高速永磁电机定子损耗和温升研究
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摘要
高速永磁电机由于具有转速高、体积小、功率密度大、高效节能等优点,在高速磨床、高速飞轮储能系统及污水处理等领域得到越来越广泛的应用。然而由于高速和高频带来的损耗、温升及散热问题也变得越来越严重,因此为了保证高速永磁电机安全可靠的运行,必须对如何降低电机损耗和温升及改善通风冷却效果等问题进行深入的研究。本文针对高速永磁电机设计中的关键问题,采用磁场、流体场和温度场相结合的分析方法对高速电机的损耗、温升和散热问题进行了研究,主要研究内容如下:
(1)针对高速永磁电机高频供电时,定子绕组电流和铁心中磁通交变频率增高导致铁耗增加的特点,通过实际测量有取向电工钢片不同频率和不同轧制方向的铁心损耗,对实验数据进行回归分析从而确定铁耗计算模型中磁滞和涡流损耗系数。然后通过有限元分析,根据定子铁心不同区域磁场的变化规律,综合考虑电机中交变与旋转磁场的影响,对一台额定转速为60000r/min的高速永磁电机的铁耗进行了分析计算,并与实验结果进行了比较。结果表明,考虑旋转磁场及谐波磁场分量影响时的铁心损耗更接近实际测量值。
(2)考虑到高速电机高频运行时由于集肤效应对绕组附加铜耗的影响,进行了高速永磁电机定子绕组附加铜耗的计算。基于电磁场理论分析了影响高频附加损耗的相关因素,采用场路耦合有限元法分析了高频附加损耗与转速之间的关系,通过损耗分离方法将高频附加损耗从电机总损耗中分离出来,并将计算结果与实验分离值相对比,验证了高频附加损耗分析方法的正确性和有效性。
(3)根据高速永磁电机通风系统的特点,基于流体力学理论建立电机轴向系统流体场数学模型,计算了高速电机轴向通风沟内冷却气体的流速,并在此基础上,分别采用热路法与流体场结合的方法和基于流固耦合场的分析方法计算了高速永磁电机的温升。与实验结果的对比表明,采用热路法与流体场结合的温升计算方法虽然没有流固耦合的分析方法准确,但是由于其计算工作量小并结合了流体场的分析结果,因此计算结果比传统的等效热路法要准确并具有实际应用价值;而采用基于流固耦合计算永磁电机的温度场分析结果则更接近实测值。
(4)针对高速永磁电机的结构特点,对一台12槽高速永磁电机的冷却系统进行了研究,分别建立了油冷及空冷和水冷相结合的混合冷却的三维流体场模型,并通过流固耦合法进行了温度场计算。
The high speed permanent magnet (PM) machine has been widely investigated since it has high speed, small size, high power density and high efficiency. The application areas for this machine include high-speed grinding machine, high-speed energy storage flywheel, and sewage treatment and so on. However, due to the high loss and small size, the heat dissipation difficulty becomes a serious problem. To ensure safe and reliable operation of high speed PM machine, it is necessary to study the methods to reduce the losses and improve the ventilation effect. This thesis is focused on the key problem in machine design. The problems of loss, temperature rise and ventilation are researched based on the analysis of electromagnetic field, equivalent heat circuit, fluid field and temperature field. The main contents are listed as follows:
(1) The core loss increases along with the alternate frequency of the magnetic field. Therefore, the accurate calculation of core loss is more important to the high speed machines. In this thesis, the coefficients of hysteretic loss and eddy-current losses in core losses calculation model are determined by the loss experiments of oriented electrical sheet in different rolling direction for different frequency. Based on the finite element analysis of magnetic field in the stator core, considering the influence of alternating and rotating magnetic field, the core losses of a 60000r/min high speed PM machine are analyzed and compared with the tested result. The comparative study shows that the calculated core losses considering the influence of rotating magnetic field as well as the harmonic magnetic field are closer to the experimental results.
(2) The additional winding losses produced by the high-frequency skin effect in high speed machine are investigated. The winding additional loss is calculated. The related factors affecting the additional winding losses are analyzed based on the theory of electromagnetic field. Through field-circuit coupled finite element analysis, the relationship between high-frequency loss and rotor speed is established and the additional winding losses are separated from the total losses. The comparison of the calculated value with the experimental result shows the validity and feasibility of the proposed copper loss calculation method for the high speed PM machine.
(3) According to the characteristics of axial ventilation system, the calculation model of high speed PM machine is established on the basis of the fluid field analysis. The fluid velocity of cooling gas in the axial ventilation duct is computed. The temperature field is calculated by using the combination method of equivalent heat circuit and fluid field solution with fluid-solid field coupled analysis method respectively. The comparison of the calculated value with the experimental result shows that the combination method of equivalent heat circuit with fluid field analysis is not accurate enough, but it is simple and easily computed. Compared with the conventional equivalent heat circuit method, the combination method is more accurate. The calculated temperature rise by the fluid-solid coupled method is closer to the experimental result.
