摘要
新型磁齿轮传动装置属于磁场调制式磁力传动结构,具有转矩密度高、运行效率高、非接触性力矩传递和过载自保护等优点,有替代机械齿轮在清洁、低温和高空等环境中运行的潜力。高性能稀土永磁材料在电机设计中的成功应用,使得现代永磁电机的转矩密度和运行效率较感应电机有了较大提高。
本文提出一种新结构稀土永磁电机,就是把普通的稀土永磁电机内嵌到磁场调制式磁齿轮里,从而形成磁齿轮复合电机,这样就把永磁电机和磁齿轮的优点结合了起来。磁齿轮复合电机作为实现低速大转矩电机的一条新途径,研究成果应用前景广泛,可应用于军事领域(舰船直接驱动)、车辆运输(电力机车、电动汽车直接驱动)、可再生能源利用开发(风力发电)、先进制造业(机床直接驱动)等场合。
本课题是国家“863”高科技项目《高效大转矩直接驱动复合式永磁电机系统研究》(2007 AA05Z233)的研究内容之一,对新型结构钕铁硼永磁电机——磁齿轮复合电机进行设计研究。
本文围绕这种新型磁齿轮复合电机展开研究,具体做了以下几方面的工作:
1)、以电机电磁场计算的解析方法为出发点,在电机气隙中求解了极坐标下数学物理方程中的拉普拉斯方程的解析解。结合有限元方法,得到电机磁场整个区域的矢量磁位,为计算其他物理量奠定了基础。
2)、分析机械齿轮和传统磁齿轮的不足之处,研究新型磁齿轮复合电机的关键部位——磁场调制式磁齿轮传动装置的运行机理。针对该装置的输入输出转子转向相反,且具有两层气隙的特点,在多气隙场合中拓展了数值解析结合法的磁场计算,编制了相应的程序。以气隙磁场谐波分析为出发点,分析了这种新型磁齿轮,虽然该装置内、外层气隙之中的磁场有多种谐波分量存在,但是电磁转矩几乎是单一主波成份,数值解析结合法仿真计算得到的定量结果与运行机理中的理论分析相一致。
3)、利用磁齿轮内转子的空间,在考虑加工、装配等的可行性之后,完成了电机拓扑结构的创新,设计出新型磁齿轮复合电机。借助于电机电磁场计算的数值解析结合法,实现了复合电机内、外两个转子任意方向任意角度的自由转动磁场计算。计算了复合电机的感应电动势和电磁转矩,捕捉了齿槽定位转矩的最大值等电机参数。按一定指标要求设计了一台低速大转矩高效磁齿轮复合电机,并研制了相应的样机。
4)、试验证明了新型磁齿轮和永磁电机的结合取得了结构上的创新,磁齿轮复合电机样机取得高转矩密度稳定运行的效果,磁齿轮样机更是取得了高转矩密度、高传动效率稳定运行的结果。试验测得的感应电势和转矩与数值解析结合法计算相吻合,验证了在多气隙场合中拓展数值解析结合法磁场计算的有效性。
新电机结构紧凑、转矩密度高、功率因数高,又有过载自保护能力,适合于低转速、高转矩直接驱动系统。磁齿轮复合电机的成功运行,取得了电机结构和设计算法上的创新,为低速大转矩电机的设计增添了新的途径。
A novel magnetic field modulation gearing transmits torque by magnetic force with high density and efficiency, and could be a potential substitute of a mechanical gearing if used in lustration, low temperature, high altitude environment etc. The development of high performance rare-earth permanent magnet material and its successful application in electrical machine, make it possible to provide more torque density and efficiency for a modern permanent magnet machine compared with for an induction motor.
A permanent magnet electrical machine combined with a field modulation magnetic gear has been presented in this paper. The paper describes the fundamental structure of an outer rotor brushless PM motor is embedded into a novel magnetic gear. Merits of the permanent magnet electrical machine and the novel magnetic gear are combined together for realizing a high toque low speed drive. The research results application prospect is widespread, may be applied in the military domain (ship direct drive), the transportation (electric locomotive, electric automobile direct drive), the renewable energy development (wind power generation), the advanced manufacturing industry (machine tool direct drive) and so on.
