EXPERIMENTAL DESIGN METHOD APPLIED TO A MULTIPHYSICAL MODEL: TRELLIS DESIGNS FOR A MULTIDIMENSIONAL SCREENING STUDY

Similar documents
Vibro-Acoustic Optimization of a Permanent Magnet Synchronous Machine Using The Experimental Design Method

A new hybrid method for the fast computation of airgap flux and magnetic forces in IPMSM

Effect of magnetic wedges on electromagneticallyinduced acoustic noise and vibrations of electrical machines

Finite Element Analysis of Hybrid Excitation Axial Flux Machine for Electric Cars

1439. Numerical simulation of the magnetic field and electromagnetic vibration analysis of the AC permanent-magnet synchronous motor

EXPERIMENTAL DESIGN METHOD APPLIED TO THE OPTIMISATION OF A LINEAR EDDY CURRENT BRAKE.

Noise and Vibration of Electrical Machines

Design of low electromagnetic Noise, Vibration, Harshness (NVH) electrical machines using FEMAG and MANATEE software

DISTINCTION OF TOOTHING AND SATURATION EFFECTS ON MAGNETIC NOISE OF INDUCTION MOTORS

ACOUSTIC NOISE AND VIBRATIONS DUE TO MAGNETIC FORCES IN ROTATING ELECTRICAL MACHINES

Multiphysics modeling: electro-vibro-acoustics and heat transfer of induction machines

Analytical and numerical computation of the no-load magnetic field in induction motors

Keywords: Electric Machines, Rotating Machinery, Stator faults, Fault tolerant control, Field Weakening, Anisotropy, Dual rotor, 3D modeling

Effect of the number of poles on the acoustic noise from BLDC motors

Eddy Current Heating in Large Salient Pole Generators

Optimization Design of a Segmented Halbach Permanent-Magnet Motor Using an Analytical Model

Analytical Calculation of Air Gap Magnetic Field Distribution in Vernier Motor

VIBRATION RESPONSE OF AN ELECTRIC GENERATOR

1 PEDAGOGICAL OBJECTIVES

2577. The analytical solution of 2D electromagnetic wave equation for eddy currents in the cylindrical solid rotor structures

Dynamic Modeling of Surface Mounted Permanent Synchronous Motor for Servo motor application

Guangjin Li, Javier Ojeda, Emmanuel Hoang, Mohamed Gabsi, Cederic Balpe. To cite this version:

Loss Minimization Design Using Magnetic Equivalent Circuit for a Permanent Magnet Synchronous Motor

This is a repository copy of Improved analytical model for predicting the magnetic field distribution in brushless permanent-magnet machines.

Analytical Model for Sizing the Magnets of Permanent Magnet Synchronous Machines

Mixed-variable optimal design of induction motors including efficiency, noise and thermal criteria

HyperStudy, OptiStruct, Flux 의연계를통한 연료모터펌프소음저감최적화 알테어황의준

Parameter Prediction and Modelling Methods for Traction Motor of Hybrid Electric Vehicle

PRINCIPLE OF DESIGN OF FOUR PHASE LOW POWER SWITCHED RELUCTANCE MACHINE AIMED TO THE MAXIMUM TORQUE PRODUCTION

An Introduction to Electrical Machines. P. Di Barba, University of Pavia, Italy

Prediction of Transformer Core Noise

A Microscopic Investigation of Force Generation in a Permanent Magnet Synchronous Machine

Doubly salient reluctance machine or, as it is also called, switched reluctance machine. [Pyrhönen et al 2008]

Design and Characteristic Analysis of LSM for High Speed Train System using Magnetic Equivalent Circuit

Study and Characterization of the Limiting Thermal Phenomena in Low-Speed Permanent Magnet Synchronous Generators for Wind Energy

Analytical Method for Predicting the Air-Gap Flux Density of Dual-Rotor Permanent- Magnet (DRPM) Machine

Comparisons of direct and adaptative optimal controls for interior permanent magnet synchronous integrated starter generator

Proceedings of the 6th WSEAS/IASME Int. Conf. on Electric Power Systems, High Voltages, Electric Machines, Tenerife, Spain, December 16-18,

Influence of different rotor magnetic circuit structure on the performance. permanent magnet synchronous motor

Vibration and Modal Analysis of Small Induction Motor Yan LI 1, a, Jianmin DU 1, b, Jiakuan XIA 1

Massachusetts Institute of Technology Department of Electrical Engineering and Computer Science Electric Machines

