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Theoretical Evaluation of The Double U-Core Switched Reluctance Machine
Theoretical Evaluation of The Double U-Core Switched Reluctance Machine
Abstract—The switched reluctance machine (SRM) has seen a refinement of the U-core technology presented in [2]. First,
a lot of interest due to its simplicity and ruggedness. Much the basic theory behind the U-core technology, followed by an
attention have been paid in academia to improve on some of the explanation of the double U-core technology, is presented in
disadvantages of the technology such as torque ripple, acoustic
noise and low torque density. In this paper a topology, namely section II. In section III the requisites and models utilised for
the double U-core SRM, is reviewed. This topology improves on the comparison are presented. In section IV the comparison
some of the disadvantages of the regular SRM. Torque ripple is is presented. The results of the comparison are evaluated
reduced and the torque density is increased for the same amount and summed up in section V. Finally, the presented work is
of material, by reconfiguring the topology of the regular SRM concluded upon in section VI.
and increasing the number of poles. The result is a segmented
stator structure where each segment can be wound individually
and assembled afterwards. Several similar technologies have been II. T HE DOUBLE U- CORE SRM
demonstrated, and the claimed advantages have been proven
in comparison with regular SRMs with a lower pole count.
In this paper, the technology will be compared to a regular
The simplest form of an SRM; a 1-phase 2/2 SRM, is
SRM with a similar pole count, to assess the advantages of the illustrated in fig. 1a. By considering the torque equation for
technology, when disregarding the increased number of poles. a non-saturated SRM, as given in (1), it can be seen that the
This paper therefore serves the purpose of proving and assessing torque is dependent on the change in inductance, the change
the technology through a straightforward theoretical comparison in position, as well as the current. By splitting the regular 2/2
of a regular and a double U-core SRM. From this comparison
the claims of the technology can be proven and the gain from
SRM in half, two U-cores can be formed, as seen in fig. 1b.
utilising the technology can be assessed objectively. This means that the number of poles is doubled, hence the
change in position from unaligned to aligned, dθ, is halved.
The area of the air gap is the same if neglecting fringing, hence
I. I NTRODUCTION the aligned inductance is not changed, and if the unaligned
The switched reluctance machine (SRM) is a worthy com- inductance is assumed to be approximately the same, dL is
petitor to the market-dominating permanent magnet (PM) and approximately the same. This means that the torque is doubled
induction machines. While it is not as widespread and only for the same amount of material [2], compared to the regular
few established production facilities exist, it has interesting SRM with a lower pole count. This is the basic principle
features, making it superior in some areas. The SRM has a behind the U-core technology.
high efficiency over a wide operating area, making it suitable
for variable-speed applications. It is fault tolerant, as it can 45o
continue to run with a winding failure, and if power to the 90o
motor is cut, there is no induced back-emf that can cause
damage to the motor or drive circuit. Finally, the SRM has a
very robust, rugged and simple construction compared to both
PM and inductions machines.
This paper is about a double U-core SRM. It has an
increased number of poles, which increases torque and reduces tp
torque ripple [1]. The copper is better utilised compared to a ½tp
regular SRM, meaning that a higher torque can be obtained for
the same amount of material. The machine has a segmented
stator consisting of double U-cores connected by a bridge. It is
a) b)
The work is partly financed by the Energy Technology Development and Fig. 1. a) 1-phase 2/2 regular SRM. b) 1-phase 4/4 U-core SRM. Unaligned
Demonstration Programme (EUDP - CIPED project, Journal Nr. 64013-0565). position is indicated by the dotted grey lines.
978-1-5090-4281-4/17/$31.00 2017
c IEEE.
deviates slightly from that of the double U-core, as it has a
1 dL 2 middle pole that splits out in two poles, whereas the double
τ= i (1) U-core has two full poles in the middle. In a comparison
2 dθ
with a conventional 12/8 SRM it was demonstrated that “the
In [2] a prototype of a 3-phase 12/10 U-core SRM was
stator-segmented SRM produces over 20 % higher torque in
developed and analysed. The result from the analysis was
comparison to the conventional SRM” [1]. In this analysis,
a comprehensive assessment of the technology and utilised
the two machines however have a different pole count, which
models. One of the biggest disadvantages of the U-core SRM
also affects the torque. The same is the case for the comparison
was the excessive amount of end windings, caused by the
conducted in [3], where a machine very similar to the U-core
full pitch winding topology. There was a number of other
SRM, with a segmented rotor [4], is compared to a regular
disadvantages, but in general, the concept of the U-core
3-phase 6/4 SRM. The increased torque is a result of the
SRM was proven. Therefore, the U-core technology is further
higher pole count, hence the results of these studies does not
developed. To reduce the amount of end winding, the full-pitch
necessarily apply when comparing machines with similar pole
windings should be avoided. This is obtained by doubling the
count. Therefore, similar pole count machines are compared in
number of U-cores, such that two coils are used per phase, and
the following. The short flux paths of the U-core technology
the U-cores sharing a coil are placed next to each other. The
has previously been claimed to reduce core losses [5] and have
result is seen in fig. 2a. As the two neighbouring segments of
been utilised in several topologies [6]. Similar flux-paths are
the same phase has equal magnetic potential, the U-cores can
also seen in rotor-segmented machines [7]. The topology of
be connected with a bridge, in order to form solid segments
the U-core machine is not new [8] [9] [5] [10] [11], but it
that can be wound individually. Due to the double U-core
is different due to the coil arrangement, where the copper is
segments, the minimum number of poles for a single phase is
much better utilised.
