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SMMA
2005 Fall Technical Conference Conference Chair - John Calico, Moog Components Group* * SMMA Member Company Wednesday,
October 5 9:00-5:00
Instructor:
William H. Yeadon, P.E., President, Yeadon Energy Systems, Inc.* 12:00-4:00
SMMA Board of Directors Meeting (includes working lunch) 1:00-5:00
Electric Motor Education and Research Foundation (EMERF) Workshop:
Combining the EMERF Lamination Steels Database with Motor Simulation
Programs Instructors:
Steve Sprague, Sales Manager, Proto Laminations Inc.*, and Dan
Jones, President, Incremotion Associates Inc.* The EMERF Workshop will include an overview
of the EMERF database for soft irons and steels used in electric
motors. This data, available on the EMERF Lamination Steels, Third
Edition CD, provides an additional tool for more accurate motor
design including magnetic saturation (first quadrant) curves and
core loss curves. The EMERF data will be combined with PC-BDC, a
SPEED brushless permanent magnet motor design program to illustrate
the basics of precision motor design. The workshop will also cover
the selection and evaluation process for soft irons, steels and
permanent magnets, as they pertain to overall motor performance. 1:00-4:00
Set-Up for Table Top Exhibitors 6:00-7:00
Registration 6:00-7:00
Beer and Pretzels Reception with Table Top Exhibits Dinner on your own.
Thursday, October 6 8:10-8:30 - The Lamination Steels Third Edition from the Electric Motor education and Research Foundation - Steve Sprague, Sales Manager, Proto Laminations* and EMERF Board of Directors EMERF, the SMMA Electric Motor Education and Research Foundation, initiated the Lamination Steels Research Project to compile and update the data available to motor designers pertaining soft magnetic alloys commonly used in electric motors. The Project has two phases. The first phase is the collection of existing information, published on a CD-ROM. The second phase is to research material properties at high frequencies and at non-sinusoidal excitations. This research is being pursued by a Consortium of SMMA member companies and is coordinated through Professor Prag Pillay at Clarkson University. An update on the work of the Consortium follows this presentation. Steve Sprague, editor of the Laminations Steels CD-ROM project, is pleased to announce the publication of the 3rd Edition CD-ROM containing material data from 14 worldwide steel producers. Also included in the 3rd Edition are core loss and magnetization data presented in both Imperial and Metric values for rolled steel, and a selection of amorphous and powdered metal core materials. 8:30-9:00 - Status of the SMMA/EMERF Research Consortium on Losses in Lamination Steels - Pragasen.Pillay, PhD, Professor, Department of Electrical & Computer Engineering; Tsakani Lotten Mthombeni, Graduate Student, and Timothy.Roth, Graduate Student -, Clarkson University* - Presenter, Mr. Mthombeni This is a status report on the progress of the EMERF Consortium work at Clarkson University. A meeting was held at Clarkson University in January 2005 to kickoff the DoE grant award. Since then, work has been done to set up a flexible core loss measurement test bench, an order has been placed for a commercial test bench and a new high-frequency frame has been designed and built. The new flexible test bench is controlled by DSPACE hardware, which allows programming in Matlab Simulink, thus reducing development time. New high frequency results on the new Epstein frame will be discussed. Problems with core loss predictions will be discussed, and plans to pursue a more physical and material science based approach will be presented. Progress on analytical core loss design formulae will be presented, together with comparisons of predicted and measured results. 9:00-9:30 - Overview of Soft Magnetic Alloys and Their Application - Dennis McBride, Materials Application Engineer, VAC Magnetics Corp.* In
most motor designs, the soft magnetic material of choice is silicon-iron.
This is largely due to its relatively low cost compared to alternative
materials. The alternative materials (e.g. nickel-iron alloys,
cobalt-iron alloys) should be considered when certain motor performance
criteria are This
paper considers the features of magnetic property formation in
quenching and following heat treatment of nanocrystalline NdFeB
based alloys on using centrifugal sputtering from liquid condition.
Maximum magnetic properties are attained for alloys which are
produced by two-stage processing, namely 80-90% of amorphisation
plus crystallization annealing. The model of formation of quenched
flakes at centrifugal sputtering of melt is considered. The formation
of structure and phase condition of the materials is studied.