THE INFLUENCE OF THE ROTOR POLE SHAPE ON THE STATIC EFICIENCY OF THE SWITCHED RELUCTANCE MOTOR

Mathematical Modelling of Permanent Magnet Synchronous Motor with Rotor Frame of Reference

Third harmonic current injection into highly saturated multi-phase machines

Determination of a Synchronous Generator Characteristics via Finite Element Analysis

Analytical Model for Permanent Magnet Motors With Surface Mounted Magnets

DESIGN AND ANALYSIS OF AXIAL-FLUX CORELESS PERMANENT MAGNET DISK GENERATOR

Optimal slot numbers combination for magnetic noise reduction in variable-speed induction motors

EXPERIMENTAL COMPARISON OF LAMINATION MATERIAL CASE OF SWITCHING FLUX SYNCHRONOUS MACHINE WITH HYBRID EXCITATION

Optimal design of a wound rotor synchronous generator using genetic algorithm

Development and analysis of radial force waves in electrical rotating machines

A NEW STRUCTURE OF A SWITCHING FLUX SYNCHRONOUS POLYPHASED MACHINE WITH HYBRID EXCITATION

STAR-CCM+ and SPEED for electric machine cooling analysis

Use of the finite element method for parameter estimation of the circuit model of a high power synchronous generator

The Nottingham eprints service makes this work by researchers of the University of Nottingham available open access under the following conditions.

Analysis of Anti-Notch Method to the Reduction of the Cogging Torque in Permanent Magnet Synchronous Generator

Vibro-acoustic Analysis for Noise Reduction of Electric Machines

Noise Reduction of an Electrical Motor by Using a Numerical Model

Regular paper. Determination of axial flux motor electric parameters by the analyticfinite elements method

Comparison between Analytic Calculation and Finite Element Modeling in the Study of Winding Geometry Effect on Copper Losses

Sensibility Analysis of Inductance Involving an E-core Magnetic Circuit for Non Homogeneous Material

PARAMETER SENSITIVITY ANALYSIS OF AN INDUCTION MOTOR

CHAPTER 3 INFLUENCE OF STATOR SLOT-SHAPE ON THE ENERGY CONSERVATION ASSOCIATED WITH THE SUBMERSIBLE INDUCTION MOTORS

SHAPE DESIGN OPTIMIZATION OF INTERIOR PERMANENT MAGNET MOTOR FOR VIBRATION MITIGATION USING LEVEL SET METHOD

International Journal of Advance Engineering and Research Development SIMULATION OF FIELD ORIENTED CONTROL OF PERMANENT MAGNET SYNCHRONOUS MOTOR

Design of a high-speed superconducting bearingless machine for flywheel energy storage systems. Li, WL; Chau, KT; Ching, TW; Wang, Y; CHEN, M

MODELING surface-mounted permanent-magnet (PM)

Chapter 5 Three phase induction machine (1) Shengnan Li

PERFORMANCE ANALYSIS OF DIRECT TORQUE CONTROL OF 3-PHASE INDUCTION MOTOR

Design and analysis of Axial Flux Permanent Magnet Generator for Direct-Driven Wind Turbines

Characteristics Analysis of Claw-Pole Alternator for Automobiles by Nonlinear Magnetic Field Decomposition for Armature Reaction

THE THEORETICAL AND EXPERIMENTAL STUDY OF CLAW POLE ALTERNATORS

EE 410/510: Electromechanical Systems Chapter 4

Electromechanical Interaction in Rotor Vibrations of Electric Machines

Cogging Torque Reduction in Surface-mounted Permanent Magnet Synchronous Motor by Axial Pole Pairing

This is a repository copy of Analytical modelling of modular and unequal tooth width surface-mounted permanent magnet machines.

Loss analysis of a 1 MW class HTS synchronous motor

UJET VOL. 2, NO. 2, DEC Page 8

M. Popnikolova Radevska, Member, IEEE, M. Cundev, L. Pelkovska

Limited Angle Torque Motors Having High Torque Density, Used in Accurate Drive Systems

Influence of Slots and Rotor Poles Combinations on Noise and Vibrations of Magnetic Origins in U -Core Flux-Switching Permanent Magnet Machines

Cogging Torque Reduction in Surface-mounted Permanent Magnet Synchronous Motor by Axial Pole Pairing

SIMULATION OF A TIME DEPENDENT 2D GENERATOR MODEL USING COMSOL MULTIPHYSICS

Static Analysis of 18-Slot/16-Pole Permanent Magnet Synchronous Motor Using FEA

Water-Cooled Direct Drive Permanent Magnet Motor Design in Consideration of its Efficiency and Structural Strength

Determination of synchronous motor vibrations due to electromagnetic force harmonics

