brushless永磁电机设计指南

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"Design of Brushless Permanent-Magnet Motors" 是一本由J.R. Hendershot Jr.和T.J. Miller两位全球知名的专家合著的专业书籍，旨在为现代电机工程师提供最全面、最有用的无刷永磁电机设计手册。这本书与现代基于软件的设计和分析技术紧密结合，涵盖了电机设计工程师和系统工程师关心的所有主题，包括电气和磁性设计、材料选择、控制策略等多个方面。无刷永磁电机因其简单、高效的运行机制和易于控制的动力输出，在许多领域中的应用日益广泛。随着新型磁性材料和数字功率控制技术的发展，它们的应用范围持续扩大，自动化程度的提高也进一步刺激了对这类电机的需求。本书不仅深入探讨了无刷永磁电机的基本原理，还详细介绍了电机设计过程中的关键步骤。电气设计部分可能涵盖电机的电磁场计算、绕组设计、效率优化等内容，确保电机在各种工作条件下都能高效运行。磁性设计则涉及磁路分析、磁体选择以及如何最大化磁能存储和转换。在材料选择方面，书中可能会讨论不同种类的永磁材料（如钕铁硼、钐钴等）的特性，以及它们对电机性能的影响。控制部分是无刷永磁电机设计中的另一个重要环节，包括电机控制系统的架构、传感器选择（如霍尔效应传感器或编码器）、逆变器设计以及先进的控制算法（如磁场定向控制或直接转矩控制）。此外，书中的其他主题可能涉及热管理、振动与噪声分析、可靠性评估以及电机的集成和封装技术。 J.R. Hendershot Jr.作为Trideha Industries MagnaPhysics Division的总经理，带来了丰富的实践经验，而T.J. Miller作为动力工程的教授，为读者提供了深厚的学术背景。他们的合作使得这本书成为无刷永磁电机设计领域的权威参考，无论对于初学者还是经验丰富的专业人士，都能从中获得宝贵的知识和指导。 “Design of Brushless Permanent-Magnet Motors”是一本全面覆盖无刷永磁电机设计各个方面的专业著作，结合了理论与实践，旨在帮助电机工程师应对不断发展的技术和市场挑战。

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CONTENTS

15.4.6 M aximum overload fa r a single puke

.........

..............

15-19

15.4.7 Required cool-down p e rio d

......................................

15-19

15*4.8 Maximum, on-time, for a given overbad fa cto r

................

15-19

15.4.9 M aximum duration of single pulse . , .

...........

15-20

15.4.10 Graphical transient heating curves

.......................15-20

15)5 Thermal modelling by com puter

..............

.........................

15-22

15.5.1 Computer model of thermal equivalent ckcu.it ....... 15-22

15.5.2 Determination o f equivalent-circuit parameters by te st. . . 15-23

16. MAGNETIC MATERIALS

D.A. Staton

16.1 Introduction

...................

....

. ,,.................................................. 16-1

16.2 Permanent magnets

...........................................

16-1

16.2.1 The hysteresis loop and demagnetization characteristic . . . 16-1

16.2.2 Permanent inagnetmaterials . : 3 . „

.................

16-4

16-2.3 Temperature effects ..........................

...................................

16-8

16.2.4 Magnet energy product

...........................................................16-9

16.2.5 M agnetization..............................................................16-10

16.2.6 Mechanical properties and h an d lin g

..........................

16-10

16.2.7 The latest trends in magnet technology

.......................

16-13

16.3 Soft magnetic iron ................................................................... 16-13

16.3.1 The DC magnetization c u rv e .......................................16-15

16.3.2 Core losses

..................................................................... 16-16

16.3.3 Calculation o f coefficients for use in core-loss formulas . . 16-17

16.3.4 Work hardenin g

...........................................................16-18

16.3.5 Special steels

................................................................16-19

16-4 Measurement of material characteristics

.............................

16-19

16.5 Copper w ire ...........................................................

......

.............