(4) The ventilation system of 12-slot high speed PM machine is investigated. The three-dimensional fluid field models with oil cooling and mixture cooling of air and water are established. The temperature field of high speed PM machine with different cooling medium is calculated by using the fluid-solid coupling analysis.
(1)针对高速永磁电机高频供电时,定子绕组电流和铁心中磁通交变频率增高导致铁耗增加的特点,通过实际测量有取向电工钢片不同频率和不同轧制方向的铁心损耗,对实验数据进行回归分析从而确定铁耗计算模型中磁滞和涡流损耗系数。然后通过有限元分析,根据定子铁心不同区域磁场的变化规律,综合考虑电机中交变与旋转磁场的影响,对一台额定转速为60000r/min的高速永磁电机的铁耗进行了分析计算,并与实验结果进行了比较。结果表明,考虑旋转磁场及谐波磁场分量影响时的铁心损耗更接近实际测量值。
(2)考虑到高速电机高频运行时由于集肤效应对绕组附加铜耗的影响,进行了高速永磁电机定子绕组附加铜耗的计算。基于电磁场理论分析了影响高频附加损耗的相关因素,采用场路耦合有限元法分析了高频附加损耗与转速之间的关系,通过损耗分离方法将高频附加损耗从电机总损耗中分离出来,并将计算结果与实验分离值相对比,验证了高频附加损耗分析方法的正确性和有效性。
(3)根据高速永磁电机通风系统的特点,基于流体力学理论建立电机轴向系统流体场数学模型,计算了高速电机轴向通风沟内冷却气体的流速,并在此基础上,分别采用热路法与流体场结合的方法和基于流固耦合场的分析方法计算了高速永磁电机的温升。与实验结果的对比表明,采用热路法与流体场结合的温升计算方法虽然没有流固耦合的分析方法准确,但是由于其计算工作量小并结合了流体场的分析结果,因此计算结果比传统的等效热路法要准确并具有实际应用价值;而采用基于流固耦合计算永磁电机的温度场分析结果则更接近实测值。
(4)针对高速永磁电机的结构特点,对一台12槽高速永磁电机的冷却系统进行了研究,分别建立了油冷及空冷和水冷相结合的混合冷却的三维流体场模型,并通过流固耦合法进行了温度场计算。
The high speed permanent magnet (PM) machine has been widely investigated since it has high speed, small size, high power density and high efficiency. The application areas for this machine include high-speed grinding machine, high-speed energy storage flywheel, and sewage treatment and so on. However, due to the high loss and small size, the heat dissipation difficulty becomes a serious problem. To ensure safe and reliable operation of high speed PM machine, it is necessary to study the methods to reduce the losses and improve the ventilation effect. This thesis is focused on the key problem in machine design. The problems of loss, temperature rise and ventilation are researched based on the analysis of electromagnetic field, equivalent heat circuit, fluid field and temperature field. The main contents are listed as follows:
(1) The core loss increases along with the alternate frequency of the magnetic field. Therefore, the accurate calculation of core loss is more important to the high speed machines. In this thesis, the coefficients of hysteretic loss and eddy-current losses in core losses calculation model are determined by the loss experiments of oriented electrical sheet in different rolling direction for different frequency. Based on the finite element analysis of magnetic field in the stator core, considering the influence of alternating and rotating magnetic field, the core losses of a 60000r/min high speed PM machine are analyzed and compared with the tested result. The comparative study shows that the calculated core losses considering the influence of rotating magnetic field as well as the harmonic magnetic field are closer to the experimental results.
(2) The additional winding losses produced by the high-frequency skin effect in high speed machine are investigated. The winding additional loss is calculated. The related factors affecting the additional winding losses are analyzed based on the theory of electromagnetic field. Through field-circuit coupled finite element analysis, the relationship between high-frequency loss and rotor speed is established and the additional winding losses are separated from the total losses. The comparison of the calculated value with the experimental result shows the validity and feasibility of the proposed copper loss calculation method for the high speed PM machine.
(3) According to the characteristics of axial ventilation system, the calculation model of high speed PM machine is established on the basis of the fluid field analysis. The fluid velocity of cooling gas in the axial ventilation duct is computed. The temperature field is calculated by using the combination method of equivalent heat circuit and fluid field solution with fluid-solid field coupled analysis method respectively. The comparison of the calculated value with the experimental result shows that the combination method of equivalent heat circuit with fluid field analysis is not accurate enough, but it is simple and easily computed. Compared with the conventional equivalent heat circuit method, the combination method is more accurate. The calculated temperature rise by the fluid-solid coupled method is closer to the experimental result.
(4) The ventilation system of 12-slot high speed PM machine is investigated. The three-dimensional fluid field models with oil cooling and mixture cooling of air and water are established. The temperature field of high speed PM machine with different cooling medium is calculated by using the fluid-solid coupling analysis.
引文
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