Comparison Between Finite-Element Analysis and Winding Function Theory for Inductances and Torque Calculation of a Synchronous Reluctance Machine

Lesson 17: Synchronous Machines

Cyclical Mutation of Stator and Rotor Designs and Their Impact to the Acoustic Behavior of Induction Motor

Finite element analysis of an eddy current heater for wind or water kinetic energy conversion into heat

Basics of rotordynamics 2

Variable Speed Drive Application Based Acoustic Noise Reduction Strategy

AXIAL FLUX INTERIOR PERMANENT MAGNET SYNCHRONOUS MOTOR WITH SINUSOIDALLY SHAPED MAGNETS

Finite Element Method based investigation of IPMSM losses

Minimizing the Detent Force in Permanent Magnet Linear Synchronous Motor for driving of 2D Laser Marking Table

Finite Element Analysis of Cogging Torque in Low Speed Permanent Magnets Wind Generators

Sensorless Control for High-Speed BLDC Motors With Low Inductance and Nonideal Back EMF

Experimental Assessment of Unbalanced Magnetic Force according to Rotor Eccentricity in Permanent Magnet Machine

Static Characteristics of Switched Reluctance Motor 6/4 By Finite Element Analysis

An improved 2D subdomain model of squirrel cage induction machine including winding and slotting harmonics at steady state

Transcription:

EXPERIMENTAL DESIGN METHOD APPLIED TO A MULTIPHYSICAL MODEL: TRELLIS DESIGNS FOR A MULTIDIMENSIONAL SCREENING STUDY S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET L2EP - Ecole Centrale de Lille, Cité Scientifique B.P. 48, 59651 Villeneuve d Ascq, France Abstract: The aim of this paper is to use an analytical multi-physical model electromagnetic, mechanic and acoustic in order to predict the electromagnetic noise of a permanent magnet synchronous machine (P.M.S.M.). Afterwards, the experimental design method, with a particular design : trellis design, is used to build response surfaces of the noise with respect to the main factors. These surfaces can be used to find the optimal design or more simply, to avoid unacceptable designs of the machine, in term of noise for a variable speed application. Key words: Experimental Design Method, Simple and Multi-space screening study, Multiphysical model, Acoustic noise, Trellis design I. Introduction The majority of the electric machines operate at variable speed. In most of cases, it involves a generation of noise and vibrations, for a given speed and frequency. For industries of manufacture, but also with the increasingly rigorous European standards, it is necessary to take into account the noise and the vibrations from the design stage. A classical method used to study electromagnetic phenomena is the finite element method (F.E.M.) in magneto-dynamics including the coupling with electrical circuits. However, in the case of strong coupling, taking into account the electromagnetic, vibro-acoustic, and thermic models in the same time would need a considerable computing effort. This would make the

2 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET structure optimization practically impossible. In order to solve this problem, an analytical approach is considered instead. The aim of this work is to develop and use an analytical multi-physical model electromagnetic, mechanic and acoustic of a synchronous machine with permanent magnets. The complete model is coded using the dataprocessing tool MATLAB, making possible the determination of fast and simple prediction models of the acoustic noise. In order to reduce noises and vibrations, two main ways can be considered: by the control of the machine excitation [1], or by modifying the system structure. In this work, only the second solution is explored. Three models are presented : electromagnetic, mechanical of vibration and acoustic. For each of them, comparisons with F.E.M. and experiments have been made. Lastly, a study of sensitivity is presented in order to deduce the influential or significant factors on the noise. For that, the technique of the experimental designs is used. More particularly, the modeling of the noise will be achieved thanks to the new trellis designs. Several response surfaces are given; they represent the noise according to influential factors, with respect to different speeds of the machine. These surfaces are useful to deduce the parts of the design space to avoid. II. Presentation of the synchronous machine This machine is composed of eight rotor poles and 48 stator slots. Figure 1. 1/8 of synchronous machine with magnet characteristic The power of this machine is about 25 kw. III. Analytical models