As one part of the national 863 program research project“Research on an efficient large torque direct-drive permanent magnet combined electrical machine system”(2007 AA05Z233),The text concentrates on the design of a permanent magnet electrical machine combined with a magnetic gear.
This article around a permanent magnet electrical machine combined with a magnetic gear expands research, do the following tasks:
1) Base upon the analytical approach of electromagnetic field as a starting point, in cylindrical coordinates find the analytical solution of Laplace’s equation in a certain annular region of the air gap. Combine the finite element method, solve overall field vector potentials in an electrical machine, and lay the foundation to calculate other physical quantities.
2) Analyze deficiencies of mechanical gears and traditional magnetic gears, research magnetic field modulation magnetic gearing which is the key part of the combined electrical machine work. For the characteristic of the device with two layers of air gap, whose input rotor and output rotor turn reversely, extend numerical and analytical combined method of magnetic field calculation, and establish the corresponding program. Both in inner layer air gap and in outer layer air gap the magnetic field has many kinds of harmonic component existence, but the electromagnetic torque is nearly the sole fundamental wave ingredient, the calculation result by way of numerical and analytical combined method is consistent with the theoretical analysis.
3) After using the inner rotor’s space of the field modulation magnetic gear, considering processing, assembly and so on feasibility, has completed the electrical machinery topology innovation, i.e., designed the permanent magnet electrical machine combined with the novel magnetic gear. With the aid of the numerical and analytical combined method, has realized the magnetic field calculation under the condition that the inner rotor and the outer rotor rotate with free pace and different direction. Parameters of the induced electromotive force and the electromagnetic torque and so on of the novel motor have been calculated, and it is not difficult to catch the maximum value of cogging torque. Has designed a low speed big torque highly effective electrical machine combined with a novel magnetic gear according to certain target requests, and developed the prototype.
4) The experiment has proven the union of a novel magnetic gear and a permanent magnet electrical machine in the structure innovation successfully. The electrical machine combined with a novel magnetic gear runs at a high torque density with a stable movement effect. The high torque density, the high transmission efficiency and stable movement result of the magnetic gearing prototype are also obtained. The induced electromotive force and electromagnetic force of the combined electrical machine have obtained consistently with the analysis by the way of numerical and analytical combined method, which proves the proposed method is correct and effective in the multiple airgaps situation.
The novel electrical machine combined with a magnetic gear has a compact structure, high torque density, high power factor and the protection ability when overloaded, suits in the low speed high torque direct drive system. The smooth movement of the novel electrical machine combined with a magnetic gear has been obtained, which proves the success of the structure and the design algorithm innovation, has increased the new way for the low speed high torque electrical machine design.
引文
[1]发改委公告.国家发展改革委办公厅关于组织实施可再生能源和新能源高技术产业化专项通知.中国创业投资与高科技,2005(5):16-17
[2]Tapio Haring, Kimmo Forsman, Tero Huhtanen, Mark Zawadzki. Direct Drive—Opening a New Era in Many Applications, Pulp and Paper Industry Technical Conference, 2003. Conference Record of the 2003 Annual, 16-20 June 2003:171 - 179
[3]Mitcham A. J.. Transverse flux motor for electric propulsion of ships. Proceedings of IEE, London UK, 1997
[4]Kang D H, Chun Y H, Weh H. Analysis and optimal design of transverse flux linear motor with PM excitation for railway traction. IEE Proceedings-Electric Power Applications, 2003(4): 493–499.
[5]Marcelo Godoy Sim?es, Petronio Vieira, Jr.. A high-torque low-speed multiphase brushless machine—a perspective application for electric vehicles. IEEE Trans. on Industrial Electronics, Vol. 49, No. 5, October 2002:1154-1164
[6]Feng Guihong, Wang Lifeng, Zhang Bingyi, Sun Guanggui, Zhao Zhongxian. Analysis of magnetic field for low speed and high torque permanent magnet synchronous machine, ICEMS 2003, Sixth International Conference on Electrical Machines and Systems, 2003. Vol.2:778– 781
[7]M.R. Dubois, H. Polinder, J.A.Ferreira. Comparison of generator topologies for direct-drive wind turbines. NORPIE 2000.
