Proceedings of the 2008 International Conference on Electrical Machines

Paper ID 1219

Design of Flat Torque Switched Reluctance Motor considering Asymmetric Bridge Converter using Response Surface Modeling
Jae-Hak Choi1, Yon-Do Chun1, Pil-Wan Han1, Dae-Hyun Koo1, Do-Hyun Kang1, Ju Lee2
1

Industry Applications Research Division, Korea Electrotechnology Research Institute, Changwon, Korea 2 Department of Electrical Engineering, Hanyang University, Seoul, Korea E-mail : choijaehak@keri.re.kr Gradient-based nonlinear optimization methods are inefficient in this application where expensive function evaluations are required, and in this application where objective and constraint functions are noisy due to modeling and cumulative numerical inaccuracy since gradient evaluation results cannot be reliable. Moreover, it is difficult to be integrated with analysis software, and they cannot be employed when only experimental analysis results are available. In this research an effective optimization method based on a response surface modeling has been used to overcome aforementioned difficulties. The optimum design, which minimizes fluctuating torque ripple could be obtained from this work and has been verified by experiment and analysis. II. MODEL AND DESIGN VARIABLE A. Model Discretion Fig. 1(a) shows construction of 6/4 SRM with stator pole arc 30 and rotor pole arc 30. The stator consists of three phases and six salient poles with concentrated winding, and the rotor consists of four salient poles. The drive circuit in Fig. 1(b) consists of a single-phase diode bridge rectifier that converts the input AC into DC and an asymmetric bridge converter that supplies power to the SRM. The specifications of the manufactured SRM are as follows. The outside diameter, lamination length, air-gap length are 80.4mm, 80mm, and 0.4mm, respectively B. Finite Element Analysis Tool In SRM with no magnetic saturation, the instantaneous torque is expressed by T ( , i ) = 1 / 2 i 2 dL( ) / d . The electromagnetic torque is proportional to the derivative of the inductance, L, which is a function of rotor position, , and the square of winding currents affected by inductance of windings. Although this mathematical equation is often quoted for SRM, it is not sufficient for accurate prediction of torque, because the magnetic saturation effect can not be considered [1]. The finite element method is essential for the precise calculation of the nonlinear magnetic saturated torque [3]. Also, the switching conditions and freewheeling diodes of the motor drive circuit have to be considered in finite element analysis. To provide continuous torque, the drive circuit must

Abstract-This paper presents an optimum design for obtaining flat torque of switched reluctance motor, which has high fluctuating torque due to its inherent salient structure. In order to reduce the fluctuating torque ripple causing noise and vibration, an optimization design technique has been introduced and investigated to find geometric and electric variables by means of combining finite element analysis considering driving circuits and response surface modeling.

I.

INTRODUCTION

Switched Reluctance Motor (SRM) has a lot of advantages such as simple and rugged motor construction, high reliability, and low cost [1]. However, SRM has some problems that limit its applications because of its inherent structure. One of the major problems is the fluctuating torque ripple that causes undesirable acoustic noise and high vibration. The flat torque depends essentially on geometric shape parameters and electric circuit parameters, which have been adopted as twodimensional design variables. As shown in Fig. 1(a), the geometric design variables are relative to the salient pole arc such as stator pole arc s , and rotor pole arc r . The electric design variables are relative to turn-on and turn-off angle, which is decided by switch Qa, Qb and Qc in Fig. 1(b) [2].

(a) Configuration of initial model: switched reluctance motor

(b) Asymmetric bridge converter Fig. 1. Cross section of switched reluctance motor and Drive Circuit