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 3 The vibration analysis of electrical machines is a rather old problem. During the 4s and 5s, it was deeply studied by various researchers [2] to [5]. Vibrations of electromechanical systems are due to excitation forces. Some of them have a magnetic origin. Other sources of vibrations, such as aerodynamic conditions, bearings, etc., will not be considered in this paper. An analytical model, considering electromagnetic phenomena, mechanical vibrations and acoustic noises, was developed to take into account the overall noise produced by a variable induction in the air-gap [6] to [9] and by forces applied to the various structures. A. Electromagnetic model It is assumed that forces in the air gap of the machine are the main mechanical excitation. To characterize induction in the air-gap, the proposed method is based on the calculation of the air-gap permeance (P e ) and the magnetomotive force (mmf) [6], [7] and [8]. To establish the analytical expression of the permeance, some assumptions are made : - the magnetic circuit has a high permeability and a linear characteristic, - the tangential component of the air-gap flux density is negligible relative to the radial component. Results are given in reference [1] and just a comparison is recalled by the following figures. Using the finite element software OPERA-2D [11], the air-gap induction created by the magnet rotor as a function of space and time has been also calculated. In figure 2, a comparison on induction wave shapes versus the angle is presented. The comparison results are very satisfactory, the induction distribution and the harmonic values determined analytically are validated numerically, as shown in ref. [6] and [12]. Amplitude [Tesla] 1.8.6.4.2 -.2 -.4 -.6 -.8 F.E.M Analytical model Amplitude [tesla].8.7.6.5.4.3.2.1 F.E.M Analytical Model -1 1 2 3 4 5 6 7 8 9 Angle[ ] 5 1 15 2 25 3 Spectrumof Induction

4 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET Figure 2. Comparison of the form induction and FFT The fft of the radial forces versus time (t) and angle (θ) is presented below in figure 3 : Amplitude (2p,2fr) (4p,4fr) (8p,8fr) θ t Figure 3. FFT 2D of radial force (fr = p N) B. Vibratory model Vibrations are the consequence of the excitation of the mechanical system by electromagnetic forces. Once the forces applied to the stator have been determined, the study of vibrations is possible. They correspond to the deformations whose amplitudes have to be calculated. For that purpose, some parameters have to be determined : the damping, the mode shapes and resonance frequencies for each mode. For the damping coefficient, we have used the experimental measurements and the software PULSE [13] to determine the resonance frequencies, the mode shapes and the damping. For example, figure 4, some results are detailed: Mode 2 376 Hz Mode 3 14 Hz Figure 4. Mode shape, resonance

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 5 frequencies with (damping coef.) obtained by measurements The studied analytical model takes into account the yoke, the frame, the teeth and the winding. The self vibration modes of the stator structure are determined, in various configurations: yoke only, yoke + teeth, yoke + teeth + carcass and yoke + teeth + winding + carcass [14]. Some results are presented in table I, with an experimental comparison. Table 2. Resonance frequencies (Hz) for each mode N Analytical N Analytical F.E.M. mode model mode model Experimental 363 3151 2736 2855 (1.46) 2 243 268 2 38 376 (3.32) 416 (3.22) 3 688 732 3 871 14 (1.44) 114 (1.74) 4 1319 1349 4 167 172 (1.31) 1968 (2.44) 5 2134 278 5 272 287 (1.54) 2944 (1.46) (yoke & teeth only) (Complete stator : yoke & teeth & winding, + carcass) Resonance frequencies of the stator have been obtained by impact testing measurements, realized thanks to the impact test method. The comparison of the results with the analytical model are very satisfactory. Let us note that the damping coefficient ξ a cannot be given theoretically. However, JORDAN [4] considers that for a synchronous machine, it stands between,1 and,4. The total vibratory spectrum obtained by our analytical model is presented above (figure 5). The simulation results agree well with the theory. In addition, the proximity of the frequency of excitation mode with the frequency of the resonant mode (at 2844 Hz) explains the vibration peak located around 29 Hz. However let us point out that precautions must be taken when analyzing the results. 12 1 474 Hz 945 Hz 3318 Hz 2844 Hz 8 6 4 2 1 2 3 4 5 6

6 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET Figure 5. Total analytical vibratory spectrum with 3555 rpm. Table 2. Main Characteristics of the machine Speed 3555 rpm Frequency of the supply f r 237 Rotational frequency f rot 237/p Frequencies of components of forces (multiple of 2f) h. 237 (h=2,4,6 ) The model giving the induction values is not perfect (the saturation phenomenon is neglected) and the formulae of TIMAR [3] giving the vibrations are also approximated. What is of interest is to determine the frequency of the main peaks and to be able to range their amplitudes. 14 Amplitude db 12 1 8 6 23 58 244 486 29 5158 4 2 Figure 6. Vibratory spectrum measured with 3555 rpm with 1/12 of octave In order to study the vibrations generated by the operating conditions, an accelerometer is positioned on the frame of the machine. It measures the deformations of the frame. The vibratory spectrum gives lines identical to those obtained by the noise measurement; it displays a dominant line situated at 29 Hz, that corresponds to the theoretical excitation mode predicted at 2844 Hz (Figure 6). C. Acoustic model Frequency Hz Acoustic intensity I(x) can be written as a function of the frequency, the amplitude of vibrations, the mode order and the stator surface [5], [9] : σ82 f 2 2 r Ymd S e I( x) = 4πx 2(2m + 1) The coefficient σ is called factor of radiation. It represents the capacity of a machine to be a good sound generator and can be calculated through

