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Design Procedure of IPM Motor Drivefor Railway Traction
Massimo Barcaro Emanuele FornasieroNicola Bianchi Silverio Bolognani
Electric Drives LaboratoryDepartment of Electrical Engineering
University of Padova
IEEE - IEMDC 2011International Electric Machines and Drives Conference
Niagara Falls, 15-18 May 2011
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
This presentation refers to the paper
Massimo Barcaro, Emanuele Fornasiero, Nicola Bianchi andSilverio Bolognani
“Design Procedure of IPM Motor Drivefor Railway Traction”
International Electric Machines and Drives Conference(IEMDC 2011)
held in Niagara Falls, CA, May 15-18, 2011
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 2
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Outline
1 Aim of this work
2 PM machine design and analysis
3 Predicted machine performance
4 Power converter
5 Results
6 Conclusions
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 3
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Aim of this work
Aim of this work
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 4
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Aim of this work
Aim of this work
The aimof this work is to investigate how the design choices of boththe machine and the power converter affect the totalperformance of the traction drive.
Railway application1 Italian system,2 Commuter train.
Adoption of a permanent magnet machine1 High efficiency2 High power density3 Lower maintenance4 Sensorless control capability5 Flux–weakening capability (Interior Permanent Magnet)
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 5
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Aim of this work
Requirements
Maximum motor size1 Frame length: 800mm,2 Frame diameter: 500mm.
Torque–to–speed curve1 Base operating point: 5000Nm @ 1200 r/min,2 Max speed: 4500 r/min.
0 500 1000 1500 2000 2500 3000 3500 4000 45000
1000
2000
3000
4000
5000
6000
Mechanical speed (rpm)
Torque(Nm)
0 500 1000 1500 2000 2500 3000 3500 4000 45000
50
100
150
200
250
300
Time(s)
TorqueTime
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 6
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Aim of this work
Requirements
Voltage1 Nominal dc bus: 3000V (min. 80%),2 Uncontrolled Generator Operation (UGO) voltage lower
than nominal voltage at maximum speed.
IGBT Volt–Ampere rating1 Series and parallel IGBT connections are avoided
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 6
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
PM machine design and analysis
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 7
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Geometries
Different rotor geometries are investigated:
Main parameters48 slots,4 poles,SmCo magnets,Different PM volume,Lstk = 500mm,
(a) IPM–3b (b) IPM–V
(c) IPM–SQ (d) SPM
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 8
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Winding design with different PM contribution
Changing the PM volume, the number of series conductorsper slot, ncs, can be changed
Variation of ncs
The variation of series conductors per slot does not affectsthe electromechanical torque for given slot current IS.
If ncs increases:the phase current decreasesthe nominal flux–linkage increasesthe base speed ωB decreases
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 9
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Winding design with different PM contribution
Uncontrolled Generator OperationThe flux–linkage due to the PM has to be limited so as tosatisfy the UGO requirement at the el. maximum speed:
ωmaxncs λm ≤Vdc,n√
3
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 10
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Base speed(Vn
ωB
)2
' Λ2 = n2cs
[(λm + ld IS,d
)2+(
lq IS,q
)2]
For a given nominal voltage Vn the increase of ncs yields anincrease of the nominal flux–linkage and a reduction of thebase speed ωB.
