Universität Stuttgart
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Item Open Access Additively manufactured transverse flux machine components with integrated slits for loss reduction(2022) Kresse, Thomas; Schurr, Julian; Lanz, Maximilian; Kunert, Torsten; Schmid, Martin; Parspour, Nejila; Schneider, Gerhard; Goll, DagmarLaser powder bed fusion (L-PBF) was used to produce stator half-shells of a transverse flux machine from pure iron (99.9% Fe). In order to reduce iron losses in the bulk components, radially extending slits with a nominal width of 150 and 300 µm, respectively, were integrated during manufacturing. The components were subjected to a suitable heat treatment. In addition to a microscopic examination of the slit quality, the iron losses were also measured using both a commercial and a self-developed measurement setup. The investigations showed the iron losses can be reduced by up to 49% due to the integrated slits and the heat treatment.Item Open Access A bidirectional wireless power transfer system with integrated near-field communication for e-vehicles(2024) Ye, Weizhou; Parspour, NejilaThis paper presents the design of a bidirectional wireless power and information transfer system. The wireless information transfer is based on near-field technology, utilizing communication coils integrated into power transfer coils. Compared with conventional far-field-based communication methods (e.g., Bluetooth and WLAN), the proposed near-field-based communication method provides a peer-to-peer feature, as well as lower latency, which enables the simple paring of a transmitter and a receiver for power transfer and the real-time updating of control parameters. Using the established communication, control parameters are transmitted from one side of the system to another side, and the co-control of the inverter and the active rectifier is realized. In addition, this work innovatively presents the communication-signal-based synchronization of an inverter and a rectifier, which requires no AC current sensing in the power path and no complex algorithm for stabilization, unlike conventional current-based synchronization methods. The proposed information and power transfer system was measured under different operating conditions, including aligned and misaligned positions, operating points with different charging powers, and forward and reverse power transfer. The results show that the presented prototype allows a bidirectional power transfer of up to 1.2 kW, and efficiency above 90% for the power ranges from 0.6 kW to 1.2 kW was obtained. Furthermore, the integrated communication is robust to the crosstalk from the power transfer and misalignment, and a zero BER (bit error rate) and ultra-low latency of 15.36 µs are achieved. The presented work thus provides a novel solution to the synchronization and real-time co-control of an active rectifier and an inverter in a wireless power transfer system, utilizing integrated near-field-based communication.Item Open Access Inductive electrically excited synchronous machine for electrical vehicles : design, optimization and measurement(2023) Müller, Samuel; Maier, David; Parspour, NejilaThe demand for electric machines has been rising steadily for several years-mainly due to the move away from the combustion engine. Synchronous motors with rare earth permanent magnets are widely used due to their high power densities. These magnets are cost-intensive, cost-sensitive and often environmentally harmful. In addition to dispensing with permanent magnets, electrically excited synchronous machines offer the advantage of an adjustable excitation and, thus, a higher efficiency in the partial load range in field weakening operation. Field weakening operation is relevant for the application of vehicle traction drive. The challenge of this machine type is the need for an electrical power transfer system, usually achieved with slip rings. Slip rings wear out, generate dust and are limited in power density and maximum speed due to vibrations. This article addresses an electrically excited synchronous machine with a wireless power transfer onto the rotor. From the outset, the machine is designed with a wireless power transfer system for use in a medium-sized electric vehicle. As an example, the requirements are derived from the BMW’s i3. The wireless power transfer system is integrated into the hollow shaft of the rotor. Unused space is thus utilized. The overall system is optimized for high efficiency, especially for partial load at medium speed, with an operation point-depending optimization method. The results are compared with the reference permanent magnet excited machine. A prototype of the machine is built and measured on the test bench. The measured efficiency of the inductive electrically excited synchronous machine is up to 4% higher than that of the reference machine of the Bayerische Motoren Werke AG (BMW) i3.Item Open Access Accelerated 3D FEA of an axial flux machine by exclusively using the magnetic scalar potential(2023) Schäfer, Adrian; Pecha, Urs; Kaiser, Benedikt; Schmid, Martin; Parspour, NejilaThis article focuses on increasing the computational efficiency of 3D multi-static magnetic finite element analysis (FEA) for electrical machines (EMs), which have a magnetic field evolving in 3D space. Although 3D FEA is crucial for analyzing these machines and their operational behavior, it is computationally expensive. A novel approach is proposed in order to solve the magnetic field equations by exclusively using the magnetic scalar potential. For this purpose, virtual variable permanent magnets (vPMs) are introduced to model the impact of the machine’s coils. The effect on which this approach is based is derived from and explained by Maxwell’s equations. To validate the new approach, an axial flux machine (AFM) is simulated using both 2D and 3D FEA with the magnetic vector potential and current-carrying coils as a reference. The results demonstrate a high level of agreement between the new approach and the reference simulations as well as an acceleration of the computation by a factor of 15 or even more. Additionally, the research provides valuable insights into meshing techniques and torque calculation for EMs in FEA.Item Open Access An easily scalable dynamic wireless power transfer system for electric vehicles(2023) Noeren, Jannis; Parspour, Nejila; Elbracht, LukasThis article deals with a LCC-LCC compensated