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 7 two different ways according to whether one assumes the machine to be a sphere or a cylinder. σ is a factor which varies with λ (wavelength) and the diameter of the machine. It also depends on the mode shape [3]: σ = f( π D), λ λ = c fr c : Traveling speed of sound (344m/s); f r : Vibration frequency. It appears that I(x) is inversely proportional to the order of the mode, in addition the acoustic intensity is proportional to the square of the vibration amplitude. In general, we define I and W in decibels. We thus define the levels of acoustic pressure, acoustic intensity and sound power as follows: 2 log( ) P P Lp =, 1 log( ) I I Li =, 1 log( ) W W Lw = with : P = 2 µpa, I = 1-12 W/m², W = 1-12 W The spectrum of the total noise obtained by our analytical model is presented below (figure 7). 12 1 12f m = 2844 Hz 3318 Hz 14f m =8 8 6 5688 Hz 4 2 1 2 3 4 5 6 Frequency Hz Figure 7. Spectrum of the noise of the simulated P.M.S.M. Figure 8 presents the measured acoustic noise spectrum at the same speed (3555 rpm). Lines are located at the same frequencies as in the vibration spectrum.

8 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET f 2f 12 95 85 75 65 24 58 91 244 459 18 3 29 4597 55 45 35 25 15,37,82 1,83 4,1 9,17 2,54 45,97 12,92 23,41 515,82 1154,78 2585,23 Frequency Hz Figure 8. Spectrum of the noise of P.M.SM measured with 3555 rpm (1/12 octave) The first line determined by measurements is located at 29 Hz (12f). In theory, the harmonic of teeth (12f) is located at 2844 Hz. The lines at low frequencies (between 24 Hz and 459 Hz) are not found in theory, because they are mainly related to the background noise. They are not generated by the P.M.S.M., but by the driving motor and the ventilator (Figure 9). 95 85 75 23 52 91 183 434 Amplitude db 65 55 45 35 25 15,37,87 2,5 4,87 11,55 27,38 64,94 153,99 365,17 865,96 253,5 4869,7 Frequency Hz Figure 9. Spectrum of the noise of driving motor & ventilator measured with 3555 rpm (1/12 octave) After this comparison, the permanent magnet synchronous machine was tested at various speeds, that allowed us to highlight a particularly dangerous speed. Moreover, some results are over-estimated but the quality of those is respected (Figure 1). In spite of the inaccuracies, major lines appear, which is of primary importance in view of noise reduction.

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 9 Amplitude db 14 13 12 11 1 9 8 7 6 5 4 3 2 1 si mul ati ons mesur es 86 rpm 86 rpm Fr equencyhz Figure 1. Level of the 12th harmonic vs. rotation speed - Vibratory comparisons To know which lines to reduce does not require to know its amplitude precisely. Its frequency, on the other hand, must be well given. Lastly, taking into account the complexity of the studied phenomena and the many steps of calculations making it possible to lead to the results, the latter seem very satisfactory. IV. Screening analysis Once the different models finalized and assembled into a single coupled model, it becomes possible to study the variations of the main variables representing the vibration sources. This is achieved by the building of response surfaces, and by the launching of optimizations. The privileged tool employed is the Experimental Design Method [15], [16]. A. Classical screening analysis 1894 rpm 2469 rpm 1894 rpm 2469 rpm 3555 rpm 3165 rpm 3945 rpm 3165 rpm Experimental frequency of resonance F = 2855 H Z 3555 rpm 3945 rpm 3 6 9 12 15 18 21 24 27 3 33 36 Frequency Hz First of all, a sensibility analysis using the global coupled model is described. The overall audible noise produced by the synchronous machine stands as the studied variable (the response). An analytical relation linking the noise amplitude with five variation sources (the factors) has been established : - the stator slot opening (lse) ; - the height of the yoke (h yoke ) ; - the opening of permanent magnet (alp) ; - the width of the air-gap (e) ; - the height of the permanent magnet (h mag ). A screening design [17] is calculated. It gives the ability to determine the influent factors, with respect to the response, inside the design space. This

