新型永磁电机的设计、分析与应用研究
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摘要
永磁电机是一种很有发展潜力的高效节能动力装置,在工业生产和日常生活的诸多领域中正日益得到广泛的应用。在我国大力提倡节能减排的宏观背景下,开发和研究新型的高效节能永磁同步电动机,降低用电设备的耗电量,不仅符合国家的宏观政策导向,而且具有良好的社会和经济效益。复式永磁同步电机和直驱式抽油机就是针对油田中耗电量最大且为数众多的传统游梁式抽油机提出的。直驱式抽油机改变了复杂笨重的机械传动方式,利用复式永磁同步电机低转速、大输出转矩的特点,直接驱动抽油机负载,提高了抽油机的系统效率和功率因数,实现了良好的节电效果。复式永磁电机是将双盘式电机与圆筒形外转子电机在三维空间上组合而成的,提高了电机单位体积内的输出转矩。本论文从复式永磁同步电机的设计计算方法、电机内电磁场的分析、电机参数的优化、齿槽转矩的抑制、电机驱动控制系统的研究,到复式永磁电机的测试试验及其在直驱式抽油机中应用和系列化的讨论,对这一新型结构的电机进行了全面的理论分析和试验验证工作。
本论文所研究的另一种永磁电机是针对磁浮交通系统中的长定子直线同步电机提出的改进型电机结构,即内置永磁体式永磁电励混合励磁直线同步电机。研究这一新型结构的出发点是为了减少悬浮励磁次级的耗电量,达到节省车载电源能耗的目的。这对减小磁浮列车上励磁次级的体积和重量,降低车载电源容量,提高整车性能都有一定的实际意义。
本论文的研究工作主要集中在以下几个方面:
1.在复式永磁同步电机这一新型结构的基础上,对现有的调速永磁同步电机的设计方法和解析计算公式进行归纳、总结及推演,形成了适用于复式永磁电机的电磁参数设计计算方法。对复式永磁电机工作特性的研究表明,定子直流电阻值对电机特性的影响很大,它使最大电磁功率对应的功角小于90°,使定子铜耗在电机总损耗中占据绝大部分,使电机效率随负载率的增加呈逐步下降的走势。
2.针对复式永磁电机结构的特殊性,先使用三维CAD软件构建立体模型,直接在三维图形中进行结构修改工作,再用工程制图软件AutoCAD绘制二维工程图。为保证电机结构的可靠性,应用材料力学的相关知识,对以电机主轴为代表的主要零部件进行强度和刚度方面的分析校核工作。对于电机温升问题,将等效热路法进行适当的修改,推导出适合于复式永磁电机使用的温升计算公式,对样机的温升进行了计算,并与试验结果进行对比,误差不大于6%。
3.应用永磁电机三维磁场的有限元分析方法,对复式永磁电机作适当简化后进行建模,使用该模型对电机内空载和负载磁场的分布情况、空载漏磁以及不同功角时的输出转矩等进行了分析计算。对于抑制复式永磁电机齿槽转矩的问题,采用齿槽转矩的解析分析与有限元计算相互印证的方式,对电机的筒形和盘形部分分别进行讨论。通过复式永磁电机的解析计算方法,以有限元方法为辅助,针对重要结构参数对电机性能的影响进行分析,由此得出这些参数的最佳取值范围。
4.根据复式永磁电机直轴和交轴电感近似相等的特点,采用合适的矢量控制策略,并使用EKF算法估计转速以替代机械传感器的检测,实现复式永磁电机的无位置传感器矢量控制系统。从控制系统硬件电路的设计、系统框图的建立到软件流程的制定,对复式永磁电机的驱动控制系统进行了前期研究工作。采用MATLAB/Simulink仿真软件对控制系统进行了仿真分析,结果表明控制系统对电机的控制效果理想。
5.在试验塔架上应用新型永磁电机测量系统对复式永磁电机进行了空载、负载和温升试验,并将电机的理论计算结果与试验数据进行了对比分析。
6.根据游梁式抽油机的型号标准,从替代游梁式抽油机的角度对直驱式抽油机及复式永磁电机的系列化进行了讨论。说明了直驱式抽油机能够节电增产的原因,并给出了节电效果的实测数据。检测数据表明,同型号的直驱式抽油机比异步电机驱动的游梁式抽油机节电50%以上。
7.对现有的永磁电励混合励磁直线同步电机进行结构改进的角度,提出了两种新型的混合励磁次级结构——内置永磁体半隔磁式和内置永磁体全隔磁式混合励磁结构。对比半隔磁式和全隔磁式结构,由于后者漏磁更少,同等条件下获得的悬浮力更大,因此对全隔磁式结构进行了更为深入细致的分析。采用二维电磁场的有限元分析方法,对全隔磁式混合励磁结构进行结构参数优化。通过分析悬浮力、推力和空载漏磁系数三个性能参数,将全隔磁式混合励磁结构与电励磁结构、与两种现有的混合励磁结构进行了对比分析。在以上所进行的全部研究工作中,第一、三和七项是本文的创新点所在。
Permanent magnet (PM) machines are a kind of highly efficient energy-saving power units, which have huge development potential. Their use is being increasingly applied in many fields of industry and daily life. Since our government has started to place emphasis on energy reduction and advocate energy reducing techniques, novel PM synchronous machines accord with energy-saving policies for this reason PM synchronous machines are primarily researched and developed in order to provide stable social and economic benefits. Compound permanent magnet synchronous machines (CPMSM) and direct-drive pumping units are put forward for replacing beam pumping units that they are in wide use and their power consumption is the largest on oil fields. The direct-drive pumping unit changes complex cumbersome mechanically-driven mode, and drives the load directly by the CPMSM that has the characteristic of low-speed and huge-torque. So it increases the system efficiency and improves the power factor. The CPMSM increases the output torque per unit volume because it combines one cylindrical outer-rotor electric machine with two disk electric machines in three-dimensional space. In this dissertation, the overall theoretical analysis and experiments of the CPMSM have been accomplished, which include design and calculation method of the CPMSM, electromagnetic field analysis, optimization of structural parameters, reduction of cogging torque, control system research, experiments on the test bed, and application & serialization of the CPMSM in the direct-drive pumping unit.
The other kind of PM machine researched in the dissertation is the PM & electromagnetic hybrid excitation linear synchronous machine (HELSM) with internally placed PM, which is put forward for improving the long stator linear synchronous machine (LSM) used in the maglev transportation system. The purpose of researching the novel HELSM is reducing power consumption of the levitation excitation secondary so that the capacity of vehicular power supply and the volume of secondary can be decreased. It is of practical significance.