dynamic wireless power transfer system for electric vehicle charging applications. The presented prototype system allows for a power transfer of about 10 kW at 20 cm coil copper to copper distance. With just one circular pickup coil and a very straightforward control scheme, a new coil arrangement enables a seamless power transfer. Furthermore, the system’s design power level is easily adjustable by the size of the the pickup coil. The hardware architecture as well as the software functionality are described in detail. A 20 m test track was built up according to the outlined principle. By measuring the transmitted power, the efficiency and the interference between the primary segments and its effect on the inverter currents are examined. The results show an effective DC to DC efficiency in the range of 91 to 92% and a power fluctuation of approximately 25%.Item Open Access Design and scaling of exoskeleton power units considering load cycles of humans(2022) Waldhof, Marcel; Wochner, Isabell; Stollenmaier, Katrin; Parspour, Nejila; Schmitt, SynExoskeletons are powerful tools for aiding humans with pathological conditions, in dangerous environments or in manually exhausting tasks. Typically, they are designed for specific maximum scenarios without taking into account the diversity of tasks and the individuality of the user. To address this discrepancy, a framework was developed for personalizing an exoskeleton by scaling the components, especially the electrical machine, based on different simulated human muscle forces. The main idea was to scale a numerical arm model based on body mass and height to predict different movements representing both manual labor and daily activities. The predicted torques necessary to produce these movements were then used to generate a load/performance cycle for the power unit design. Considering these torques, main operation points of this load cycle were defined and a reference power unit was scaled and optimized. Therefore, a scalability model for an electrical machine is introduced. This individual adaptation and scaling of the power unit for different users leads to a better performance and a lighter design.Item Open Access A wireless multicoil charging system for low-voltage electric vehicle applications(2021) Elbracht, Lukas; Noeren, Jannis; Parspour, NejilaIn order to inductively charge electric vehicles, which are based on a low-voltage drive train, high currents have to be overcome. This work describes a simulative approach to charge 48 V-based electric vehicles wirelessly with high power. A system was designed on the basis of various boundary conditions and validated by simulation. In order to increase the transmittable power, the system was investigated for an extendable approach and was examined for modularity. In particular, the influences of the secondary coils on each other must be taken into account. Finally, the entire system was evaluated by physical and electrical simulation.Item Open Access Identification of electro-mechanical interactions in wind turbines(2024) Lüdecke, Fiona Dominique; Schmid, Martin; Cheng, Po WenLarge direct-drive wind turbines with a multi-megawatt power rating face design challenges, especially concerning tower top mass, due to scaling laws for high-torque generators. This work proposes to extend the design space by moving towards a more system-oriented approach, considering electro-mechanical interactions. This requires an extension of the state-of-the-art wind turbine models with additional degrees of freedom. To limit the computational effort of such models, a profound understanding of possible interaction mechanisms is required. This work aims to identify interactions of an additional degree of freedom in the radial direction of the generator with the wind turbine structure, the aerodynamics, and the wind turbine controller. Therefore, a Simpack model of the IEA 15 MW RWT is implemented and coupled to a quasi-static analytical generator model for electromagnetic forces. The analytical model, sourced from literature, is code-to-code validated against a finite element model of the generator in COMSOL Multiphysics. Electro-mechanical simulation results do not show interactions with the aerodynamics or the controller. However, interactions with the wind turbine structure occur. It is shown that the modelling approach can affect the system's natural frequencies, which can potentially impact the overall system design choices.Item Open Access Numerical aspects of a two-way coupling for electro-mechanical interactions - a wind energy perspective(2022) Lüdecke, Fiona Dominique; Schmid, Martin; Rehe, Eva; Panneer Selvam, Sangamithra; Parspour, Nejila; Cheng, Po WenItem Open Access Comparison of rotor arrangements of Transverse Flux Machines for a robotic direct drive optimized by genetic algorithm and Regression Tree Method(2023) Kaiser, Benedikt; Schmid, Martin; Parspour, NejilaArticulated robotics applications typically have a demand for high torque at low speed. However, conventional electrical machines cannot generate a reasonable amount of torque directly by electro-magnetics. Therefore, gearboxes are used to convert speed and torque, accepting loss of mechanical power due to additional friction. Although geared solutions for robotic drive trains already offer exceedingly high torque densities, they are limited by the drawbacks of high reduction gears, such as non-linearities in friction, complex flexibility effects, and limited service life of mechanics in contrary to direct drive solutions. The Transverse Flux Machine with the high gravimetric torque density may be a solution for reducing or eliminating the need for a gearbox. Using a genetic algorithm, the proposed Transverse Flux Machines are optimized. To enhance the optimization’s speed, the machines’ calculations done by Finite-Element-Analysis of selected generations are replaced by a Regression Tree Model whose results are verified after a defined expired model service life with a subsequent adjustment of the model. The eligibility of different arrangements the Transverse Flux Machines’ rotor are compared regarding the application as low-speed direct drive in robotics, also compared to similar Radial Flux Machines. The optimized Transverse Flux Machines have a higher efficiency due to lower copper loss and a higher active gravimetric torque density. However, the Radial Flux Machines have higher total torques and power factors.