1 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET domain is implicitly defined by the intervals of variation, for the five factors (Table III). Table 3. Intervals of variation Screening analysis Factors Lower bound Upper bound lse L se min L se min + 2% h yoke h yoke min h yoke min + 2% alp 3 32 e e min e min + 2% h mag 1 mm 12 mm The following figure (Figure 11) gives a representation of the influence of each factor on the noise. Firstly, it shows that the opening of the permanent magnets (alp) is a very influential factor, since its variation from its middle value (31 ) to its upper limit (32 ) makes the noise increase by about 15 db. The height of the yoke (h yoke ), the width of the air-gap (e) and the stator slot opening (lse) are also significant factors according to this figure, since they all exceed the two 95% significance levels. It means that the probability to declare these factor influential although they are not, is equal to 5%. They all have a negative influence on the noise variations: their values have to be increased to reduce the noise amplitude. The height of the magnets (h mag ) is not considered as an influent factor, if the same significance level is used. 14 12 1 Effects 8 6 4 2 95% 95%.21478 -.21478 h yoke e h mag alp lse Figure 11. Factor influences on the noise amplitude It is important to keep in mind that these conclusions only hold inside the design domain. The previous results have been obtained for a fixed rotor speed (3 rpm). Imposing different speeds do not change the relative influence of the factors. However, one can say that effect values increase for speeds around

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 11 3 rpm. This aspect will be confirmed by through the research of the optimal conditions. B. Multi-space screening analysis B.1. Introduction The previous study deduces the influence of the factors over the conception domain, through the computation of effects. These values can be deduced if each factor takes, at least, two different level within its corresponding variation interval. Mostly, these two levels correspond to the lower and upper boundaries of the variation interval. The positive effect of a factor stands as the increase of the response when this factor goes from its lower value to its upper limit, while the other factors take their mean values. Hence, it appears that the effect of a factor depends on the definition of its variation interval, and on the mean values of the other factors. The way the conception domain is defined is therefore a very important matter. So, one understand that, if the conception space is large enough, quadratic effects can appears, that is the influence of some factors may change. In order to lower the impact of the conception space definition, it is sometimes advantageous to cut this domain into slices, according to each factor. The original space is then reduced to elementary sub-spaces, in each of which a screening analysis is calculated. For this study, the following factors have been considered. Table 1. Factor characteristics Factors Lower bound Upper bound Unit lse lse min lse min + 2% mm h yoke h yoke min h yoke + 5% mm alp 26 34 e e min e min + 5% mm N 35 45 rpm For the five factors, five different levels, regularly distributed between the lower and upper corresponding limits, will be considered. Taking an odd number of levels allows to take account of the central value; it will be shown that this aspect is quite important when considering the permanent magnet opening (alp) in particular.

12 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET Defining five levels for each of the five factors, leads to 5 5 =3125 experiments. This is a relatively large problem; it can then be interesting to take advantage of the trellis design []. B.2. Presentation of Trellis designs Trellis designs can be conceived as multilevel factorial fractional designs, or in an equivalent way as fractional grid designs. The five levels per factor implicitly define four contiguous intervals per dimension, that is 4 5 =124 adjacent five-dimensions sub-spaces. Instead of defining a full factorial (2 5 ) design inside each of these subdomains, fractional designs are preferred. By this choice, the grid design becomes a trellis design, which combines a lot of advantageous properties. The most important is certainly the possibility to divide the initial number of experiments needed by the corresponding grid design, by 2, 4, 8 etc. according to the fractional design chosen for the building of the trellis design. Other important properties will be presented afterwards. An important matter concerns the definition of the fractional designs, for each sub-domain. Generally speaking, one must decide of a reference subspace, inside which a reference fractional design is set. This elementary design is naturally and fully described by its independent generators that define the experiments to be calculated. For instance, the following figure gives an illustration of a 2 3-1 fractional design (that is an half of a full factorial design 2 3 ): Factor 3 Factor 3 Factor 1 Figure 12. Fractional factorial design (2 3-1 Generators: I=abc) The reference design is used to deduce the definition of the other elementary fractional designs making up the trellis design. The reference fractional design will then be bordered by an other elementary design of the same type, but with different generators. Indeed, it is necessary to adapt the definition of the generators in order to maximize the number of experiments shared between the two adjacent sub-spaces. This is illustrated by Figure 13. In this example, the reference design is defined by the generator I=abc. The second design must adopt the generator I=-abc, unless existent experiments can not be re-used.

