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Coupled Problem Study with Structural Analysis Considering Barrier Filling of PMa-SynRM for Railway Vehicle

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Abstract

This paper investigates the structural-electromagnetic coupled problem of a permanent magnet assisted-synchronous reluctance motor (PMa-SynRM) for railway vehicles considering the barrier filling. The PMa-SynRM is suitable as a traction motor for railway vehicles but is vulnerable to the structural stability of the rotor under centrifugal force. Therefore, the structural characteristics of the PMa-SynRM should be considered, and the structural influences on the electromagnetic performance are also important based on the stress-dependent properties of the electrical steel core. To improve the structural stability, the concept of barrier filling is proposed, which involves inserting a substance into the magnetic flux barrier region of the PMa-SynRM and balancing the loads in the rotor core. The structural analysis results with the barrier fillings are compared for a wide range of their physical properties. We input stress and strain data by element into the rotor electrical steel core of the electromagnetic model, which consists of the identical mesh as the rotor structural analysis results and set conditions to reflect the stress-dependent B-H and iron loss data to analyze the electromagnetic performance including coupled effects. Finally, the best filling substance is derived and applied based on the previous structural analysis results, clarifying the improvement in the structural and electromagnetic characteristics.

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Acknowledgements

This work is supported by Korea Institute of Energy Technology Evaluation and Planning (KETEP) grant funded by the Korea government (MOTIE) (20224000000440, Sector coupling energy industry advancement manpower training program)

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Authors and Affiliations

  1. Department of Electrical and Computer Engineering, Sungkyunkwan University, Suwon, South Korea

    Seung-Gu Kang, Do Hyun Kang, Hyung-Woo Kim, Seok-Won Jung & Sang-Yong Jung

  2. Department of Electrical Engineering, Chonnam National University, Gwangju, South Korea

    ** Hwan Lee

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  1. Seung-Gu Kang
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Correspondence to Sang-Yong Jung.

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Appendices

Appendix A

This Appendix discusses the general limitation of the material properties of the electrical steel core. The limitation is introduced in Sect. 3 and is similar to those reported in previous studies regarding stress-dependent electrical steels [20, 21]. Therefore, the impact of this limitation on the coupled analysis should be discussed. The detailed contour image plots at a high-speed operating point of 366.66 Nm and 6,000 rpm are presented in Fig. 

Fig. 21
figure 21

Contour image plots at a high-speed operating point of the a major-PS, b minor-PS, and c iron loss

Full size image

21. The mechanical stresses, including the major- and minor-PS, were concentrated in the bridge ribs, as shown in Fig. 21a, b. The other regions were under a relatively low stress and the limitation was insignificant. Figure 21c shows that the iron loss density is not high in the bridge ribs because variations in the magnetic flux are important for iron loss. The regions of PS and iron loss did not directly match, and a PS value of greater than 100 MPa affected the low-loss region. Therefore, the limitations of the stress-dependent property data were not significant. However, if further research is conducted in the future and stress-dependent data are studied over a larger area, these limitations may not need to be considered.

Appendix B

The structural characteristics were analyzed for a wide range of physical properties in Sect. 5.2, and a bamboo was proposed as the best substance in Sect. 7.1. Other candidate substances are introduced, and their physical properties and analysis results are derived in Table 

Table 7 Physical properties and structural analysis results according to the substance candidates
Full size table

7. While there are many candidate substances provided by GRANTA, some substances that were considered suitable, were selected, and analyzed. Suitability is determined by the values of MD, PR, and YM being in the general range of non-negative values, excluding materials that are not at the level to be used in electric motor development, such as diamond.

The results were varied, and some substances have trade-off characteristics and have the potential to be optimal. Pine wood reduces VMS slightly less, but it has the lowest MD of the candidates, which is more favorable in terms of weight reduction and improving the power density of the motor. Concrete lags behind in the aforementioned characteristics but has advantages when considering the manufacturability of the practical motor, making it a prime candidate in some cases.

Previous reference studies [13, 14, 16] suggested the effect of epoxy adhesive bonding, it was also included in the substance candidates, which improved the FOS 1.92 times better than air filling. Therefore, the effectiveness of the epoxy resin filling considered in the previous studies was verified, and the improvement results in this paper can also be confirmed.

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Kang, SG., Kang, D.H., Kim, HW. et al. Coupled Problem Study with Structural Analysis Considering Barrier Filling of PMa-SynRM for Railway Vehicle. J. Electr. Eng. Technol. (2024). https://doi.org/10.1007/s42835-024-01924-6

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  • DOI: https://doi.org/10.1007/s42835-024-01924-6

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