16-20

1. GENERAL INTRODUCTION

1.1 Definitions and types of brushless motor

A brushless motor, as its name suggests, is a motor without brushes,

slip rings or mechanical commutator, such as are required in

conventional DC motors or synchronous AC machines for connection

to the rotor windings, [1 ,2].

Several motors satisfy this basic definition. The commonest is the AC

induction motor, in which current in the rotor windings is produced

by electromagnetic induction. As an AC motor, the induction motor

employs a rotating magnetic field that rotates at a synchronous speed

set by the supply frequency. However, the rotor rotates at a slightly

slower speed because the process of electromagnetic induction

requires relative motion, or slip, between the rotor conductors and the

rotating field. The slip makes the induction motor asynchronous,

meaning that the rotor speed is no longer exactly proportional to the

supply frequency. The induced rotor currents also give rise to I

losses which heat the rotor and decrease the efficiency. Variation of

the rotor resistance with temperature causes the effective torque per

ampere to vary, and this makes the motor more difficult to control,

especially in high-precision motion-control applications. We shall sec

that the brushless permanent-magnet motor overcomes all of these

limitations of the induction motor.

The stepper motor is another common example of a brushless motor.

It has all its windings in the stator, while in most cases the rotor has

permanent magnets and laminated soft iron poles. Torque is

developed by the tendency of the rotor and stator teeth to pull into

alignment according to the sequential energization of the phases

(usually two phases). An advantage of the stepping motor is open-loop

operation: in other words, position control can be achieved without

shaft position feedback. However, in order to achieve stable operation

with adequate holding torque, stepper motors are designed with small

step angles, fine tooth geometry, and a small airgap; these features

tend to increase cost and acoustic noise levels. Stepper motors suffer

from resonances which may occur at multiple speeds in the overall

speed range, and in order to overcome these, inertial dampers or five-

phase configurations are sometimes used. The stepper motor does not

1-1

D e s ig n o f b r u s h le ss p e rm a n en t -m ag n e t m o t o r s

have a fixed torque constant or EMF constant, and it is not amenable to

linear control system design.

The brushless DC motor is essentially configured as a permanent magnet

rotating past a set of current-carrying conductors. In this respect it is

equivalent to an inverted

DC commutator motor, in that the magnet

rotates while the conductors remain stationary. In both cases, the current

in the conductors must reverse polarity every time a magnet pole passes

by, in order to ensure that the torque is unidirectional. In the DC

commutator motor, the polarity reversal is performed by the commutator

and brushes. Since the commutator is fixed to the rotor, the switching

instants are automatically synchronized with the alternating polarity of

the magnetic field through which the conductors are passing. In the

brushless DC

motor, the polarity reversal is performed by power transistors

which must be switched in synchronism with the rotor position. The

process of commutation is similar in the two machines, and the resulting

performance equations and speed/torque chracteristics are almost

identical.

When the phase currents in the brushless DC motor are of this type, i.e.

DC current which switches polarity in synchronism with the passage of

alternate N and S magnet poles, the motor is said to operate with

squarewave excitation. The back-EMF in this case is usually arranged to

be trapezoidal, and the terms squarewave and trapezoidal are used

interchangeably to refer to the motor and its controller.

There is however, another mode of operation, in which the phase

currents are sinewaves. The back-EMF in this case should ideally be

sinusoidal. Physically the motor and its controller look similar to the

squarewave motor and drive, but there is an important difference. The

sinewave motor operates with a rotatingampere-conductor distribution, similar

to the rotating magnetic field in the induction motor or the AC

synchronous machine. This type of brushless motor is a pure

synchronous AC motor, with fixed excitation from the permanent

magnets. It is more akin to the wound-rotor synchronous machine than

to the DC commutator motor, and for this reason it is often called a

brushless AC motor.

Many brushless permanent-magnet motor products from Japan and

Europe are referred to as AC servo motors rather than brushless DC

machines. Usually when American manufacturers refer to AC machines

1-2

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brushless永磁电机设计指南

Hendershot

electric motor drives

Permanent Magnet Synchronous and Brushless DC Motor Drives

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