[8]H. Polinder, B.C. Mecrow, A.G. Jack et al. Conventional and TFPM Linear Generators for Direct-Drive Wave Energy Conversion. IEEE Transactions on Energy Conversion. 2005, 20(2):260– 267
[9]刘彬.舵机用无刷直流电机控制系统研究.西北工业大学硕士学位论文,2004年3月
[10] K. Strnat, G. Hoffer, J. Olson, and W. Ostertag. A Family of New Cobalt-Base Permanent Magnet Materials. Journal of Applied Physics, Vol.38, Issue 3, 1967:1001-1002.
[11] K.Atallah, D. Howe, A Novel High-Performance Magnetic Gear, IEEE Trans. on Magnetics, Vol.37, No.4, 2001:2844-2846
[12] K.Atallah, S.D. Calverley and D. Howe, Design, analysis and realization of a high-performance magnetic gear, IEE Proc.-Electr. Power Appl. Vol. 151 No. 2, 2004:135-143
[13] Peter Omand Rasmussen, Torben Ole Andersen, Frank T. J?rgensen, and Orla Nielsen. Development of a High-Performance magnetic gear. IEEE Transactions on Industry Applications, Vol. 41, No. 3, May/June 2005:764–770
[14]唐任远等编著.现代永磁电机理论与设计.机械工业出版社,1996
[15]Yeong-Der Yao, Gwo-ji Chiou, Der-Ray Huang, Shyh-jier Wang. Theoretical Computations for The Torque of Magnetic Coupling. IEEE Transactions on Magnetics. Vol. 31, No. 3, May 1995:1881-1884
[16]D. R. Huang, Y. D. Yao, S. M. Lin, S. J. Wang. The Radial Magnetic Coupling Studies between Magnetic Gears. IEEE Transactions on Magnetics. Vol. 31, No. 6, November 1995:3752-3754
[17]Y. D. Yao, D. R. Huang, S. M. Lin, S. J. Wang. Theoretical Computation of the Magnetic Coupling between Magnetic Gears. IEEE Transactions on Magnetics. Vol. 32, No. 3, May 1996: 710-713
[18]D. R. Huang, C. C. Hsieh, D. Y. Chiang, S. J. Wang, T. F. Ying. The Radial Magnetic Coupling Studies of Perpendicular Magnetic Gears. IEEE Transactions on Magnetics. Vol. 32, No. 5, September 1996:5061-5063
[19]Y. D. Yao, D. R. Huang, C. C. Hsieh, D. Y. Chiang, S. J. Wang. Simulation Study of the Magnetic Coupling between Radial Magnetic Gears. IEEE Transactions on Magnetics. Vol. 33, No. 2, March 1997:2203-2206
[20]Y. D. Yao, D. R. Huang, C. M. Lee. S. J. Wang, D. Y. Chiang, T. F. Ying. Magnetic Coupling Studies between Radial Magnetic gears. IEEE Transactions on Magnetics. Vol. 33, No. 5, September 1997:4236-4238
[21]E. P. Furlani. Formulas for the Force and Torque of Axial Couplings. IEEE Transactions on Magnetics. Vol. 29, No. 5, September 1993:2295-2301
[22]E. P. Furlani. A Formula for the Levitation Force between Magnetic Disks. IEEE Transactions on Magnetics. Vol. 29, No. 6, November 1993:4165-4169
[23]R. Wang, E. P. Furlani, Z. J. Cendes. Design and Analysis of a Permanent Magnet Axial Coupling Using 3D Finite Element Field Computations. IEEE Transactions on Magnetics. Vol. 30, No. 4, July 1994:2292-2295.
[24]E. P. Furlani. A Two-Dimensional Analysis for the Coupling of Magnetic Gears. IEEE Transactions on Magnetics. Vol. 33, No. 3, May 1997:2317-2321.