All research work in the dissertation can be summarized in the following items.
1. After putting forward the structure of the CPMSM, the electromagnetic parameters calculation methods of the CPMSM came into being, which based on generalizing the design methods and deducing the design formulae of variable-speed PM synchronous machines. The operating characteristic of the CPMSM manifests that the value of stator resistance has great influence on the machine characteristic. The stator resistance results that the power-angle corresponding for the maximal electromagnetic power is less than 90 degree, the stator copper loss is the main portion of the machine gross loss, and the machine efficiency gradually decreases with the load ratio increasing.
2. Because of the special structure of the CPMSM, the three-dimensional machine model was designed with the three-dimensional CAD software in order to modifying the model conveniently. Then the planar engineering drawings were drawn with AutoCAD software. In order to ensure reliability of the structure, strength and rigidity of the main shaft were checked applying the theory of mechanics of materials. About temperature rise of the CPMSM, the equivalent thermal loop method was applied in the calculation of temperature rise. Furthermore, the calculation formulae of temperature rise for the CPMSM were deduced. Then the temperature rise of the model machine is calculated and compared with the experimental results. The error percentage is less than 6%.
3. After building the analysis model for the CPMSM, the no-load & load magnetic field distribution, the no-load leakage flux, and the output torque under the different power-angle were analyzed and calculated with applying the three-dimensional finite element method of PM machines magnetic field. The measures which can reduce the cogging torque of the cylindrical part and the disk part were discussed respectively with applying the analytical method and the finite element method. In the same way the important structural parameters of the CPMSM were analyzed according to their effect on the machine performance. Therefore the optimal span of these parameters could be ascertained.
4. Considering the d-axis and q-axis inductance of the CPMSM are almost equal, the sensorless vector control system of the CPMSM adopts suitable strategy of vector control and sensorless technology that estimates the rotational speed with Extended Kalman Filtering (EKF) algorithm. The primary research work was accomplished in the dissertation, such as designing circuits of the control system, plotting the system block diagram, framing the software flowchart and so on. The control system was analyzed with MATLAB/Simulink simulation software. The simulation results manifest that control effect of the machine control system is ideal.
5. The no-load, load, and temperature rise test of the CPMSM were accomplished on the test bed with the novel PM machine measurement system. Then the theoretical calculation results were compared to the experimental data.
6. According to the national standard of beam pumping units, the issues about serialization of CPMSM and direct-drive pumping units were discussed in order to replace already existing beam pumping units. The reasons why the direct-drive pumping unit can save energy and increase in yield are explained, and the test data about energy-saving effect are shown in the dissertation. The test data manifest that the same type of direct-drive pumping units can save 50% more energy than beam pumping units which are driven by induction machines.