Once the ncs is defined, the nominal current of the machineIn,mot is selected to satisfy the requirements.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 11
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Summary of the motor designs parameters
Motor Vpm ξB ncs In,mot Λm ωB,max(%) (A) (Vs) (el .rad/s)
IPM–3b 100% 3.34 6.0 512 1.93 448IPM–3b 90% 3.35 7.0 458 1.95 382IPM–3b 80% 3.34 8.0 422 1.88 332IPM–3b 70% 3.12 9.5 379 1.82 272IPM–3b 60% 3.02 8.5 458 1.26 299IPM–3b 40% 2.84 7.0 667 0.47 351
ncs is due to UGO requirement (Λm < 2Vs). It increaseswith the PM volume reduction (IPM–3b).ncs = 9.5⇒ limit value: the minimum ωB is reachedIPM–3b with 60% and 40% Vpm ⇒ UGO satisfaction isnot sufficient. ncs reduced, with a correspondingincrease of the current to provide suitable FW torque.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 12
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Motor Vpm ξB ncs In,mot Λm ωB,max(%) (A) (Vs) (el .rad/s)
IPM–3b 100% 3.34 6.0 512 1.93 448IPM–3b 90% 3.35 7.0 458 1.95 382IPM–3b 80% 3.34 8.0 422 1.88 332IPM–3b 70% 3.12 9.5 379 1.82 272IPM–3b 60% 3.02 8.5 458 1.26 299IPM–3b 40% 2.84 7.0 667 0.47 351IPM–V - 2.38 5.0 650 1.83 522IPM–SQ - 1.41 5.0 750 2.08 509SPM - 0.81 3.5 1006 1.83 794
ξB is almost equal to 3 for all the IPM–3b machines.The IPM–V and the IPM–SQ machine has lowersaliency.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 13
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Motor Vpm ξB ncs In,mot Λm ωB,max(%) (A) (Vs) (el .rad/s)
IPM–3b 100% 3.34 6.0 512 1.93 448IPM–V - 2.38 5.0 650 1.83 522IPM–SQ - 1.41 5.0 750 2.08 509SPM - 0.81 3.5 1006 1.83 794
The IPM–V machine requires lower current than theIPM–SQ machine thanks to the higher saliency ratio.The SPM machine requires an excessive current andthe base speed is about 3 times higher than therequired.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 14
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Procedure to compute machine performance
Finite element simulationsTorque, Flux linkages, Flux densities
Maximum machine performanceMTPA trajectory is followed up to the voltage limit: fromzero up to the base speed ωB, B base point.At higher speed the flux–weakening control is adopted.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 15
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Procedure to compute machine performance
Fitting of the required torque–to–speed
The current vector trajectory is modified,The lowest current that satisfies both the voltage limitand torque requirement is selected.
0 200 400 600 800 10000
2000
4000B
FTor
que
(Nm
)
Electric speed (rad/s)
Required torqueMaximum torque
−800 −700 −600 −500 −400 −300 −200 −100 00
100
200
300
400
1000 100010002000
2000
2000
3000
30003000
4000
4000
4000
5000
5000
Id(A)
I q(A)
B
F
Required torqueMaximum torqueEllipse centerTorque map
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 16
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Procedure to compute machine performance
Operations with reduced voltage
The required torque has to be satisfied also considering thevariation of the grid voltage, e.g. according to the 80% of therated voltage. A decrease of Vdc implies a shift of the torquecharacteristic due to the reduction of speed ω associated toeach vector position.
0 200 400 600 800 10000
2000
4000
Torque(Nm)
Electric speed (rad/s)
Required torqueMaximum torque
VnV80%
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 17
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
PM machine design and analysis
Procedure to compute machine performance
Machine lossesThe machine losses are computed considering thestandard traction cycle,
0 500 1000 1500 2000 2500 3000 3500 4000 45000
1000
2000
3000
4000
5000
6000
Mechanical speed (rpm)
Torque(Nm)
0 500 1000 1500 2000 2500 3000 3500 4000 45000
50
100
150
200
250
300
Time(s)
TorqueTime
0 50 100 150 2000
10
20
30
Loss
es (
kW)
Time (s)
PJoule
PFe
Ptotal
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 18
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Predicted machine performance
Predicted machine performance
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 19
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Predicted machine performance
IPM 3b
IPM 3b - 100% Vpm
0 200 400 600 800 10000
2000
4000B
FTor
que
(Nm
)
Electric speed (rad/s)
Required torqueMaximum torque
−600 −500 −400 −300 −200 −100 00
50
100
150
200
250
300
1000 1000100
0
1000
2000
2000
20002000
3000
3000
3000
3000
4000
4000
4000
5000
5000
6000
Id(A)
I q(A)
B
F
Required torqueMaximum torqueEllipse centerTorque map
0 50 100 150 2000
10
20
30
Loss
es (
kW)
Time (s)
PJoule
PFe
Ptotal
IPM 3b - 70% Vpm
0 200 400 600 800 10000
2000
4000B
FTor
que
(Nm
)
Electric speed (rad/s)
Required torqueMaximum torque
−400 −350 −300 −250 −200 −150 −100 −50 00
50
100
150
200
1000 10001000
1000
1000
2000
2000
20002000
3000
3000
3000
3000
4000
4000
4000
5000
5000
Id(A)
I q(A)
B
F
Required torqueMaximum torqueEllipse centerTorque map
0 50 100 150 2000
10
20
30
40
Loss
es (
kW)
Time (s)
PJoule
PFe
Ptotal
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 20
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Predicted machine performance
Summary of motor performance
Motor Vpm Voltage Pmotavg PCu PFe(%) 80% (kW ) (%) (%)
IPM–3b 100% X 13.86 48.0 50.5IPM–3b 90% X 13.34 58.0 40.5IPM–3b 80% X 14.21 65.0 33.6IPM–3b 70% - 18.68 76.3 22.6IPM–3b 60% - 18.87 73.1 25.9IPM–3b 40% - 22.05 69.7 29.4IPM–V - X 16.13 40.3 58.5IPM–SQ - X 20.20 39.7 59.3SPM - X 20.00 35.4 63.6
Only the IPM–3b configurations with Vpm from 70% to40% are not able to provide the required torque versusspeed characteristic at a reduced voltage (80%).