Examples of application of quenched powders for bonded magnets
are considered. 10:00-10:30
Networking Break with Table Top Exhibits 10:30-11:00 - High Performance Bonded Magnets - Bhanu Chelluri, Edward Knoth, Edward Schumaker, IAP Research Inc.*, Melania Marinescu and George Hadjipanayis, University of Delaware - Presenter Dr. Chelluri Bonded
magnets offer greater benefit over sintered and hot pressed magnets
in terms of their net shape manufacturing flexibility. However,
the magnetic performance of current bonded magnets is limited
by the amount of polymer used (25-40 % by volume) and the density
achieved in the final molded magnet. In this presentation, properties
of a new class of bonded magnets of higher density made with half
the polymer content that are molded by Dynamic Magnetic Compaction
(DMC) will be presented. The properties of DMC magnets are found
to be superior to compression and injection molded magnets and
their magnetic properties will fit into a class close to hot pressed
magnets. Moreover, DMC molded magnets can be made into net shape
for various common magnet applications. 11:00-11:30 - Radially Oriented, Hot-Formed Anisotropic NdFeB Magnets, Dr. Hitomi Yamada, Daido Steel Co., Ltd. (Nagoya, Japan) and Dr. Norio Yoshaikawa, Daido Electronics Co., Ltd. - Presenter Dr. Yamada Hot
formed anisotropic NdFeB magnets are very unique in terms of their
magnetic alignment mechanism. Rapidly quenched flakes are compacted
to full density by cold- and hot-pressing, and then during the
subsequent hot plastic deformation process, easy magnetization
axes of fine crystals are aligned along the compression axis.
When a ring magnet is made using hot extrusion, over 40 MGOe of
energy product can be achieved along the radial direction. Magnets
with high heat resistance up to 150 C can also be produced. 11:30-12:00 - Light Cure Adhesives Enable Innovative Improvements in Stepper Motors - Jamie Serenson, Market Development Manager, Loctite Industrial Adhesives, Henkel;* Chris Verosky, Senior Application Engineer, Loctite Industrial Adhesives, Henkel* and Belal Azim, Marketing Coordinator, Lin Engineering - Presenter Mr. Verosky Stepper and brushless DC motors are some of the most technologically advanced motors that are used in the most sophisticated end-use applications. Adhesives are widely used in motor manufacturing to reduce costs, improve quality and enhance the manufacturability. Henkel and Lin Engineering have worked together to implement bonding, retaining, potting, gasketing, threadlocking and thread sealing applications. This paper will discuss specific case histories implemented to enhance the motors performance and ease of manufacturing. For each application, the performance specification will be described, the adhesive solution will be compared and contrasted to alternative methods of assembly and the benefits accomplished when utilizing adhesives will be detailed. Additionally, for selected applications the first-hand experiences of Lin Engineering, step motor specialists, will be discussed in detail. The experiences of Lin Engineering will detail the strenuous tests that adhesives are subject to before being qualified for these applications as well as the benefits of adhesives versus "traditional" assembly methods for reducing cost and improving quality and performance of the end product. 12:00 - 1:00 - Lunch 1:00-1:30 - Design Optimization of Small Electrical Machines - Mikhail Khanin, PhD, Baldor* The use of finite element analysis to optimize the performance of small electrical machines is presented. The capability and effectiveness of using finite element analysis for a variety of design and development problems in small electrical motors and generators are demonstrated. The FEA approach has been proven adequate and is now being used in Baldor Electric Company to develop new designs and to improve existing designs with respect to performance and manufacturing cost. Examples presented in this paper refer to electromagnetic analysis, and are followed by heat transfer and stress analysis if needed. FEA can also help to predict and minimize vibroacoustic responses or change harmonic spectra by modeling different slot combinations, winding configurations, and lamination geometries. FEA software has become an essential part of electric motor design practice for both research and product development projects. 1:30-2:00 - Control of Torque Ripple in Mass-Produced Permanent Magnet Synchronous Machines - Steve Pekarek PhD, Associate Professor, Purdue University, EE* In most mass-produced drives where vibration and noise are a design issue, mitigation is achieved through machine design (magnet design, tooth/slot design, etc). This is due to the cost that has been required to implement torque ripple mitigation strategies and/or the sensitivity of control approaches to system parameters. Specifically, most control-based methods have required precise knowledge of rotor position and have therefore utilized high precision position encoders. In
this presentation, a hall-effect-sensor-based position observer
is developed and coupled to a torque ripple sensor to provide
encoderless feedback-based torque ripple mitigation. The observer
includes a routine to compensate for offset in placement of sensors,
which is shown to be necessary for effective control of torque
harmonics. The proposed approach makes the use of control-based
strategies to achieve vibration/noise mitigation across a mass-produced
drive system platform possible, and perhaps more cost effective
than machine design approaches. 2:00-2:30 - A New Permanent Magnet Technology - John Petro., President, NovaTorque Inc.*, Ken Wasson, Owner, Wasson Associates* - Presenter, Mr. Wasson A new motor design concept improves motor efficiency by taking advantage of new ideas of motor topology and construction techniques. By reducing losses in the magnetic structures of the motor, greater torque per unit power can be achieved. Alternatively, greater torque per unit size or weight can be realized. Eddy current losses in the windings and in the iron are reduced and hysteresis losses in the iron are minimized while still providing high motor performance. In addition, shielding techniques are employed to reduce stray fields. Given the specific performance data and the expected low manufacturing costs, this appears to be a disruptive motor technology. The
comparative performance data will be presented in a 3D graphical
format which provides a potentially standard way to compare motor
performance with customer needs…and comparisons between commercially
available motors. This approach allows the user to gain more insight
about losses relative to operation at various speeds and loads.