7. For improving on the existent structure of HELSM, two kinds of novel structure of HELSM are put forward, i.e. the incompletely isolated magnetic-field mode and the completely isolated magnetic-field mode with internally placed PM. By comparison of the incompletely isolated magnetic-field mode and the completely isolated magnetic-field mode, it can be seen that leakage flux of the latter is smaller, and its suspension force is larger under the same conditions. So the completely isolated magnetic-field HELSM is the main subject of investigation. The structural parameters of the completely isolated magnetic-field HELSM were optimized with the finite element method of two-dimensional magnetic field. By analyzing the suspension force, the propulsive force, and the no-load leakage coefficient, the completely isolated magnetic-field HELSM was compared with electromagnetic excitation LSM and with two kinds of existent HELSM.
The first, third, and seventh items of above research work are the innovative points of the dissertation.
本论文所研究的另一种永磁电机是针对磁浮交通系统中的长定子直线同步电机提出的改进型电机结构,即内置永磁体式永磁电励混合励磁直线同步电机。研究这一新型结构的出发点是为了减少悬浮励磁次级的耗电量,达到节省车载电源能耗的目的。这对减小磁浮列车上励磁次级的体积和重量,降低车载电源容量,提高整车性能都有一定的实际意义。
本论文的研究工作主要集中在以下几个方面:
1.在复式永磁同步电机这一新型结构的基础上,对现有的调速永磁同步电机的设计方法和解析计算公式进行归纳、总结及推演,形成了适用于复式永磁电机的电磁参数设计计算方法。对复式永磁电机工作特性的研究表明,定子直流电阻值对电机特性的影响很大,它使最大电磁功率对应的功角小于90°,使定子铜耗在电机总损耗中占据绝大部分,使电机效率随负载率的增加呈逐步下降的走势。
2.针对复式永磁电机结构的特殊性,先使用三维CAD软件构建立体模型,直接在三维图形中进行结构修改工作,再用工程制图软件AutoCAD绘制二维工程图。为保证电机结构的可靠性,应用材料力学的相关知识,对以电机主轴为代表的主要零部件进行强度和刚度方面的分析校核工作。对于电机温升问题,将等效热路法进行适当的修改,推导出适合于复式永磁电机使用的温升计算公式,对样机的温升进行了计算,并与试验结果进行对比,误差不大于6%。
3.应用永磁电机三维磁场的有限元分析方法,对复式永磁电机作适当简化后进行建模,使用该模型对电机内空载和负载磁场的分布情况、空载漏磁以及不同功角时的输出转矩等进行了分析计算。对于抑制复式永磁电机齿槽转矩的问题,采用齿槽转矩的解析分析与有限元计算相互印证的方式,对电机的筒形和盘形部分分别进行讨论。通过复式永磁电机的解析计算方法,以有限元方法为辅助,针对重要结构参数对电机性能的影响进行分析,由此得出这些参数的最佳取值范围。
4.根据复式永磁电机直轴和交轴电感近似相等的特点,采用合适的矢量控制策略,并使用EKF算法估计转速以替代机械传感器的检测,实现复式永磁电机的无位置传感器矢量控制系统。从控制系统硬件电路的设计、系统框图的建立到软件流程的制定,对复式永磁电机的驱动控制系统进行了前期研究工作。采用MATLAB/Simulink仿真软件对控制系统进行了仿真分析,结果表明控制系统对电机的控制效果理想。
5.在试验塔架上应用新型永磁电机测量系统对复式永磁电机进行了空载、负载和温升试验,并将电机的理论计算结果与试验数据进行了对比分析。
6.根据游梁式抽油机的型号标准,从替代游梁式抽油机的角度对直驱式抽油机及复式永磁电机的系列化进行了讨论。说明了直驱式抽油机能够节电增产的原因,并给出了节电效果的实测数据。检测数据表明,同型号的直驱式抽油机比异步电机驱动的游梁式抽油机节电50%以上。
7.对现有的永磁电励混合励磁直线同步电机进行结构改进的角度,提出了两种新型的混合励磁次级结构——内置永磁体半隔磁式和内置永磁体全隔磁式混合励磁结构。对比半隔磁式和全隔磁式结构,由于后者漏磁更少,同等条件下获得的悬浮力更大,因此对全隔磁式结构进行了更为深入细致的分析。采用二维电磁场的有限元分析方法,对全隔磁式混合励磁结构进行结构参数优化。通过分析悬浮力、推力和空载漏磁系数三个性能参数,将全隔磁式混合励磁结构与电励磁结构、与两种现有的混合励磁结构进行了对比分析。在以上所进行的全部研究工作中,第一、三和七项是本文的创新点所在。
Permanent magnet (PM) machines are a kind of highly efficient energy-saving power units, which have huge development potential. Their use is being increasingly applied in many fields of industry and daily life. Since our government has started to place emphasis on energy reduction and advocate energy reducing techniques, novel PM synchronous machines accord with energy-saving policies for this reason PM synchronous machines are primarily researched and developed in order to provide stable social and economic benefits. Compound permanent magnet synchronous machines (CPMSM) and direct-drive pumping units are put forward for replacing beam pumping units that they are in wide use and their power consumption is the largest on oil fields. The direct-drive pumping unit changes complex cumbersome mechanically-driven mode, and drives the load directly by the CPMSM that has the characteristic of low-speed and huge-torque. So it increases the system efficiency and improves the power factor. The CPMSM increases the output torque per unit volume because it combines one cylindrical outer-rotor electric machine with two disk electric machines in three-dimensional space. In this dissertation, the overall theoretical analysis and experiments of the CPMSM have been accomplished, which include design and calculation method of the CPMSM, electromagnetic field analysis, optimization of structural parameters, reduction of cogging torque, control system research, experiments on the test bed, and application & serialization of the CPMSM in the direct-drive pumping unit.