[25]陈匡非,杜玉梅.平行轴永磁齿轮的特性研究.微特电机,2004(4):5~8
[26]张建涛,夏东.永磁齿轮转矩特性研究.机械,2005(3):3~5
[27]张建涛,夏东.永磁齿轮在人工心脏中的应用研究.微特电机,2005 (9):5~10
[28]赵韩,杨志轶,田杰.永磁齿轮传动力矩计算方法研究.机械工程学报,2001, 37(11):66~70
[29]赵韩,杨志轶.永磁齿轮传动力矩三维分析与计算.农业机械学报,2001, 32(6):95~99
[30]田杰,邓辉华,赵韩,王勇.稀土永磁齿轮传动系统动态仿真研究.中国机械工程,2006, 17(22):2315~2318
[31]田杰,邓辉华,张萍,赵韩.考虑非线性磁导率稀土永磁齿轮磁场研究.机械工程师,2006(1):92~94
[32]赵韩,陶骏,田杰,杜世俊.磁场积分法在稀土永磁齿轮传动结构场分析中的应用.机械工程学报,2000,36(8):29~32
[33]赵韩,田杰.用有限元法设计稀土永磁齿轮传动.机械科学与技术,2000, 19(2): 207~209
[34]郑伟刚,罗延科,李屹.稀土永磁磁力齿轮传动实验研究.机械制造,2004,42(483):52~54
[35] K. Atallah, J. Wang, and D. Howe. A high-performance linear magnetic gear[J]. Journal of Applied Physics, 2005, 97(10):10N516.1-10N516.3.
[36] S. Mezani, K. Atallah, and D. Howe. A high-performance axial-field magnetic gear[J]. Journal of Applied Physics, 2006, 99(8):08R303.1-08R303.3.
[37] Li Yong, Xing Jingwei, Peng Kerong, Lu Yongping. Principle and simulation analysis of a novel structure magnetic gear. International Conference on Electrical Machines and Systems 2008, 2008:3845–3849.
[38] Nicolas W. Frank, Hamid A. Toliyat. Gearing ratios of a magnetic gear for marine applications. 2009 IEEE Electric Ship Technologies Symposium, 2009:477-481
[39] Wolfgang Hafla, Andre Buchau, Wolfgang M. Rucker. Efficient design analysis of a novel magnetic gear on a high performance computer. www.emeraldinsight.com/0332-1649.htm.
[40]Frank T. J?rgensen, Torben Ole Andersen, and Peter Omand Rasmussen. The Cycloid Permanent Magnetic Gear. IEEE Transactions on Industry Applications, Vol. 44, No. 6, November/Decembr 2008: 1659-1665
[41] Laxman Shah, A. Cruden and Barry W. Williams. A Magnetic Gear Box for application with a Contra-rotating Tidal Turbine. PEDS 2007: 989- 993
[42] Jan Rens, Richard Clark, Stuart Calverley, Kais Atallah, David Howe. Design, Analysis and Realization of a Novel Magnetic Harmonic Gear. Proceedings of the 2008 International Conference on Electrical Machines, Paper ID 1454
[43] F. T. Joergensen , T.O. Andersen, P.O. Rasmussen. The cycloid permanent magnetic gear. 1-4244-0365-0/06/$20.00 (c) 2006 IEEE: 373-378
[44] J. Rens, K. Atallah, S.D.Calverley and D. Howe. Anovel magnetic harmonic gear. 1 -4244-0743-5/07/$20.OO ?C2007 IEEE: 698- 703
[45]Xinhua Liu, K. T. Chau, J. Z. Jiang, L. N. Jian. Analysis of Concentric Magnetic Gears Using Three Dimensional Scalar Magnetic Potential Finite Element Method. Intermag2008, Madrid, Spain, May,4-8, 2008, no, AL-04.
[46]Linni Jian, K. T. Chau, Yu Gong, J. Z. Jiang, Chuang Yu, and Wenlong Li. Comparison of Coaxial Magnetic Gears With Different Topologies. IEEE Transactions on Magnetics, Vol. 45, No.10, October 2009:4526-4529.
[47] Evon, S.; Schiferl, R.; Direct Drive Induction Motors, Pulp and Paper Industry Technical Conference, 2004. Conference Record of the 2004 Annual, 27 June-1 July 2004:49 - 54
[48] Salminen, P.; Niemela, M.; Pyhonen, J.; Mantere, J.;Performance analysis of fractional slot wound PM-motors for low speed applications, Industry Applications Conference, 2004. 39th IAS Annual Meeting. Conference Record of the 2004 IEEE Vol. 2, 3-7 Oct. 2004:1032 - 1037
[49]程树康、寇宝泉、杨世彦等.串联磁路结构双定子混合式直接驱动电机的转矩特性.中国电机工程学报,2004,24(7):127-132
[50] Weh, H. Transversal flow machine in accumulator arrangement[P]. United States Patent:5051641,1991
[51] Jiang Jianzhong. Analytische und dreidimensionale numerische berechung von transversalful ? MASCHINEN. 1988.