978-1-4244-1736-0/08/$25.00 2008 IEEE

Proceedings of the 2008 International Conference on Electrical Machines be commutated that the switches S1 and S2 of phase-A turn off and the switches S3 and S4 of phase B turn on. When S1 and S2 of phase-A turn off, the current flows through the freewheeling diodes D1 and D2. The current is restored to DC link capacitor or flows through other phases. The current flow of this case is shown in Fig. 2 as a dotted line. When switches of phase B turn on, the current flows as the solid line. Therefore, these kinds of conditions must be considered in analysis. The time-stepped voltage source Finite Element Method (FEM) is coded with the circuit equation considered turn-on, turn-off switches and freewheeling diodes. C. Significant Design Variables and Formulation Inductance profile varies with the combination of stator and rotor pole arcs, and influences the torque characteristics. Each phase inductance profile shifts 30 in 6/4 SRM. For the flat torque and maximum average torque, the pole arcs of the stator and rotor have to be more than 30. If the pole arcs of stator and rotor are smaller than 30, a large torque ripple will be periodically generated. It is impossible to obtain flat torque although the phase current flows ideally as shown in Fig 3(a). Fig. 3(b) shows inductance profile of A-phase, switching current of A-phase and torque characteristic of three phase, and illustrate torque generation principles with pole arc combination when s =30 and r 30. In order to generate flat torque, the flat current of each phase has to flow in risinginductance period (30), and can be possible by adjusting the on and off. The stator pole arc is set to 30, because widening the pole arc of rotor is better than widening the pole arc of stator with respect of high slot fill factor. Torque ripple is ideally able to be zero while increasing average torque. Consequently, the pole arcs of rotor and stator, turn-on angle and turn-off angle among electric and geometric variables are selected as design variables for optimization. The object function and design variables are represented by (1) Object Function: Minimize torque ripple, Tripp Subject to: Average torque, Tave 0.1Nm Stator & rotor pole arcs s = 30, 30 r < 60, Turn on angle, (60 s )/2 on + (60 r )/2 Turn off angle, 30 off 30 + ( r s ). (1)

(a) s & r < 30 (b) s =30 and r 30 Fig. 3. Torque generation principles

III. OPTIMIZATION PROCEDURE The approximate optimization procedure is useful tool to find optimum value about undefined relative equations between objective and design variable. This method approximates objective and constraint functions to quadratic functions within the reasonable design space and sequentially optimizes the approximate optimization problems in the context of the design space adjustment strategy. Approximate optimization problem is converged by agreement with the actual function within an acceptable tolerance for error. The approximate optimization based on a response surface modeling has been applied to the optimum design of SRM. Approximate optimization procedure consist of four parts; Design of Experiments (DOE), Finite Element Method (FEM), Response Surface modeling (RSM), Optimization. Firstly, The analysis points through the DOE is well adapted to contain the combinatorial exploration of numerous finite element simulations required by the investigations on the effect of all design variables of a given device [4]. Secondly, the response values of analysis points are obtained through 2-D FEM coupled with circuit equations of the converter. Thirdly, a response surface and equation are estimated from the analyzed response values by using RSM and regression analysis. Fourthly, a feasible design region is chosen for an optimum design. The conjugate gradient method in Microsoft Excel has been used when deciding the best optimal model with estimated quadratic regression equations. A. Response Surface Modeling The Central Composite Design (CCD) on the various DOE is well adapted to contain the combinatorial explosion of numerous finite element simulations required by the investigations on the effect of all design variables of a given device [4]. RSM is a set of useful mathematical and statistical technology. RSM statistically approximates the relationship between the response value from performing FEA and design variables. To make an approximate function, Least Square Method and Variable Selection Method are used. To evaluate the function, Analysis of Variance (ANOVA) is used. Among many DOEs, CCD that is generally used for polynomial models is used because maximum information can be obtained with the number of minimum analysis times for the system.

Fig. 2. Current flow in the drive circuit

Proceedings of the 2008 International Conference on Electrical Machines Fig. 4 shows the analysis points for CCD when there are two factors for 2-Levels. The number of the CCD analsysis can be calculated as follows.

n = 2 k + 2 k + nc

(2)

where k is the number of design variable, 2k is the number of experiment for the 2k factorial design, 2k is the number of axial point, and nc is the number of replication for the center point. RSM statistically approximates the relationship between the response value, y, from performing FEM analysis and the design variables with an error, and the equation can be expressed in (3).