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 21
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Predicted machine performance
Motor Vpm Voltage Pmotavg PCu PFe(%) 80% (kW ) (%) (%)
IPM–3b 100% X 13.86 48.0 50.5IPM–3b 90% X 13.34 58.0 40.5IPM–3b 80% X 14.21 65.0 33.6IPM–3b 70% - 18.68 76.3 22.6IPM–3b 60% - 18.87 73.1 25.9IPM–3b 40% - 22.05 69.7 29.4IPM–V - X 16.13 40.3 58.5IPM–SQ - X 20.20 39.7 59.3SPM - X 20.00 35.4 63.6
The IPM–3b motors with a Vpm > 80% exhibit loweraverage losses during the standard cycle.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 22
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Predicted machine performance
Motor Vpm Voltage Pmotavg PCu PFe(%) 80% (kW ) (%) (%)
IPM–3b 100% X 13.86 48.0 50.5IPM–3b 90% X 13.34 58.0 40.5IPM–3b 80% X 14.21 65.0 33.6IPM–3b 70% - 18.68 76.3 22.6IPM–3b 60% - 18.87 73.1 25.9IPM–3b 40% - 22.05 69.7 29.4IPM–V - X 16.13 40.3 58.5IPM–SQ - X 20.20 39.7 59.3SPM - X 20.00 35.4 63.6
With IPM–3b machines the Vpm reduction leads to ashift of the losses from iron to copper, due to the higheraverage phase current.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 23
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Predicted machine performance
This behaviour is reasonable, since the current of theIPM–3b with 100% Vpm decreases significantly from thenominal value In,mot at the base point B.
IPM 3b - 100% Vpm
−600 −500 −400 −300 −200 −100 00
50
100
150
200
250
300
1000 1000100
0
1000
2000
2000
20002000
3000
3000
3000
3000
4000
4000
4000
5000
5000
6000
Id(A)
I q(A)
B
F
Required torqueMaximum torqueEllipse centerTorque map
IPM 3b - 70% Vpm
−400 −350 −300 −250 −200 −150 −100 −50 00
50
100
150
200
1000 10001000
1000
1000
2000
2000
20002000
3000
3000
3000
3000
4000
4000
4000
5000
5000
Id(A)
I q(A)
B
F
Required torqueMaximum torqueEllipse centerTorque map
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 24
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Power converter
Power converter
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 25
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Power converter
IGBT choiceUse of a single power switch for each inverter leg. ⇒power switch must be chosen with a reverse voltage of6500 V , to sustain voltage peaks due to thecommutations.Referring to the values of the machine phase currentIn,mot , an IGBT with nominal current equal to 750A isadopted in the computation of the power converterlosses.
IGBT parameters, Vn = 3600V
Ic Vce,on Ron Vd,on Rd,on Eon Eoff EdA V mΩ V mΩ J J J
400 2.8 6.2 2.1 4 4 2.3 1.05600 2.9 4 2.3 2.7 5.9 3.5 1.6750 2.2 2 1.7 1.38 6.5 4.2 3
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 26
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Power converter Control strategy
Switching frequency profile
0 200 400 600 8000
200
400
600
electric speed (rad/s)switc
hing
freq
uenc
y (
Hz)
Switching frequencyMotor frequency
The switching frequency is kept constant(fsw = 500 Hz) up to the electrical base speedωB = 251 el .rad/s.Then, it decreases linearly until about two times thebase speed.Finally, the switching frequency is kept equal to themain frequency of the drive, so that the motor ispractically supplied with a square wave voltage.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 27
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Power converter Computation of IGBT losses
IGBT losses computation
PIGBT = Pcd︸︷︷︸conduction losses
+ Psw︸︷︷︸switching losses
Conduction losses
Pcd = Vce,onIavg + RonI2rms︸ ︷︷ ︸
IGBT losses
+ Vd ,onId ,avg + Rd I2d ,rms︸ ︷︷ ︸
diode losses
Switching losses
Psw = (Eon + Eoff + Erec)fswVdc
VIGBT
Losses scaled with the supply voltage (Vdc), since thedatasheet refers to a supply voltage VIGBT = 3600 V .
