Electrical Manufacturing

Technical Conference 2009

Electrical Manufacturing & Coil Winding Expo

Nashville, Tennessee, USA

29 September - 1 October 2009

ISBN: 978-1-61782-198-1
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 TABLE OF CONTENTS

BUSINESS INTELLIGENCE IN MANUFACTURING

Making the Case for Business Intelligence in Manufacturing ........................................................................................... 1

Brian Lewandowski
Recycling to be Green............................................................................................................................................................ 5
Timothy A. Pancake

DESIGNING ENERGY EFFICIENT MOTORS

Multi-fault Analysis in Induction Motors Using Multi-sensor Features ......................................................................... 10

Xin Xue, V. Sundararajan
Feasibility of Wireless Sensors for Health Monitoring In Small Induction Motors....................................................... 21
Xin Xue, V. Sundararajan

PRODUCT TESTING AND QUALITY ASSURANCE

Testing and Anallysis of Fractional Horse Power Induction Motors .............................................................................. 30

William H. Yeadon, Brad Frustaglio
Testing Military Grade Magnetics (Transformers, Inductors, Coils) ............................................................................. 33
Paul Vrabel
Why Test Magnet Wire? ..................................................................................................................................................... 39
John A. Whitney, Richard B. Duke
Problems with In-line High Voltage Continuity (HVC) Testing...................................................................................... 42
John A. Whitney

NEW DEVELOPMENTS IN MOTION TECHNOLOGY

The Advantages of Round Liner Actuators....................................................................................................................... 45

Tom Griffin, Tom Lemley
A Comparison Study of the Commutation Methods for the Three-Phase Permanent Magnet Brushless
DC Motor ............................................................................................................................................................................. 49
Shiyoung Lee, Tom Lemley
Best Practices in Coil Manufacturing ................................................................................................................................ 56
Samir R. Kagalwala
Designng the Sine Wave Quiet Converter ......................................................................................................................... 59
W. T. McLyman

POWER ELECTRONICS

Design of Re-Choke Inductors Using Core Geometry Coefficient................................................................................... 64

Hiroo Sekiya, Marian K. Kazimierczuk
Analysis and Design of Common-Diode Tapped-Inductor PWM Buck Converter in CCM......................................... 72
Nisha Kondrath, Marian K. Kazimierczuk
Effects of Load Changes on the Control-to-output Transfer Function of a Buck-Boost Converter in
CCM ..................................................................................................................................................................................... 79
Julie J. Lee, Marian K. Kazmeiriezuk
POWER ELECTRICS II

Review of Zero-Current Switching Flyback PWM DC-DC Converters ......................................................................... 83

Dakshina Murthy Bellur, Marian K. Kazimierczuk
Role of Power Electronics in Renewable Energy Systems................................................................................................ 91
Veda Prakash Galigekere, Marian K. Kazimierczuk
An Overview and Simulation of DC-DC and Z-Source Grid Connected Inverters ....................................................... 98
Veda Prakash Galigekere, Dakshina Murthy Bellur, Marian K. Kazimierczuk

EMERGING MAGNETIC TECHNOLOGIES

Superparamagnetic Materials: Properties and Uses ...................................................................................................... 107

James V. Masi

INDUCTION MACHINES FOR WIND TURBINE APPLICATIONS

Comprehensive Flux Estimator Implementation Procedures for Advanced Control of Inverter-Fed

Induction Machines ........................................................................................................................................................... 114
Ali M. Bazzi, Philip T. Krein
Doubly-Fed Induction Machine in Wind Power Generation ......................................................................................... 123
Hector A. Pulgar-Painemal, Peter W. Sauer
Design and Evaluation of a 300kW Dual Mechanical Port Machine Used as Variable Gearbox in
Wind Power Generation.................................................................................................................................................... 131
Yuan Zhang, Longya Xu, Xikai Sun

ELECTRIC AND HYBRID VEHICLES: NEW MARKETS FOR MANUFACTURING. A

COLLABORATIVE AGREEMENT BETWEEN INDUSRY AND EDUCATION

The Development of the eZE Hybrid Drive Oil CooledElectric Drive (OCED) Traction Module.............................. 136
Anthony Palumbo, Charles Codding, Michael Simecek, Jeff Major, Aaron Bloomfield, Barry Piersol

IMPREGNATING APPLICATION

Nanomaterials in Liquid Insulation to Improve Moisture Resistance and Pulse Endurance in Inverter
Duty Motor Applications .................................................................................................................................................. 149
Mark Winkeler, Ronald W. Goetter
Impregnation Methods, Resings and Equipment............................................................................................................ 152
Peter Caine

COIL MANUFACTURING IN THE 21ST CENTURY

A Robot-Based Winding-Process for Flexible Coil Production ..................................................................................... 157

Jörg Franke, Andreas Dobroschke
Special Problems Incurred When Manufacturing Coils With Fine Magnet Wire ....................................................... 164
Thomas A. Manning
Author Index