Fig. 4. Central Composite Design for 2-Levels 2 Factors

y = f ( x1 , x2 , , xk ) +

(3)

where u=f(x1, x2, , xk) is the true response function that has k design variables, and denotes the random error that includes measurement error on the response and is inherent in the process or system. For most of the response surfaces, the functions for the approximations are polynomials because of its simplicity, though the functions are not limited to the polynomials. The response surface is described as follow.

y = 0 + j x j + jj x j +
2 j =1 j =1

k 1

i =1 j = i +1

ij

xi x j

(4)

where represents regression coefficients, x is the design variable, and k is the number of variables. B. Approximate Optimization Process Fig. 5 describes the optimization procedure of the SPSRM in detail. The computational procedure is as follows: Step 0. Set the initial design and the design space. The initial design space is assumed 50% ~ 100% of the whole design space that includes the initial design. Step 1. Select CCD (2k+2k+nc) sampling points within the design space. Calculate the sampling points set by Finite Element Analysis (FEA). Step 2. Approximate the objective and constraints functions to quadratic polynomial functions by RSM and ANOVA. Step 3. Find an approximate optimum using the approximate objective and constraint functions. Step 4. Evaluate actual objective and constraints at the approximate optimum value by real FEA. Step 5. Check convergence at the approximate optimum using actual objective and constraints function values. If the approximate optimization problem is converged, then terminate the optimization. Otherwise adjust the design space. Step 6. Select CCD (2k+2k+nc) design points within the new design space. The new sampling points set consists of the previous approximate optimum points and newly selected design points. Go to Step 2 again.
Fig. 5. Approximate Optimization procedures

IV. RESULTS COMPARISON AND DISCUSSION A. Geometric Design Variable Optimization: Rotor Pole Arc Fig. 6 shows regression analysis results of the rotor pole arcs on conditions that the stator pole arc is set to 30 as explained in section II-C, and that the turn-on and turn-off angle is set to 0 and 37.5 to raise phase current as shown in Fig. 3(b). The quadratic equation of the torque ripple and average torque are respectively estimated in (5) and (6). Table I show the results compared with the initial model as shown in Fig. 1.

Trip = 391.8 15.8( r ) + 0.18( r ) 2

(5) (6)

Tave = 0.4006 0.0058( r )

30 s =

(a) Torque ripple (b) average torque Fig. 6. Regression analysis of torque characteristics with rotor pole arc

r=44

Proceedings of the 2008 International Conference on Electrical Machines B. Electric Design Variable Optimization: Switching Angles Table II and Table III show the optimum results of the switching variables on the initial shape model as shown in Fig. 1 and the optimum shape model as shown in Fig. 6, respectively. Fig. 7 shows the feasible region of turn-on and turn-off on the optimum shape. The gray color area indicates the feasible region and includes optimum value. Fig. 8 shows the inductance profile and current waveform of one phase of motor. The optimum turn-on and turn-off of the initial shape are -6.0 and 45.0 as shown in table II.
TABLE I GEOMETRIC VARIABLES DESIGN RESULTS OF ROTOR POLE ARC Initial (1)Approx. (2)Real Convergence Point Optimum Optimum Error (FEM) (RSM) (FEM) (1) vs. (2) Torque ripple (Trip) 44.6% 2.4% 73.8% 43.5% Torque average (Tave) 0.225Nm 0.144Nm 0.143Nm 0.7% Rotor pole arc (r) 30.0 43.96 44.0 at the same switching angle (turn-on angle: 0, turn-off angle: 37.5) Rotor Pole Arc Optimization

The negative torque is generated because the phase current flowed in the falling inductance period. However, the switching angles of the optimum shape are -0.1 and 35.0 as shown in table III. The negative torque is not generated because the phase current was off before the falling inductance period. Fig. 9 and Fig. 10 show the waveform of one phase terminal voltage and three phase current on initial model and optimum model, respectively. The currents are measured as ratio of 4.2(A/div) to 3(V/div) in Fig. 9 and as ratio of 2.8(A/div) to (2V/div) in Fig. 10. Both of the motor voltage and current waveforms generally regard as important electric parameters for a prediction of motor performance. The flat-top current doesnt flow at initial model in Fig. 9, otherwise the flat-top current flows at optimum model in Fig. 10. Here it can be known the flat-top current waveform is important to make flat torque waveform, because the motor torque is proportional to the square of winding currents. If the rising and falling of phase current is fast or slow according to the switching angle, the flat torque can not be obtained.