The energies are computed from the component datasheet,according to its actual current.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 28
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Power converter Computation of IGBT losses
IPM 3b machine with 100% Vpm
0 200 400 600 800 10000
2000
4000B
FTor
que
(Nm
)
Electric speed (rad/s)
Required torqueMaximum torque
0 50 100 150 2000
5
10
15
20
25
time (s)
loss
es (
kW)
Vnom
= 1730 V, IIGBT
= 750 A
conduction lossesswitching lossestotal losses
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 29
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Power converter Computation of IGBT losses
IPM 3b machine with 70% Vpm
0 200 400 600 800 10000
2000
4000B
FTor
que
(Nm
)
Electric speed (rad/s)
Required torqueMaximum torque
0 50 100 150 2000
5
10
15
20
25
time (s)
loss
es (
kW)
Vnom
= 1730 V, IIGBT
= 750 A
conduction lossesswitching lossestotal losses
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 30
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Results
Results of the losses computation
Motor Vpm Voltage Pmotavg PCu PFe PIGBT ,avg(%) 80% (kW ) (%) (%) (kW )
IPM–3b 100% X 13.86 48.0 50.5 5.17IPM–3b 90% X 13.34 58.0 40.5 4.81IPM–3b 80% X 14.21 65.0 33.6 4.61IPM–3b 70% - 18.68 76.3 22.6 4.71IPM–3b 60% - 18.87 73.1 25.9 5.18IPM–3b 40% - 22.05 69.7 29.4 6.56IPM–V - X 16.13 40.3 58.5 6.00IPM–SQ - X 20.20 39.7 59.3 6.57SPM - X 20.00 35.4 63.6 -
SPM not consideredSPM nominal current In,mot = 1006A > 750A
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 31
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Results
Results of the losses computation
Motor Vpm Voltage Pmotavg PCu PFe PIGBT ,avg(%) 80% (kW ) (%) (%) (kW )
IPM–3b 100% X 13.86 48.0 50.5 5.17IPM–3b 90% X 13.34 58.0 40.5 4.81IPM–3b 80% X 14.21 65.0 33.6 4.61IPM–3b 70% - 18.68 76.3 22.6 4.71IPM–3b 60% - 18.87 73.1 25.9 5.18IPM–3b 40% - 22.05 69.7 29.4 6.56IPM–V - X 16.13 40.3 58.5 6.00IPM–SQ - X 20.20 39.7 59.3 6.57SPM - X 20.00 35.4 63.6 -
Best converter performance
IPM–3b with 80% PM volume
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 31
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Results
Results of the losses computation
Motor Vpm Voltage Pmotavg PCu PFe PIGBT ,avg(%) 80% (kW ) (%) (%) (kW )
IPM–3b 100% X 13.86 48.0 50.5 5.17IPM–3b 90% X 13.34 58.0 40.5 4.81IPM–3b 80% X 14.21 65.0 33.6 4.61IPM–3b 70% - 18.68 76.3 22.6 4.71IPM–3b 60% - 18.87 73.1 25.9 5.18IPM–3b 40% - 22.05 69.7 29.4 6.56IPM–V - X 16.13 40.3 58.5 6.00IPM–SQ - X 20.20 39.7 59.3 6.57SPM - X 20.00 35.4 63.6 -
Best drive performance
IPM–3b with 90% PM volume
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 31
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Conclusions
Conclusions
A railway application has been considered; inparticular:
a torque/speed characteristic was givendifferent motors topologies have been comparedthe motors are different in terms of the amount of fluxgiven from the magnets and rotor saliency.the number of turns per phase ncs is computed duringthe design process in order to avoid a too high UGOvoltage and to satisfy the required torque versus speedcharacteristic.the same IGBT component have been used for all themotor drives
All motors satisfy the requirements of the tractionapplication
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 32
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PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Conclusions
Conclusions
The SPM motor is not suitable for the application, sinceit has a limited flux weakening capability and presents atoo high currentMotors with low volume of permanent magnet does nothave an adequate Torque/Volume ratioMotors characterized by higher saliency exhibit betterperformance.In addition, the fulfillment of the different requirementsleads to configurations with also high PM fluxThe IPM–3b 90% machine is characterized by a highsaliency and high PM volume (90%), that leads tocurrent and losses reduced. It results to be the moresuitable candidate for the commuter train considered inthis study.
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 32
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Aim of thiswork
PM machinedesign andanalysis
Predictedmachineperformance
Powerconverter
Results
Conclusions
Conclusions
Thank you for the attention
IEMDC 2011 Design Procedure of IPM Motor Drive for Railway Traction 33