thermalcoefficient of water channel and water speed is obtained through the fluid calculation. Theair flow characteristic in the motor is analyzed through the fluid field analysis, and the airflow speed distribution is obtained. On this basis, the steady-state and transient temperature field of 20kW prototype is analyzed; a real-time correction flow chart of motor losses intransient temperature and their correction formulation are given. The temperature testresults verified the correctness of the calculation results. According to the experimentresults, the permitted time of short-time overload with the thermal-load is obtained.
Finally, combination the control method of PMSM for EVs application and motordesign technology, the electromagnetic design and calculated method is analyzed. Theinfluence of parameter coordination to efficiency and field weakening performance are alsopresented. Then, the rotor structure, pole slot combination and no load back-EMF arestudied. At last，two PMSM prototypes for EVs which rotor structure is "V一" type and"V" type are designed, manufactured and comprehensive tested. The rated data of thesetwo prototypes is rated power 20kW, rated speed 4500r/min, peak power 40kW, powerdensity greater than 1.5kW/kg, high efficiency area ratio greater than 80%. The gapbetween the test results and analysis results is small, and the correctness of analysis andcalculation method is verified.
首先，对正弦波电压供电和变频器供电下的车用永磁同步电机磁场特性进行了详细分析。在此基础上，采用有限元方法对永磁同步电机在正弦波电压供电和变频器供电下的空载铁耗进行了分析计算和实验测试。给出了采用有限元方法计算的铁耗修正系数。通过实验测试得到了变频器供电后空载铁耗增加率与供电电压调制比的关系。在计算和实验的基础上，提出了一种综合考虑气隙磁密谐波幅值、电机极槽配合的电机空载铁耗最小化的气隙磁密优化判据ironloss_index。运用该优化判据，对不同极槽配合的极弧因数和转子外圆进行了详细分析，给出了不同极槽配合下的最优极弧因数和8极48槽结构转子外圆最优辅助槽位置。
其次，针对负载杂散损耗分布复杂，难于准确计算的问题，从定子、转子和永磁体三方面对车用永磁同步电机的负载杂散损耗进行了理论分析和有限元求解，并通过实验给出了计算结果的修正系数。从定子磁动势着手，给出了定子负载杂散损耗和转子涡流损耗解析表达式。重点分析了定子磁动势各次时间谐波和空间谐波对转子损耗的影响。直接从麦克斯韦方程出发推导了永磁体涡流损耗解析计算表达式，为永磁体涡流损耗的抑制提供了依据。通过负载杂散损耗的实验测试，给出了有限元计算的修正系数和负载杂散损耗与电机输入功率的比例关系以及时间谐波电流所产生的杂散损耗随负载的变化关系。采用推导的永磁体涡流损耗解析表达式结合有限元方法对分段法抑制永磁体涡流损耗进行了详细分析，给出了普遍适用的分段规律。设计了一种永磁体涡流损耗测试装置，对不同尺寸的永磁体测试结果验证了所得结论的正确性。
再次，在损耗计算基础上，采用流体场和温度场相结合的方式对车用永磁同步电机冷却系统和热管理进行详细分析。根据车用电机的安装和尺寸特点，确定了周向螺旋结构最适合车用永磁同步电机。运用流体场软件分析得到了水道散热系数与水流速度的关系。同时采用流体场对机内空气流动特性进行了详细分析，得到了空气流速分布。在此基础上，对20kW样机进行了稳态和瞬态温度场分析计算，给出了一种实时修正电机损耗的瞬态温度场计算流程图和损耗修正公式。测试结果验证了温度场计算结果的正确性。给出了允许短时过载时间随热负荷的变化关系。
最后，结合车用永磁同步电机的控制方法对永磁同步电机的电磁设计计算方法以及参数配合对高效区范围、弱磁性能的影响进行了详细分析。对车用永磁同步电机的转子结构形式、极槽配合和空载反电动势的选择进行了研究，最终设计制造了转子结构为“V一”型和“V”型，额定功率20kW，4500r/min，峰值功率40kW，功率密度大于1.5kW/kg，高效区比例>80%的两台车用永磁同步电机样机，并进行了全面的实验测试。测试结果与计算结果误差较小，验证了分析和计算方法的正确性。
With global climate warming and energy issue becoming increasingly severe, a globalupsurge of new energy vehicles development has emerged. Because of the high efficiency,good speed control performance and other advantages, the permanent magnet synchronousmotors (PMSM) is concerned widespread. As the key component of the power of newenergy vehicles, the PMSM directly determines the vehicle performance. The researchwork of this thesis is supported by the Liaoning province Engineering Research Centerfunded projects permanent magnet AC traction motor common key technologies andproduct development. Through theoretical analysis and experiment test, the no load ironloss, stray load loss, thermal management, motor design and calculation technologies andsome other key technical issues of high efficiency, high power density PMSM for electricvehicles(EVs) application are analyzed in-depth.