TABLE II ELECTRIC VARIABLES 1ST ITERATION DESIGN RESULTS OF INITIAL SHAPE Initial (1)Approx. (2)Real Convergence Point Optimum Optimum Error (FEM) (RSM) (FEM) (1) vs. (2) Torque ripple (Trip) 73.8% 50.4% 9.8% 55.9% Torque average (Tave) 0.223Nm 0.327Nm 0.317Nm 3.1% Turn-on angle (on) 0.0 -6.0 -6.0 Turn-on angle (off) 37.5 45.0 45.0 at the same initial shape (stator pole arc: 30, rotor pole arc: 30) Turn-on and off at initial model

(a) Initial shape (b) Optimum shape Fig. 8. Inductance profile and current of initial and optimum motor

TABLE III ELECTRIC VARIABLES 3RD ITERATION DESIGN RESULTS OF OPTIMAL SHAPE Shape (1)Approx. (2)Real Convergence Optimum Optimum Optimum Error (FEM) (RSM) (FEM) (1) vs. (2) Torque ripple (Trip) 43.5% 37.3% 3.1% 38.5% Torque average (Tave) 0.143Nm 0.140Nm 0.138Nm 1.4% Turn-on angle (on) 0.0 -0.1 -0.1 Turn-on angle (off) 37.5 35.0 35.0 at the same Optimum shape (stator pole arc: 30, rotor pole arc: 44) Turn-on and -off at optimum model

(a) simulation

Fig. 7. 3rd iteration feasible design region of turn-on and off on optimum shape

(b) experiment (20V/div, 4.2A/div) Fig. 9. The voltage and current of initial model

Proceedings of the 2008 International Conference on Electrical Machines Fig. 11 shows the energy conversion loop of initial model and optimal models. Estimation for the average torque could be illuminated with areas on the energy conversion loop. It can be known that the initial model has an advantage with respect of the high average torque, because the energy conversion loop of initial shape is much wider than that of optimum model. Fig. 12 shows the analyzed torque waveform. The torque ripple is reduced from 73.8% to 43.5% by optimizing the geometric pole arcs, and is reduced from 43.5% to 38.5% by optimizing the electric switching angles. The torque ripple is reduced by about two times than the initial one. The average torque was satisfied of constraint condition.

Fig. 12. Instantaneous torque waveform

V. CONCLUSIONS Firstly, to minimize torque ripple, the geometric rotor pole arc has been optimized from initial 30 to optimum 44 by using the approximate optimization. Secondly, the optimum combination of electric turn-on and turn-off angle can also be obtained for each initial and optimum shape. The torque ripple is reduced by about two times than the initial one. It can be also known that there is the trade-off between a torque ripple and an average torque. This paper measured the phase currents and the terminal voltage of both models and then shows that the analysis method considering the drive circuit is suitable for SRM optimization. The results prove that the optimization procedure is efficient in this application where expensive function evaluations are required and in this application where objective and constraint functions are noisy due to modeling and cumulative numerical inaccuracy. The optimization introduced in this article may be also used effectively for various electric machines. REFERENCES
[1] [2] (b) experiment (20V/div, 2.8A/div) Fig. 10. The voltage and current of optimum model T. J. E. Miller, Switched Reluctance Motors and their control, Oxford University Press, 1993, pp. 53-70 Jae-Hak Choi, Youn-hyun Kim and Ju Lee, "Geometric design of pole arcs considering electric parameters in switched reluctance motor," International Journal of Applied Electromagnetics and Mechanics, vol. 19, no.1-4, pp. 275-279, 2004. Jae-Hak Choi, Tae-Heoung Kim, Yong-Su Kim, Seung-Jun Lee, YounHyun Kim, and Ju Lee, Finite Element Analysis of Switched Reluctance Motor Considering Asymmetric Bridge Converter and DC Link Voltage Ripple, IEEE Transactions on Magnetics, vol.41, no.5, 1640-1643, May 2005. Box, G. E. P. and Willson, K. B., On the Experiment Attainment of Optimum Conditions, Journal of the Royal Statistical Society, Series B., 13, pp.1~14, 1951.

(a) simulation

[3]

[4]

Fig. 11. Energy conversion loop