8. This means that a 3-phase machine would have 24 stator
The purpose of this paper is to try and verify some of
poles, similar to the machine seen in fig. 2b. It will have the
the above mentioned claims, to see if the double U-core has
same increased torque as the regular U-core machine, but due
the expected advantages and hence is superior to the regular
to the high number of poles, the commutation frequency will
SRM. The machines are compared with a similar pole count,
also be high. This means that this topology is not suitable for
to disregard the effect of increasing the number of poles. In
very high speed applications.
order to assess the advantages of the topology, the simplest
form of the double U-core SRM, a 1-phase 8/8 machine, will
be compared to a similar regular SRM, a 1-phase 8/8 SRM.
III. R EQUISITES
a) b)
Fig. 2. a) 1-phase 8/8 double U-core SRM. b) 3-phase 24/22 double U-core
SRM.
2000 Hz
In order to compare the two SRMs, a finite element (FE)
model is set up in COMSOL. This allows a comparison of
1
the magnetic circuit as well as the torque output of the two
SRMs. The model is a 2D magnetostatic model. 3D effects
have not been taken in to account, as it is assumed that these
will have similar impact on both machines.
1
B. Copper loss 0.03 0.1 0.5 1 2
Flux density [T]
In order to determine the amount of copper as well as Fig. 5. Core loss data for 20HTH1200 [12].
the resistance of the coils, the length of the coils must be
determined. Due to the winding scheme of the two SRMs the In order to use these data to determine core losses of the
lengths alter. The regular SRM has more copper through the SRMs, the frequency and flux density must be estimated. As
stack length, whilst the double U-core SRM has longer end the yoke and pole thicknesses are uniform and flux is assumed
windings for each coil. The length of the coil of the regular and to be distributed evenly across the pole, it is assumed that
double U-core SRM used for the following analyses, is given the flux density is also uniform throughout the laminations.
in (4) and (7). l−,stack is the length of the coil through the The flux waveform is estimated to an equivalent sinusoidal
stack plus an overhang in each end, l−,end is the end winding waveform, even though the actual flux waveform is triangular.
arch and l−,coil is the total length of a single coil. rmidcoil , By studying the flux variations in the laminations of the SRMs,
θs and βs are illustrated in fig. 4. it is found that the laminations of the regular SRM has two
areas with different flux waveforms, whilst the double U- • Material use and cost
core SRM has three areas with different flux waveforms. The • Copper loss
different areas are marked on fig. 6. The appertaining flux • Core loss
waveforms for each color are given in fig. 7. • Combined loss
The magnetisation and torque curves are derived from an
FE model, and indicates the performance of the machine,
regarding inductance and torque. By considering the geometry
of the two machines, material use and cost can be determined
and discussed. Finally, copper, core and combined loss are
considered, to give an indication of the efficiency of the two
machines.
1
Area 2 - Actual
loss.
0 Area 2 - Equaivalent
10-3
-1
40 U-core
8
1 Regular
Area 3 - Actual
Flux Linkage [Wb]
-1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 4 20
Time [pu]
Fig. 7. Actual and equivalent flux waveforms of the areas given by color in 2 10
fig. 6. U-core (2 turns)
Regular (1 turn)
0 0
Notice in fig. 7 how the actual waveforms are triangular. 0 500 1000 1500 2000 0 50 100 150
The stator waveform is unipolar, whilst the rotor waveforms Current [A] Electrical Position [°]
are bipolar. Furthermore, the rotor yoke of the double U-core a) b)
SRM has half the frequency. The equivalent flux frequencies Fig. 8. a) Magnetisation and b) torque curves of the two SRMs.
can be written to be a function of the speed ω as well as
number of stator and rotor poles, Ns and Nr . B. Material use and cost
ω
f1,eq = Nr (8) As the laminations as well as winding topology of the two
4π
ω machines differ, the resulting material use will also differ. In
f2,eq = Ns (9) fig. 9 the total mass as well as copper and core material mass
4π
ω is given as a function of stack length. It is found that depending
f3,eq = Ns (10)
8π on the length of the machine, the relation between the mass of
Using these equivalent frequencies, as well as the maximum the two SRMs varies. This is due to a slightly larger amount
flux density, the core loss of each section and hence the total of end-windings on the double U-core SRM, meaning that
SRM can be determined. for shorter machines, the regular SRM uses less copper. For
the exemplified SRMs, there is an equal amount of copper
IV. C OMPARISON at a stack length of 23.9 mm. It is furthermore seen that the
In order to compare the two machines, they are judged based double U-core SRM always uses more core material than the
on the following analyses: regular SRM, due to the thicker yokes. This means that the
• Magnetisation and torque curves total mass of the double U-core SRM will be larger than that
of the regular SRM for machines shorter than 95.3 mm and lengths, the resistance of the double U-core SRM decreases.
vice versa for longer machines. For example, with a stack length of 60 mm, the copper loss
of the double U-core SRM will be 19 % lower than that of
the regular SRM.