2:30-3:00 Networking
Break with Table Top Exhibits 3:00-5:00 - Break-outs
6:00-7:00 Reception 7:00-9:00 - Dinner Friday, October
7 7:30-8:00
Continental Breakfast with Table Top Exhibits 8:00-8:30 - Why a Motor Won't Output More Continuous Torque by Simply Increasing Its Operating Temperature - Richard Welch Jr., Senior Member IEEE and Alex Ruderman, PhD, Bar-Ilan University, Ramat-Gan, Israel - Presenter, Mr.Welch A common myth amongst application engineers and motor users is that increasing a motor's operating temperature always results in higher continuous torque output. In this paper we prove why the motor's temperature dependent electrical resistance actually inhibits torque output with increasing motor temperature. For all permanent magnet motors we also prove that thermal demagnetization of its magnets further inhibits torque output such that motors containing specific magnet materials will actually output higher continuous torque at a lower operating temperature. 8:30-9:00 -Manufacturing Unique Shaped Laminations for the Enhancement of Motor Performance - Dean Higa, Regional Sales Manager, Mitsui High-tec (USA) Inc. There are several types of motor lamination stacks available that are designed to maximize slot fill. For example, by allowing the winding area to be easily accessible before assembling the stator, a much higher slot fill can be achieved. This presentation will show tooling technologies that will allow manufacturability of two new lamination designs for maximizing slot fill and improving motor performance. 9:00-9:30 - Integrated Linear Motion Systems - Dan Jones, President, Incremotion Associates*, Max Morita and Nick Johnatgen, Oriental Motor (USA) Inc.* - Presenter, Mr. Jones Most
applications on the factory floor use linear motion. A rotary
electric motor is connected to a rotary-to-linear power transmission
device via some shaft coupling to achieve linear motion. Oriental
Motor has combined a rotary step motor and position feedback device
with a precision THK ball screw to create a high performance integrated
linear motion system. This integrated construction eliminates
a number of assembly misalignment problems and provides compact
motorized slider and cylinder family configurations. 9:30-10:00
Networking Break with Table Top Exhibits This
paper will discuss some methods used to identify noises that are
often the cause of customer complaints and returns. Typically,
the descriptors of such problems are subjective, rather than quantitative,
which makes it impossible sometimes to define the problem. This
paper will show how measurable sound quality parameters can be
used to link subjective and quantitative methods of sound and
vibration identification. This
paper presents an overview of a unique 2-phase switched reluctance
drive system providing good performance at a low cost. It is comprised
of a motor with a geometry which inherently reduces stator vibration
and mechanically reduces excitation causing resonant frequency
problems. A significant component of the acoustic noise (ovalization)
is suppressed or neutralized by means of a flux switching transition.
The flux transforms naturally and smoothly Motor
manufacturers and users alike have had difficulty matching needs
to motor performance except within catalog data bands and simplistic
graphs. An important parameter in any motor application is control
of losses since thermal dissipation ultimately defines motor performance
limits. This paper proposes a three dimensional approach to defining
important motor performance and loss parameters in an easily visualized
format. SMMA may wish to incorporate this format as a standard
way, or the start of a standard way, to present motor performance
data. 11:30-12:00 - UL and Industry - Partnering for Success - Frank Ladonne, Primary Designated Engineer (PDE), Motors and Generators, Underwriters Laboratories, Inc. 12:30-4:00 - EMERF Board of Directors Meeting (includes working lunch)
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