高速无刷直流电机案列～帮忙检查下不合理之处？

cxj

BRUSHLESS PERMANENT MAGNET DC MOTOR DESIGN

                      File: Setup1.res


     GENERAL DATA

Rated Output Power (kW):        1.2
Rated Voltage (V):        220
Number of Poles:        4
Given Rated Speed (rpm):        60000
Frictional Loss (W):        8
Windage Loss (W):        6
Rotor Position:        Inner
Type of Load:        Constant Power
Type of Circuit:        Y3
Lead Angle of Trigger in Elec. Degrees:        0
Trigger Pulse Width in Elec. Degrees:        120
One-Transistor Voltage Drop (V):        2
One-Diode Voltage Drop (V):        2
Operating Temperature (C):        75
Maximum Current for CCC (A):        0
Minimum Current for CCC (A):        0


     STATOR DATA

Number of Stator Slots:        12
Outer Diameter of Stator (mm):          48
Inner Diameter of Stator (mm):          28

Type of Stator Slot:        2
Stator Slot       
            hs0 (mm):          0.5
            hs1 (mm):          0.8
            hs2 (mm):          2.5
            bs0 (mm):          1.8
            bs1 (mm):          4.56026
            bs2 (mm):          5.90001
Top Tooth Width (mm):          3.5
Bottom Tooth Width (mm):          3.5
Skew Width (Number of Slots)        1

Length of Stator Core (mm):          45
Stacking Factor of Stator Core:        0.95
Type of Steel:        DW540_50
Slot Insulation Thickness (mm):          0.3
Layer Insulation Thickness (mm):          0.3
End Length Adjustment (mm):          0
Number of Parallel Branches:        1
Number of Conductors per Slot:        22
Type of Coils:        21
Average Coil Pitch:        1
Number of Wires per Conductor:        2
Wire Diameter (mm):          0.541
Wire Wrap Thickness (mm):          0
Slot Area (mm^2):        30.1893
Net Slot Area (mm^2):        18.2868
Limited Slot Fill Factor (%):        75
Stator Slot Fill Factor (%):        70.4222
Coil Half-Turn Length (mm):          52.3194


     ROTOR DATA

Minimum Air Gap (mm):          1
Inner Diameter (mm):          8
Length of Rotor (mm):          45
Stacking Factor of Iron Core:        0.95
Type of Steel:        DW540_50
Polar Arc Radius (mm):          13
Mechanical Pole Embrace:        0.7
Electrical Pole Embrace:        0.696949
Max. Thickness of Magnet (mm):          2
Width of Magnet (mm):          13.1947
Type of Magnet:        NdFe35
Type of Rotor:        1
Magnetic Shaft:        No


     PERMANENT MAGNET DATA

Residual Flux Density (Tesla):        1.23
Coercive Force (kA/m):        890
Maximum Energy Density (kJ/m^3):        273.675
Relative Recoil Permeability:        1.09981
Demagnetized Flux Density (Tesla):        7.50732e-005
Recoil Residual Flux Density (Tesla):        1.23
Recoil Coercive Force (kA/m):        890

     MATERIAL CONSUMPTION

Armature Copper Density (kg/m^3):          8900
Permanent Magnet Density (kg/m^3):          7400
Armature Core Steel Density (kg/m^3):          7750
Rotor Core Steel Density (kg/m^3):          7750

Armature Copper Weight (kg):          0.056516
Permanent Magnet Weight (kg):          0.0351507
Armature Core Steel Weight (kg):          0.275497
Rotor Core Steel Weight (kg):          0.109289
Total Net Weight (kg):          0.476453

Armature Core Steel Consumption (kg):          0.699111
Rotor Core Steel Consumption (kg):          0.162633


     STEADY STATE PARAMETERS

Stator Winding Factor:        0.5
D-Axis Reactive Inductance Lad (H):        5.12912e-005
Q-Axis Reactive Inductance Laq (H):        5.12912e-005
D-Axis Inductance L1+Lad(H):        9.1299e-005
Q-Axis Inductance L1+Laq(H):        9.1299e-005
Armature Leakage Inductance L1 (H):        4.00078e-005
Zero-Sequence Inductance L0 (H):        0.000130474
Armature Phase Resistance R1 (ohm):        0.217316
Armature Phase Resistance at 20C (ohm):        0.17876
D-Axis Time Constant (s):        0.000236022
Q-Axis Time Constant (s):        0.000236022

Ideal Back-EMF Constant KE (Vs/rad):        0.033842
Start Torque Constant KT (Nm/A):        0.0183314
Rated Torque Constant KT (Nm/A):        0.0287419


     NO-LOAD MAGNETIC DATA

Stator-Teeth Flux Density (Tesla):        1.58087
Stator-Yoke Flux Density (Tesla):        1.32501
Rotor-Yoke Flux Density (Tesla):        0.801317
Air-Gap Flux Density (Tesla):        0.665767
Magnet Flux Density (Tesla):        0.807713