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 13 Factor 3 2 nd design 1 st design (reference design) Factor 1 Factor 2 Experiments shared between the two fractional designs Figure 13. Example of experiment sharing between two fractional designs (2 3-1 ) (left: I=abc right: I=-abc) It can easily be demonstrated that if a new elementary fractional design must be added along the a direction (in other words, along the dimension of the first factor), one must change any a in the independent generator writing by -a. This is a general rule. One gives below the representation of two trellis designs, having the same properties, except the definition of the independent generators used inside the reference sub-domain. This slight change leads to define two designs with different number of experiments. x 3 x 3-1 1-1 1 x 2 x 2 1 1 x 1 Figure 14. Two identical trellis designs with different values of the reference fractional design generators (left: I=abc : 22 experiments right: I=-abc : 23 experiments) x 1 B.3. Effective trellis design In the framework of our study, the trellis design is defined as follows. Each of the five factors takes five different levels. The reference fractional design is a 2 5-2, that is a quarter (1/2 2 ) of a full factorial design (2 5 ). The independent generators of this reference design are I=-abc=-ade. The trellis

14 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET design counts then 795 experiments (approximately a quarter of the number of experiments needed by a 5-level grid design (3125); in other words 5 5 /2 2 ). It takes approximately 16 hours to compute these 795 experiments on a PC, under the Matlab environment. B.4. Multi-zone screening analysis Since a 2 5-2 fractional design is defined in each sub-domain, 4 5 =124 independent screening analyses can be calculated inside the trellis design, thanks to its 795 experiments. One can notice here, that the amount of information deduced by this method is far more important than the initial cost. This approach is interesting because it allows powerful graphical representations. For example, one can plot the evolution of the permanent magnet opening influence with respect to its own values: 1 5 E(alp) -5-1 1 2 3 4 alp Figure 15. Variations of the permanent magnet opening (alp) effect, over the noise creation for different intervals of values of this same factor (alp) (1: 26 to 28 ; 2: 28 to 3 ; 3: 3 to 32 ; 4: 32 to 34 ) V. Research of optimal conditions Once more time, the particular and interesting properties of the trellis design will be used, in order to make the response variations easier to understand. No additional experiment is needed for that.

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 15 Hence, the previously used trellis design is now used to build response surfaces. In a second stage, our purpose was to model the part of the conception domain in which the global audible noise produced by the P.M.S.M. was smaller than a predefined limit: 8 db was considered as the maximal admissible noise intensity. This frontier for the noise the response has been computed with respect the same factors except the height of the permanent magnet (h mag ) and in addition, the motor speed (N). These factors have been selected thanks to screening analyses realized with the complete coupled model. Their intervals of variation are given by Table IV. Table 4. Intervals of variation Modeling stage Factors Lower bound Upper bound lse l se min l se min + 2% h yoke h yoke min h yoke min +5% alp 26 34 e e min e min + 5% N 35 rpm 45 rpm Since we want to have a good description of the variations of the noise with respect to the five factors, it is necessary to increase the number of the different levels taken by each factor. Considering 5 levels is in general enough. Such a configuration leads to 5 5 =3125 experiments with the use of a grid design that is a multi-level full factorial design. This number of evaluations of the coupled model is relatively large, and it can be interesting to take advantage of the new trellis deigns [17]. Trellis designs can be described as multi-level fractional grid design. They are build from fractional 2-level factorial designs judiciously superposed (Figure 12). For this reason, under important hypotheses, they keep their interesting mathematical characteristics, such as for instance the orthogonality property. Figure 12. Example of experiment sharing between two fractional designs (2 3-1 )

16 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET When 5 factors are present, it is possible to use the 2-level fractional factorial design defined as 2 5-2, that is the quarter (2 2 =4) of the corresponding full factorial design 2 5. When this design is used to build the trellis design, it leads to definition of a 5-level incomplete grid, with only 795 experiments instead of 3125 with a complete grid. It takes approximately 16 hours to compute this trellis design on a PC. Instead of using the 795 values of noise directly, we have exploited the interesting relative location of the experiments inside the design domain: an iterative procedure has been applied to estimate the noise values for each of the 3125-795=233 initially non-evaluated experiments. It has been shown that the overall error made for these 233 interpolations, realized thanks to the 795 initial experiments, is lower than.8%. The different results that follow are deduced from the 795 first experimental points mixed with the estimated ones. It quickly appeared that the opening of the permanent magnets (alp) and the motor speed (N) were the two most influential variables over the noise production. The following response surface shows the corresponding variations, as shown in figure 13. It is very clear that the noise is strongly reduced when the permanent magnet area in fact the corresponding angular opening is equal to 3. This result is confirmed by practical considerations. The rotor speed has also a neat influence over the noise production. A resonance phenomenon is visible near the speed value 35 rpm, whatever the factor alp values. 85 8 75 Noise (db) 7 65 6 55 5 26 28 alp ( ) 3 32 45 4 35 3 N (rpm ) 34 25 Figure 13. Noise variations vs. alp and N

