Design for Manufacture of a Brushless Synchronous Servomotor
PhD Thesis
Da Silva, Helder 2014. Design for Manufacture of a Brushless Synchronous Servomotor. PhD Thesis University of East London Architecture Computing and Engineering https://doi.org/10.15123/PUB.4620
Authors | Da Silva, Helder |
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Type | PhD Thesis |
Abstract | This thesis presents research into the design of brushless permanent magnet (BPM) interior rotor synchronous servomotor for both performance and manufacturability. The investigation has been supported by experimental evidence gathered with the aid of two prototype servomotors, having the same frame sizes and stator stack lengths, designed by the author and manufactured by the sponsoring company, Control Techniques Dynamics (CTD) Ltd. One servomotor, upon which the research is focussed, has the relatively new segmented stator structure containing concentrated windings. The other servomotor has a conventional structure with a solid stator containing distributed windings and this has provided the means of assessing the degree of improvement attainable with the new structure. It has been established that the new structure enables more cost-effective manufacture than attainable with the conventional structure. A significant contribution of the research programme is the special notch for retention of the surface mounted permanent magnets in the rotor. This innovation enables a more uniform and smaller air gap, which greatly improves the dynamic and thermal performance for a given frame size and stator stack length, thereby advancing the state of the art. This, together with the greatly reduced stator winding overhang in the new structure, enables a physically smaller motor for a given application, thereby reducing active material usage. Also the design methodology has focused on reducing energy and eliminating waste in the manufacturing process. Regarding the thermal aspects, only natural cooling has been considered. Conduction, convection and radiation heat transfer in the servomotor has been investigated theoretically, by simulation and by experiments to identify where design improvements can be made. The most critical area identified is the paper wall insulation and comprehensive experiments have been carried out to identify the commercially available material with the highest thermal conductivity to maximise the removal of heat from the stator windings. An array of strategically located thermocouples was used to obtain temperature distributions. The performance indicators for comparison of the new and conventional servomotors are cogging torque, iron loss and dynamic torque. The cogging torque proved to |
Year | 2014 |
Digital Object Identifier (DOI) | https://doi.org/10.15123/PUB.4620 |
Publication dates | |
Sep 2014 | |
Publication process dates | |
Deposited | 03 Dec 2015 |
Publisher's version | License CC BY-NC-ND |
https://repository.uel.ac.uk/item/8591x
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