Stator-Teeth By-Pass Factor:        0.00266866
Stator-Yoke By-Pass Factor:        1.61284e-005
Rotor-Yoke By-Pass Factor:        8.60624e-006

Stator-Teeth Ampere Turns (A.T):        8.84341
Stator-Yoke Ampere Turns (A.T):        3.0444
Rotor-Yoke Ampere Turns (A.T):        0.501011
Air-Gap Ampere Turns (A.T):        598.607
Magnet Ampere Turns (A.T):        -611.115

Armature Reactive Ampere Turns
  at Start Operation (A.T):        3309
Leakage-Flux Factor:        1
Correction Factor for Magnetic
  Circuit Length of Stator Yoke:        0.556164
Correction Factor for Magnetic
  Circuit Length of Rotor Yoke:        0.81639

No-Load Speed (rpm):        61439
Cogging Torque (N.m):        6.57424e-014


     FULL-LOAD DATA

Average Input Current (A):        6.96522
Root-Mean-Square Armature Current (A):        4.82152
Armature Thermal Load (A^2/mm^3):        151.758
Specific Electric Loading (A/mm):        14.4704
Armature Current Density (A/mm^2):        10.4875
Frictional and Windage Loss (W):        13.097
Iron-Core Loss (W):        280.494
Armature Copper Loss (W):        15.1559
Transistor Loss (W):        23.1925
Diode Loss (W):        0.43051
Total Loss (W):        332.369
Output Power (W):        1199.98
Input Power (W):        1532.35
Efficiency (%):        78.3098

Rated Speed (rpm):        57864.1
Rated Torque (N.m):        0.198032

Locked-Rotor Torque (N.m):        9.09444
Locked-Rotor Current (A):        496.182


     WINDING ARRANGEMENT

The 3-phase, 2-layer winding can be arranged in 6 slots as below:

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Angle per slot (elec. degrees):        60
Phase-A axis (elec. degrees):        30
First slot center (elec. degrees):        0



     TRANSIENT FEA INPUT DATA

For Armature Winding:
  Number of Turns:        44
  Parallel Branches:        1
  Terminal Resistance (ohm):        0.217316
  End Leakage Inductance (H):        5.25685e-007
2D Equivalent Value:
  Equivalent Model Depth (mm):        45
  Equivalent Stator Stacking Factor:        0.95
  Equivalent Rotor Stacking Factor:        0.95
  Equivalent Br (Tesla):        1.23
  Equivalent Hc (kA/m):        890
Estimated Rotor Moment of Inertia (kg m^2):        1.57471e-005

cxj

请高手帮忙解决一下问题：
1.效率太低了，有没有办法让效率达到0.85以上？
2。铁耗太大了，有没有方法让其减少一点？
3.我这样设计合不合理？
迫切需要高手指点，一个人搞太闷了！谢谢！！

cxj

有没有人回答啊？快快，

cxj

唉 ，没人关注啊 ？

powerwucun

你设计方案效率不能提高，额定输出1200W,转速高达60,000,电流密度偏高了，效率如何提升？
除非你使用液氮冷却，呵呵。

-----把电机外径放大优化定子转子槽型&内外径比或者叠厚加长

cxj

回复 5# powerwucun


    电流密度的范围是4～15 A/mm^2 吧，我的才到10 ，
定子外径是不能在增加，厂家有规定，优化定子槽型倒是可以考虑，但是小弟不知道是从哪方面去优化，是增加面积，还是减少？或者其他什么办法啊？

jackyancs72

帮你顶一下吧 我也不会

zxhua_407

回复 6# cxj

电流密度10已经是个很大的数值了，如果你的电机不是短时工作的话，电机肯定要烧。 连续工作的电流密度一般在4~7啊。你要提高效率现加大线径看看，你可以加大槽面积，你齿宽3.5，我觉得没必要那么宽。这个电机这么小怎么嵌线啊？

cxj

回复 8# zxhua_407


    恩。好的，我试试看，谢谢你咯

cxj

回复 7# jackyancs72


    谢谢～～希望一直顶下去

yunfengren

我也是初学者，象这样的帖子大家应多讨论一下，向高手们学习

powerwucun

Stator-Teeth Flux Density (Tesla):        1.58087
Stator-Yoke Flux Density (Tesla):        1.32501
Rotor-Yoke Flux Density (Tesla):        0.801317
---定子内径比例不对，可以缩小，增大定子槽型面积，或者定子齿和轭部宽度做优选（RMXPRT有参数化扫描功能的）

powerwucun

电流密度选择是看电机温升要求和冷却条件估算选择的，然后根据效率、成本综合考虑，----最直接那人家现成的电机做仿真对比计算，再自己优化设计

cxj

回复 12# powerwucun


    恩，还有像电机的转速除了这个公式之外（n=60f/p），还与什么有关？有哪些参数影响到效率和转速？

cxj

回复 13# powerwucun


   我现在还没到优化设计这一块，有没有相关的一些例子可以供我参考呢?

cxj

回复 13# powerwucun


    可以加你QQ吗?小弟向您学习啊！