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 17 The influence of the three other factors are relatively small in comparison. However, we can notice that the decrease of h yoke leads to move the resonance point towards lower rotation speed values. The 8 db limit can be graphically represented with respect to alp, N and h yoke, thanks to iso-value surfaces (figure 14). Two iso-value surfaces are represented: one showing the noise equal to 8 db, and the other to 84 db. The graphic is nearly symmetrical: 3 standing as the central value for the magnet opening (alp). Then, the admissible sub-space of the conception domain is modeled by the zone delimited by the two central 8 db surfaces. This indicates that it is always possible to conceive a P.M.S.M. generating a noise lower than 8 db, provided that the magnet opening is chosen between 28.5 and 31.5. This interval can be extended for particular rotor speeds greater than 4 rpm or lower than 27 rpm. Figure 14. Noise iso-value surfaces (8 and 84 db) versus N, h yoke and alp VI. Conclusion The purpose of this work is to present some results obtained from the exploitation of a complete coupled model of a permanent magnet synchronous machine. Different multi-physical aspects are considered: electromagnetic, mechanic and acoustic phenomena are taken into account thanks to a single analytical model.

18 S. VIVIER, M. HECQUET, A. AIT-HAMMOUDA, P. BROCHET The Experimental Design Method is the privileged tool used to make the complex relationships between the main variables appear. The first study a screening analysis shows that, whatever the rotor speed considered, the angular opening is a very influential factor: the particular value 3 is certainly the best choice. It is more difficult to set the other factors, since the rotor speed interacts with them. However, the height of the permanent magnets is declared non significant in term of acoustic noise. The second study is designed to work on more precise data. For that purpose, a trellis design with five levels per factor and only 795 experiments, is computed. The advantageous properties of this type of design allow the subsequent evaluations of 233 other points, with an excellent accuracy, leading to practical design choices for lowering the limited noise. REFERENCES [1] M. Gabsi, Conception de machines spéciales et de leurs alimentations. Réduction du bruit d origine électromagnétique, Habilitation à diriger des recherches, Juillet 1999. [2] Timochenko S., Théorie des vibrations, Librairie Polytechnique, CH Beranger, 1939. [3] Timar P.L., Noise and Vibration of Electrical Machines, Elsevier, 1989. [4] Jordan. H., Electric motor silencer - Formation and elimination of the noises in the electric motors W.Giradet-Essen Editor 195. [5] S.J. Jang, Low-noise electrical motors, Clarendon Press Oxford, 1981. [6] Boules N., Prediction of no-load flux density distribution in permanent magnet machines, IEEE Transactions on Industry Applications, Vol. IA 21, N 4, 1985. [7] Ree J.D.L., Boules N., Torque production in permanent magnet synchronous motors, IEEE Industry Application Soc. Conf. Record, Vol87, 1987, pp15-2. [8] Zhu Z.Q., Howe D., Instantaneous magnetic field distribution in brushless permanent magnet DC motors. Part III : Effect of stator slotting Field IEEE Transaction on Magnetics, Vol.29 N 1 January1993- pp.143-151. [9] R.Corton, Bruit magnétique des machines asynchrones, procédure de réduction passive et active, thèse, 2, Université d Artois - France. [1] A.Ait-hammouda, M.Hecquet, M.Goueygou, P.Brochet, A.Randria. Analytical approach to study noise and vibration of a synchronous permanent

Experimental Design Method applied to a multiphysical model: trellis designs for a multidimensional screening study 19 magnet machine, ISEF 23, Maribor, 18 Sept. 23, CD. [11] OPERA_2D, Reference Manual, VECTOR FIELDS, http://www.vectorfield.co.uk. [12] Breahna R., Viarouge P., Space and time harmonics interactions in synchronous machines, 1999, proceedings of Electrimacs pp 45-5. [13] Brüel & Kjaer, PULSE system : modal test consultant, http://www.bksv.com. [14] Verma S.P., Wen Li, Experimental procedures for measurement of vibration and radiated acoustic noise of electrical machines, Power System Research Group 22, p432, ICEM 22. [15] J.J. Droesbeke, J. Fine, G. Saporta, Plans d expériences Applications à l entreprise [16] J. Goupy, La Méthode des plans d Expériences, Dunod, Paris, 1988. [17] Vivier S., Stratégies d'optimisation par plans d'expériences et Application aux dispositifs électrotechniques modélisés par éléments finis, Thèse de doctorat, Université des Sciences et Techniques de Lille, July 22.