高速开关磁阻电机的关键技术研究与实践
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摘要
随着科技水平的发展,航空航天、能源、精密制造等诸多领域对高转速电机的需求越来越多。电机转速的大幅提升有利于提高电机的功率密度,减小设备的体积重量。因此,高速/超高速电机在军事和民用领域应用越来越广泛,已成为当今国际电工界的研究热点。
开关磁阻电机(SRM)是近年来随着电力电子技术和控制技术的发展而逐渐完善起来的一种新型调速电机。由于SRM定转子均为凸极实心叠片结构,定子上绕有集中绕组,转子上无绕组、永磁材料及鼠笼线圈,具有结构简单坚固、成本低、可靠性高的特点,因此在许多工业调速领域获得了广泛应用。SRM的转子结构可以承受很高的机械应力,特别适合高转速要求,能适应高温等恶劣环境,在航空航天、高速加工等高速/超高速领域应用具有独特优势。
本文主要致力于高速SRM系统的理论和应用基础研究,目标是为高速SRM的系统设计和工程应用提供较为完整的基本理论和关键技术支撑。在对前人成果的广泛了解和深入研究的基础上,本文以高速SRM电机本体的多参数综合设计、功率变换器主电路、专用集成电路等核心关键技术为突破口,对高速SRM在机理研究、样机研制、实验研究和工程应用中存在的关键技术难题进行了系统研究,建立了高速SRM研究与实验的技术平台。
针对高速SRM的运行特点,本文在常规SRM的电磁设计流程的基础上,基于电磁、铁损、应力、转子振动等多物理场的有限元计算,构建了包括电磁设计、损耗计算、结构应力分析、转子动力学分析在内的高速SRM电机本体的多参数综合设计方法,成功研制了三种高速SRM实验样机,为高速SRM的电机本体设计奠定了理论基础。结合高速SRM样机的研究与实验需要,本文还对高速SRM的电磁性能优化、转子结构应力及动力学性能分析、铁损及风阻损耗计算等关键技术进行了理论和实验研究。
分析了不对称半桥式主电路、裂相式主电路等典型SRM功率变换器主电路的优缺点,对适合于高速SRM的功率变换器主电路拓扑进行了探讨,分析了典型功率变换器主电路拓扑对SRM换相性能的影响,并对传统的双开关式不对称半桥主电路进行了改进,提出了一种可提高电机换相性能的三开关式不对称半桥主电路拓扑,并在一台SRM实验样机上,对双开关式主电路和三开关式主电路进行仿真分析和对比实验。
成功研制了国内第一片SRM控制专用集成电路SR3P10K07A,介绍了SR3P10K07A的设计思路和设计过程,较为详细的介绍了该芯片中各功能模块的实现算法,并基于硬件电路对该芯片进行了逻辑功能验证。基于SR3P10K07A,本课题还设计制作了通用的SRM数字控制器,并在多台高速SRM样机中获得了成功应用。
此外,本文分别对三种高速SRM样机进行了实验研究和工程应用。其中,样机Ⅰ的最高转速达到了136,000r/min,成功实现了该样机的超高速运行;作为高速原动机,样机Ⅰ还在南京航空航天大学微型发动机研究所开发的气浮轴承性能测试平台中获得了成功应用;对分别采用常规凸极转子和圆柱复合型转子这两种不同转子结构的样机Ⅱ进行了空载实验,对比了两种转子结构的风阻损耗;样机Ⅲ在常州新罗特数控机械有限公司生产的NRT40M高速数控模具雕刻机上进行了成功应用。
With the development of the science and technology, there is urgent need for high speed motor in aerospace, energy, precision manufacturing and many other fields. The increase of motor speed is conductive to improve the electrical power density, reduce the size and the weight of the equipment. As a result, high speed / super high speed motor have received high popularity in the field of military and civilian applications, and it have been the hot topic in the international electrical field at present.
Switched reluctance machine (SRM) is a new type of adjustable-speed motor, based on the development of power electronic and control technology in recent years. It has been employed in variable speed industrial applications due to their simple and rugged structure, low cost, and high reliability. The rotor has no windings, magnets, or squirrel-cage winding, but is constructed from a stack of salient-pole laminations. This structure can withstand high mechanical stress, especially fit for the high speed requirements and adapt to the harsh environment. Therefore, SRM is considered the motor which has the advantage in the field of aerospace, high speed manufacturing of high speed / super high speed applications.
This dissertation focuses on basic research for the theory and application of high speed SRM system, in order to lay the foundation for the high speed SRM system design and engineering application. Based on the extensive and in-depth understanding of the outcomes in the past, some breakthrough have been made toward the multi-parameter integrated design, main circuit of power converter, application specific integrated circuit, and other core technology. At the mean time, some systematic study have been conducted toward the mechanism, prototype design, experiment and engineering applications, and a experimental platform of the high speed SRM has been built.
In terms of the operational features of the high speed SRM, a multi-parameter integrated design method has been developed in this paper, on the basis of regular electromagnetic design process and the finite element calculation of multi-physics field, including the electromagnetic, core loss, stress, rotor vibration, etc. The method comprises of electromagnetic design, loss calculation, the structural stress analysis, rotor dynamic analysis. At the same time, three high speed SRM experimental prototypes were successfully developed, laying the theoretical foundation for SRM prototype designing. Taking into account the need for the experiment and research of high speed prototype, much theoretical and experimental research have been conducted toward key techniques such as electromagnetic performance optimization, rotor structure stress and dynamic performance analysis, iron and windage loss calculation, etc.