The other kind of PM machine researched in the dissertation is the PM & electromagnetic hybrid excitation linear synchronous machine (HELSM) with internally placed PM, which is put forward for improving the long stator linear synchronous machine (LSM) used in the maglev transportation system. The purpose of researching the novel HELSM is reducing power consumption of the levitation excitation secondary so that the capacity of vehicular power supply and the volume of secondary can be decreased. It is of practical significance.
All research work in the dissertation can be summarized in the following items.
1. After putting forward the structure of the CPMSM, the electromagnetic parameters calculation methods of the CPMSM came into being, which based on generalizing the design methods and deducing the design formulae of variable-speed PM synchronous machines. The operating characteristic of the CPMSM manifests that the value of stator resistance has great influence on the machine characteristic. The stator resistance results that the power-angle corresponding for the maximal electromagnetic power is less than 90 degree, the stator copper loss is the main portion of the machine gross loss, and the machine efficiency gradually decreases with the load ratio increasing.
2. Because of the special structure of the CPMSM, the three-dimensional machine model was designed with the three-dimensional CAD software in order to modifying the model conveniently. Then the planar engineering drawings were drawn with AutoCAD software. In order to ensure reliability of the structure, strength and rigidity of the main shaft were checked applying the theory of mechanics of materials. About temperature rise of the CPMSM, the equivalent thermal loop method was applied in the calculation of temperature rise. Furthermore, the calculation formulae of temperature rise for the CPMSM were deduced. Then the temperature rise of the model machine is calculated and compared with the experimental results. The error percentage is less than 6%.
3. After building the analysis model for the CPMSM, the no-load & load magnetic field distribution, the no-load leakage flux, and the output torque under the different power-angle were analyzed and calculated with applying the three-dimensional finite element method of PM machines magnetic field. The measures which can reduce the cogging torque of the cylindrical part and the disk part were discussed respectively with applying the analytical method and the finite element method. In the same way the important structural parameters of the CPMSM were analyzed according to their effect on the machine performance. Therefore the optimal span of these parameters could be ascertained.
4. Considering the d-axis and q-axis inductance of the CPMSM are almost equal, the sensorless vector control system of the CPMSM adopts suitable strategy of vector control and sensorless technology that estimates the rotational speed with Extended Kalman Filtering (EKF) algorithm. The primary research work was accomplished in the dissertation, such as designing circuits of the control system, plotting the system block diagram, framing the software flowchart and so on. The control system was analyzed with MATLAB/Simulink simulation software. The simulation results manifest that control effect of the machine control system is ideal.
5. The no-load, load, and temperature rise test of the CPMSM were accomplished on the test bed with the novel PM machine measurement system. Then the theoretical calculation results were compared to the experimental data.
6. According to the national standard of beam pumping units, the issues about serialization of CPMSM and direct-drive pumping units were discussed in order to replace already existing beam pumping units. The reasons why the direct-drive pumping unit can save energy and increase in yield are explained, and the test data about energy-saving effect are shown in the dissertation. The test data manifest that the same type of direct-drive pumping units can save 50% more energy than beam pumping units which are driven by induction machines.
7. For improving on the existent structure of HELSM, two kinds of novel structure of HELSM are put forward, i.e. the incompletely isolated magnetic-field mode and the completely isolated magnetic-field mode with internally placed PM. By comparison of the incompletely isolated magnetic-field mode and the completely isolated magnetic-field mode, it can be seen that leakage flux of the latter is smaller, and its suspension force is larger under the same conditions. So the completely isolated magnetic-field HELSM is the main subject of investigation. The structural parameters of the completely isolated magnetic-field HELSM were optimized with the finite element method of two-dimensional magnetic field. By analyzing the suspension force, the propulsive force, and the no-load leakage coefficient, the completely isolated magnetic-field HELSM was compared with electromagnetic excitation LSM and with two kinds of existent HELSM.
The first, third, and seventh items of above research work are the innovative points of the dissertation.
引文
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