Firstly, the magnetic field characteristics of PMSM when fed from sine voltage andconverters are analyzed in details. On this basis, the finite element method (FEM) isadopted to calculate and analyze the no load iron loss when fed from sinusoidal voltageand converters, and then the experimental test is carried out. The iron loss correction factorof FEM calculation result is presented. The relationship between the no load iron lossincremental ratio and supply voltage modulation ratio is obtained by experiment. Based onthe calculation and test results, an optimization criterion which minimize the no load ironloss named ironloss_index and comprehensive consider the harmonic amplitude of air-gapflux density, pole slot combinations is proposed. Using this optimization criterion, the pole arc factor and rotor cylindrical of different pole slot combination is analyzed in details, andthen the optimal pole arc factor of different pole slot combination and the optimal groovesposition on rotor cylindrical of 8 poles 48 slots structure is given.
Secondly, because of distribution complexand difficult to accurately calculation, thetheoretical analysis and FEM calculation of the stray load loss of the PMSM for EVsapplication is presented from the stator, rotor and magnets. The correction factor of thecalculated results is obtained based on the test results. Commence from the stator magneticmotive force (MMF), the analytical expression of stator stray load loss and rotor eddycurrent loss is presented. The influence of the time and spatial harmonics of stator MMF onrotor loss are mainly analyzed. An magnets eddy current loss analytical expression isderived directly from the basic equation of electromagnetic field，and it provides thetheoretical basis for loss reduction. Through the stray load loss test results, the correctionfactor of stray load loss FEM calculation results is obtained, the proportional relationshipof stray load loss to motor input power and the relationship between the stray load lossgenerated by current time harmonics and load torque are also given. Combination with theanalytical expression and FEM, The magnet eddy current loss suppression technology ---magnet segmentation is investigated, and then a common segmentation law is obtained. Atest device is designed for magnet eddy current loss test, the eddy current loss test resultsof different size magnets verified the validity of the results.
Thirdly, based on the iron loss calculated results, the cooling system and thermalmanagement are analyzed in details combination the fluid field and temperature field.According to motor installation environment and size characteristics, the spiral structure isdetermined as the suitable cooling structure. The relationship between the thermalcoefficient of water channel and water speed is obtained through the fluid calculation. Theair flow characteristic in the motor is analyzed through the fluid field analysis, and the airflow speed distribution is obtained. On this basis, the steady-state and transient temperature field of 20kW prototype is analyzed; a real-time correction flow chart of motor losses intransient temperature and their correction formulation are given. The temperature testresults verified the correctness of the calculation results. According to the experimentresults, the permitted time of short-time overload with the thermal-load is obtained.
Finally, combination the control method of PMSM for EVs application and motordesign technology, the electromagnetic design and calculated method is analyzed. Theinfluence of parameter coordination to efficiency and field weakening performance are alsopresented. Then, the rotor structure, pole slot combination and no load back-EMF arestudied. At last，two PMSM prototypes for EVs which rotor structure is "V一" type and"V" type are designed, manufactured and comprehensive tested. The rated data of thesetwo prototypes is rated power 20kW, rated speed 4500r/min, peak power 40kW, powerdensity greater than 1.5kW/kg, high efficiency area ratio greater than 80%. The gapbetween the test results and analysis results is small, and the correctness of analysis andcalculation method is verified.
引文
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