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FEMAG Anwender Treffen: Ergebnisse der Untersuchung zu PMSM mit orientierungsprofilierten Magneten (Nutzung des Nord- / Süd- Effektes) 08.-09. 11. 2016 Ingolstadt, Germany presented by Michael Weickhmann; Jörn Steinbrink

VACUUMSCHMELZE GMBH & Co KG VACUUMSCHMELZE GmbH & Co KG Grüner Weg 37 D-63450 HANAU, Germany Ansprechpartner: Michael Weickhmann Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 2

Magnetic Materials Saturation magnetization J s / T 2.5 2.0 1.5 1.0 0.5 0 0.001 Rapid Solidification Rolling Process Powder Route Nanocrystalline Amorphous Co-based 0.01 FeNi (medium) FeSiAl FeNi 80% (Permalloys) FeCo Pure Fe, 3%FeSi Soft ferrites SMC C- Steels Fe Powder cores Ni-Fe Coercivity Hc /(A/cm) FeNiAlTi Cr -, Co- Steels CoFeNi FeCoCr FeCoV FeMnNiTi FeCoVCr Fe Cr Co Cu Ni Fe AlNiCo Hard ferrites NdFeB RE-Co MnAlC Pt Co 0.1 1 10 100 10 3 10 4 NdFeB bonded 2.5 2.0 1.5 1.0 0.5 0 Remanece B r / T soft magnetic semi hard magnetic hard magnetic Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 3

Production process sintered RE magnets H P P P P Vacuum-Melting Casting isosta tic- Crushing Milling Aligning Pressing die- H Production- Process for Rare- Earth Permanent Magnets H = AP H = TP Sintering /Annealing Machining/ Surface-Treatment H Magnetizing H Licensed by Hitachi Metalls Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 4

Agenda Introduction / Motivation Theoretical Work Aim of the project Design of the electrical machine Results and Measurements Summary and future activities Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 5

Motivation Influence of textured magnets on the power of electric PM-machine Application of different magnetic topologies (by using Hot/Side Cold/Side effect and other magnetic Orientation) Verification of the setup of the PM machines Analysis of eddy current within the magnets by segmentation (Comparison Calculation FEA vs. Reality) Power improvement by using Fe-Co Alloys (incorporating weight reduction) Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 6

Block Hot-Side/ Cold-Side Effect Subdividing a Block magnet in 3 Blocks 7.667 x 11 x 4.4 mm Remanence Br 1 [T] Left/ Right Block inclined orientation of 15 ; middle Block oriented perpendicular to pole face Evaluation @ + / - 12.2 mm from origin max. Flux density 50 [mt] / 39 [mt] Hot- / Cold-Side-Effect = 24.7 % E-MOTIVE 07./08.09.2011 Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 7

Flux density @ Hot- / Cold- Side of a 6 segmented Magnet vs. Distance and Angel of orientation Cold Hot Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 8

Analysis of Hot / Cold Side effect using magneto optic Kerr effect Hot / Cold side effect of VACODYM 837 AP and VACODYM 688 AP EBSD Mapping VACODYM 688 Source: Magneto optic Kerr effect EBSD Mapping Analysis was done by the University of Aalen, Germany by Prof. Dr. D. Goll VACODYM 837 Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 9

Partial Halbach designed magnets vs. Block cut conventional magnets Embedded Magnets for Rotors +7 % Conventional magnet Integrated Halbach Magnets: 23 x 11 x 4,2 mm³ Ang el Integrated partial Halbach magnet stray flux density is slightly less than with conventional magnets block cut conventional magnet Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 10

Magnetisation of embedded tangential magnets with 16% Hot / Cold Side effect Hot Side simulated Cold Side simulated Hot Side scanned Cold Side scanned The FEM simulated (5 inclination i.e. 16% NS-effect) data is compared to the scanned Data. The difference of Hot side vs. Cold side is 0.349 T 0.332 T in the simulation. The difference of Hot side vs. Cold side is 0.332 T 0.312 T Scanned Data. FEM simulation fits well with the scanned Data! Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 11

Design and Motivation Dimensions Topology Magnet/Motor magmom [mm³] [piece] [piece] [nvsm] 23x11x4,4 0% NS 56 42 1213 23x11x4,4 16% NS 56 42 1138 23x11x4,4 32% NS 56 42 1156 20x11,5x4,4 11 56 1138 9,85x11,5x4,4 10,8 84 1114 22,3x20x4,4 0% NS 28 1111 Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 12

Comparison of NS8 with T4 Topology T4 with 11 Inclination Test NS 8 T4 NS-Effect / Angle [%] / [ ] 0 11 Mag. Moment [nvsm] 1110 1114 α taup_grad [ ] 21,5 22,5 α taup [mm] 22,32712446 23,36559536 Examp_cross [T] 0,38 0,415 WR(3D) [1/mm²] 0,00764352 0,008704418 rel WR(3D) [%] 100,00% 113,88% NS 8 with 0% NS Effect Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 13

Case Study: How to increase power density with magnetic materials and technologies Embedded Magnets for Rotors with Hot / Cold side effect parallel oriented magnets as block cut flux density in back iron converging flux due H/C magnets as die pressed flux density in back iron slightly higher Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 14

Si-Fe (NO20) PSM machine vs. Co-Fe (VACOFLUX / VACODUR) PSM machine Si-Fe Stator and Si-Fe Rotor 44 mm 10% increased current I while Torque T identical (15% decreased Voltage U) 4,2 KW @ 1715 min -1 and 23,5 Nm Co-Fe Stator and Co-Fe Rotor 33 mm Reduction of Motor size by 25 % Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 15

Comparison of noload mode FEM-Analysis and Measurements comply disregarding measurements accuracy corrected by volume 5% increase is possible by using inclined magnets 5% Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 16

Calculation vs. Measurement classic FOR-control measured value: 17,1A Efficiency-control machine NS1 Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 20

Calculation vs. Measurement NS1 Measurement at 1715 1/min Comparison without Correction of magnetic moment NS2 NS3 measured value NS1: 21,3Nm; 17,1A measured value NS2: 21,4Nm; 17,8A measured value NS3: 21,4Nm; 17,2A Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 21

V rms vs. Amps and Torque vs. Amps of NS1 NS2 NS3 in motor-mode Motor: at 1715 1/min (.) ; at 3430 1/min (*) and at 5140 1/min (x) Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 22

V rms vs. Amps and Torque vs. Amps of NS1 NS2 NS3 in generator-mode Generator: at 1715 1/min (.) ; at 3430 1/min (*) and at 5140 1/min (x) Company confidential All Right Reserved IAL / DM-PM-4 J. Steinbrink / Mi. Weickhmann Nov 2016 page 23