8
U-core total
Regular total
6 Break-even total
U-core copper 0.7 30
Regular copper U-core/Regular
Mass [kg]
Resistance [m ]
10
150
U-core is cheapest
Regular SRM is cheapest 300 13
U-core/Regular, B=0.5 T
U-core, B=0.5 T U-core/Regular, B=1 T
Stack length [mm]
U-core, B=2 T
200
Deviation [%]
Regular, B=0.5 T
Regular, B=1 T
50 150 Regular, B=1.5 T 11
Regular, B=2 T
100
10
0 50
1 2 3 4 5 6 7 8 9 10
pcu /plam [-] 0 9
0 5000 10000 15000 0 5000 10000 15000
Fig. 10. Combinations of copper/core price relation and stack length where Speed [rpm] Speed [rpm]
one SRM is cheaper than the other.
a) b)
Fig. 12. a) Total core loss and b) deviation between the two SRMs as a
C. Copper loss function of speed and flux density.
The reduced amount of copper also affects the copper loss.
The resistance is determined from the length of the coil and
can be seen in fig. 11a. The resulting deviation in copper loss In fig. 13 the core loss of the rotor and stator is seen. It is
due to the different resistances is seen in fig. 11b. Similar seen that the core loss of the rotor is almost identical on the
to what is seen in fig. 9, there is a break-even at 23.9 mm, two SRMs. This means that the main difference between the
where the coil resistance of the two is equal. At longer stack two is in the core loss of the stator.
100 250
V. E VALUATION
U-core, B=0.5 T U-core, B=0.5 T Through the comparison of the double U-core SRM with
U-core, B=1 T U-core, B=1 T
80 U-core, B=1.5 T 200 U-core, B=1.5 T a similar regular SRM, the claims given in section II can be
E. Combined loss a given length the double U-core SRM uses less copper.
• Depending on the length of the machine as well as the
In fig. 14 the combined copper and core loss is given at relation between copper and core material cost, in most
two stack lengths and three different current densities, as a cases, the total material cost of the double U-core SRM
function of speed. This gives an overview of the total loss, will be less than that of the regular SRM.
neglecting mechanical loss, for the exemplified SRMs. The • The double U-core SRM has lower copper loss at a given
current densities represent three different scenarios. Running length.
continuously with 5 A/mm2 is possible without forced cool- • The regular SRM has lower core loss.
ing, 10 A/mm2 is possible using liquid cooling, while 15
A/mm2 is possible, but challenging, using liquid cooling [14]. These findings apply only for the comparison between
For the shorter exemplified stack length, the loss of the two the two single-phase 8/8 SRMs. In other configurations, the
SRMs is almost equal. The double U-core SRM has lower findings might be different. The purpose of these analyses is to
losses at high currents, whilst the regular SRM has lower give a direct comparison between two very similar machines,
losses at high speeds. For the longer stack length, the double where the only differences are the lamination and winding
U-core SRM has much lower losses at high currents, whilst at topologies, allowing for a direct assessment of the double U-
low currents and high speeds, the two SRMs has equal losses. core technology, leaving out as many influential parameters
It is evident that for longer stack lengths, the double U-core as possible. As expected, the magnetic circuits and therefore
SRM has a lower combined loss. output torque are similar. The analysis of the mass and cost
indicates that the double U-core SRM is cheaper in most cases,
OVWDFN PP even though it uses more material in total. The real benefit of
400
the double U-core SRM is however expected to be lowered
manufacturing costs due to the segmented structure, which
300
can reduce the amount of waste material substantially. It is
Total loss [W]
also found that the double U-core SRM has lower copper loss
200
in most configurations. This is due to the better utilisation of
copper, where each coil magnetises four poles, where each
100
coil of the regular SRM only magnetises a single pole. This
also significantly reduces the number of coils from eight to
0 U-core, i=5 A/mm2 / B=1.42 T
0 5000
U-core, i=10 A/mm2 / B=1.69 T
10000 15000 two.
U-core, i=15 A/mm2 / B=1.84 T OVWDFN PP Contrary to the expected, the regular SRM has lower core
1000 Regular, i=5 A/mm2 / B=1.43 T loss than the double U-core SRM. In the presented 1-phase
Regular, i=10 A/mm2 / B=1.72 T
800 topology, the advantages of short flux paths and reduced flux
Regular, i=15 A/mm2 / B=1.87 T
reversal are present in both SRMs. Considering a multi-phase
Total loss [W]
ACKNOWLEDGEMENT
The development of the U-core SRM and double U-core
SRM is a part of the CIPED [15] project. The authors of this