[52] Hasubek B E, Nowicki E P. Two dimensional finite element analysis of passive rotor transverse flux motors with slanted rotor design. IEEE Canadian Conference on Electrical and Computer Engineering, 1999 (2):1199–1204
[53]张东、江建中、施进浩.车用轮毂式永磁无刷直流电动机设计.微特电机,2005 (6):5-8
[54] Feng Chai, Shumei Cui, Shukang Cheng, Performance Analysis of Double-Stator Starter Generator for Hybrid Electric Vehicle, IEEE Trans. on Magnetics, Vol. 41, No.1, 2005:484-487
[55]寇宝泉、张千帆、程树康、裴宇龙.串联磁路结构双定子混合式直接驱动电动机的定位转矩分析及抑制策略.中国电机工程学报,2005,25(8):145-150
[56]王晓冬、王卫、徐殿国、王炎.直接驱动控制系统的研究.电工技术杂志,1997(2):2-4
[57]郑文鹏、江建中、李永斌、张东.基于三维磁网络法E型铁心横向磁场电机的设计与研究.中国电机工程学报,2004,24(8):138-141
[58]李永斌、袁琼、江建中.一种新型聚磁式横向磁场永磁电机研究.电工技术学报,2003, 18(5):46-49
[59]李永斌、高瑾、江建中.横向磁场开关磁阻电机永磁屏蔽技术研究.中国电机工程学报,2003,23(11):164-168
[60]施进浩、李永斌、江建中.聚磁式横向磁场永磁电机自定位转矩研究.电工技术学报,2005,20(3):36-39
[61]柴凤、崔淑梅、宋立伟、程树康.双定子永磁同步电动机的结构设计.微电机,1999,32(6):12-14
[62] Abdel-Razek, A.; Coulomb, J.; Feliachi, M.; Sabonnadiere, J.; Conception of an air-gap element for the dynamic analysis of the electromagnetic field in electric machines,IEEE Trans. on Magnetics, Vol. 18 , Issue: 2 , 1982:655– 659
[63] Lee, K.; DeBortoli, M.J.; Lee, M.J.; Salon, S.J.; Coupling finite elements and analytical solution in the airgap of electric machines, IEEE Trans. on Magnetics, Vol. 27 , Issue: 5 , 1991:3955– 3957
[64] Bi Chao; Chen, S.X.; Liu, Z.J.; Low, T.S.; Electromagnetic field analysis in rotational electric machines using finite element-analytical hybrid method, IEEE Trans. on Magnetics, Vol.30, Issue: 6 ,1994 :4314– 4316
[65]苑津莎、张金堂.电机暂态过程电磁场数值计算的一种新方法.华北电力学院学报,1993(4):1-8
[66] Zhang Y.J., Jiang J.Z., Tu G.Z., Numerical-Analytical Method for Magnetic Field Computation in Rotational Electric Machines, Journal of Shanghai University,vol.7 No.3 2003: 270-274
[67]章跃进、江建中、屠关镇.应用数值解析结合法计算旋转电机磁场.电工技术学报2004,19(1):7-11
[68]章跃进、江建中、屠关镇.旋转电机磁场计算中转子的自由转动.2004台达电力电子新技术研讨会论文集,2004:369-372
[69]章跃进、崔巍、张东、江建中.高性能永磁电机感应电动势计算.2005台达电力电子新技术研讨会论文集,2005:168-171
[70]章跃进、崔巍、张东、江建中.旋转电机电磁转矩精确计算.2005台达电力电子新技术研讨会论文集,2005:160-163
[71]Gu Qishan, Gao Hongzhan. Effect of slotting in PM eletric Machines. Electric Machines and Power Systems, No.10,1985:273-284
[72]Gu Qishan, Gao Hongzhan. Airgap field for PM electric machines. Electric Machines and Power Systems, No.10,1985:459-470
[73]Gu Qishan, Gao Hongzhan. The fringing effect in PM eletric machines. Electric Machines and Power Systems, No.11,1985:159-169
[74] Z.Q.Zhu, David Howe, Ekkehard Bolte, and Bernd Ackermann. Instantaneous Magnetic Field Distribution in Brushless Permanent Magnet dc Motors, PartⅠ:Open-Circuit Field. IEEE Transactions on Magnetics, Vol 29, No.1 January 1993:124-134
[75]Z.Q. Zhu, and David Howe. Instantaneous Magnetic Field Distribution in Brushless Permanent magnet dc Motors, PartⅡ:Armature-Reaction Field. IEEE Transactions on Magnetics, Vol.29, No.1, January 1993:136-142
[76] Z.Q. Zhu, and David Howe. Instantaneous Magnetic Field Distribution in Brushless Permanent Magnet dc Motors, PartⅢ:Effect of Stator Slotting. IEEE Transactions on Magnetics, Vol.29, No.1, January 1993:143-151
[77] Z.Q. Zhu, and David Howe. Instantaneous Magnetic Field Distribution in Brushless Permanent Magnet dc Motors, PartⅣ:Magnetic Field on Load. IEEE Transactions on Magnetics, Vol.29, No.1, January 1993:152-158
[78]Amuliu Bogdan Proca, Ali Keyhani, Ahmed EL-Antably, Wenzhe Lu, and Min Dai. Analytical Model for Permanent Magnet Motors with Surface Mounted Magnets. IEEE Transactions on Energy Conversion, Vol.18, No.3, September 2003:386-390
[79]王兴华,励庆孚,王曙鸿.永磁无刷直流电机磁阻转矩的解析计算方法.中国电机工程学报,2002,22(10):104-108
[80]王兴华,励庆孚,王曙鸿.永磁无刷直流电机空载气隙磁场和绕组反电势的解析计算.中国电机工程学报,2003,23(3):126-130
[81]王兴华,励庆孚,王曙鸿.永磁无刷直流电机负载磁场及其电磁转矩的计算.中国电机工程学报,2003,23(4):140-144
[82]Sheppard J. Salon. Finite Element Analysis of Electrical Machines. Kluwer Academic Publishers, 1995
[83]江建中,傅为农.异步电机电磁场计算的有限元模型综述.电工技术杂志,1998(1):3-6
[84]胡之光主编.电机电磁场的分析与计算.机械工业出版社,1982
[85]傅为农,江建中.现代永磁电机的设计环境.微特电机,1997(6):37-40
[86]屠关镇.电机磁场有限元新技术.电机技术,2007(2):1-4
[87]K. Tsurumoto, S. Kikuchi. A New Magnetic Gear Using Permanent Magnet. IEEE Transactions on Magnetics. Vol. MAG-23, No. 5, September 1987:3622-3624.
[88]S. Kikuchi, K. Tsurumoto. Design on Characteristics of A New Magnetic Worm Gear Using Permanent Magnet. IEEE Transactions on Magnetics. Vol. 29, No. 6, part 2, November 1993: 2923-2925.
[89]Shinki Kikuchi, Katsuo Tsurumoto. Trial Construcion of A New Magnetic Skew Gear Using Permanent Magnet. IEEE Transactions on Magnetics. Vol. 30, No. 6, November 1994:4767-4769.
[90]Koji Ikuta, Shunichi Makita, Suguru Arimoto. Non-contact Magnetic Gear for Micro Transmission Mechanism. Micro Electro Mechanical Systems, 30 January-2 February 1991:125-130.
[91]J. Rizk, M. H. Nagrial, A. Hellany. Analysis and Design of Torque Couplers and Magnetic Gears. The 4th International Power Electronics and Motion Control Conference. Vol. 3, August 2004:1799-1804.
[92]W. Wu, H. C. Lovatt, J. B. Dunlop. Analysis and Design Optimisation of Magnetic Couplings Using 3D Finite Element Modelling. IEEE Transactions on Magnetics. Vol. 33, No. 5, September 1997:4083-4085.
[93]施卫东,魏东.磁力泵中磁力驱动装置的设计.四川工业学院学报,1999,18(4):5~9
[94]Doug Twyford.英国HMD公司无泄漏磁力驱动泵的开发与研究.化工装备技术, 1997,18(3):50~53
[95]董玲生.谐波磁齿轮减速器设计.雷达与对抗,2002(1):68-74