In the dissertation, the advantages and disadvantages of some typical main circuit of SRM power converter, such as the asymmetrical half-bridge, split-phase main circuit is analyzed, and the influence to the SRM commutation performance brought by the topology of the typical power converter have also been discussed. On the basis of the topology of the conventional double-switch asymmetrical half-bridge main circuit, a three-switch asymmetrical half-bridge topology is proposed which could enhance the motor commutation performance. Meanwhile, the simulation analysis and comparison experiment was conducted between the double-switch and the three-switch main circuit based on a experiment prototype.
An application specific integrated circuit (ASIC) of SRM named SR3P10K07A was designed, which is the first integrated circuit for the SRM control in our country. The specific design process and the detailed information of the implementation algorithms of every function block have been introduced in this paper. Then the logic function of this chip has been verified on the basis of the hard-ware circuit. Based on the SR3P10K07A, a common set of SRM digital controller was designed and developed in this dissertation, the successful application to several high speed SRM have proved the feasibility of this chip.
In addition, the experiment research and engineering application was initiated toward three high speed SRM prototypes in this dissertation. The experiment result shows the maximum speed of the prototypeⅠachieve 136,000r/min. As a high speed prime motor, the prototypeⅠhave acquired the successful application in the air-bearing performance test platform developed by the Micro Engine Institute of NUAA. Meanwhile, a no-load experiment was made to conventional salient rotor and cylindrical composite salient rotor respectively based on the prototypeⅡ, and the comparison of the windage loss was made toward this two different rotor structure. The prototypeⅢhave a successful application in the high speed computerized numerical control engraving machine NRT40M produced by the CHANGZHOU NEW ROUTER NC MACHINERY CO., LTD.
开关磁阻电机(SRM)是近年来随着电力电子技术和控制技术的发展而逐渐完善起来的一种新型调速电机。由于SRM定转子均为凸极实心叠片结构,定子上绕有集中绕组,转子上无绕组、永磁材料及鼠笼线圈,具有结构简单坚固、成本低、可靠性高的特点,因此在许多工业调速领域获得了广泛应用。SRM的转子结构可以承受很高的机械应力,特别适合高转速要求,能适应高温等恶劣环境,在航空航天、高速加工等高速/超高速领域应用具有独特优势。
本文主要致力于高速SRM系统的理论和应用基础研究,目标是为高速SRM的系统设计和工程应用提供较为完整的基本理论和关键技术支撑。在对前人成果的广泛了解和深入研究的基础上,本文以高速SRM电机本体的多参数综合设计、功率变换器主电路、专用集成电路等核心关键技术为突破口,对高速SRM在机理研究、样机研制、实验研究和工程应用中存在的关键技术难题进行了系统研究,建立了高速SRM研究与实验的技术平台。
针对高速SRM的运行特点,本文在常规SRM的电磁设计流程的基础上,基于电磁、铁损、应力、转子振动等多物理场的有限元计算,构建了包括电磁设计、损耗计算、结构应力分析、转子动力学分析在内的高速SRM电机本体的多参数综合设计方法,成功研制了三种高速SRM实验样机,为高速SRM的电机本体设计奠定了理论基础。结合高速SRM样机的研究与实验需要,本文还对高速SRM的电磁性能优化、转子结构应力及动力学性能分析、铁损及风阻损耗计算等关键技术进行了理论和实验研究。
分析了不对称半桥式主电路、裂相式主电路等典型SRM功率变换器主电路的优缺点,对适合于高速SRM的功率变换器主电路拓扑进行了探讨,分析了典型功率变换器主电路拓扑对SRM换相性能的影响,并对传统的双开关式不对称半桥主电路进行了改进,提出了一种可提高电机换相性能的三开关式不对称半桥主电路拓扑,并在一台SRM实验样机上,对双开关式主电路和三开关式主电路进行仿真分析和对比实验。
成功研制了国内第一片SRM控制专用集成电路SR3P10K07A,介绍了SR3P10K07A的设计思路和设计过程,较为详细的介绍了该芯片中各功能模块的实现算法,并基于硬件电路对该芯片进行了逻辑功能验证。基于SR3P10K07A,本课题还设计制作了通用的SRM数字控制器,并在多台高速SRM样机中获得了成功应用。
此外,本文分别对三种高速SRM样机进行了实验研究和工程应用。其中,样机Ⅰ的最高转速达到了136,000r/min,成功实现了该样机的超高速运行;作为高速原动机,样机Ⅰ还在南京航空航天大学微型发动机研究所开发的气浮轴承性能测试平台中获得了成功应用;对分别采用常规凸极转子和圆柱复合型转子这两种不同转子结构的样机Ⅱ进行了空载实验,对比了两种转子结构的风阻损耗;样机Ⅲ在常州新罗特数控机械有限公司生产的NRT40M高速数控模具雕刻机上进行了成功应用。
With the development of the science and technology, there is urgent need for high speed motor in aerospace, energy, precision manufacturing and many other fields. The increase of motor speed is conductive to improve the electrical power density, reduce the size and the weight of the equipment. As a result, high speed / super high speed motor have received high popularity in the field of military and civilian applications, and it have been the hot topic in the international electrical field at present.
Switched reluctance machine (SRM) is a new type of adjustable-speed motor, based on the development of power electronic and control technology in recent years. It has been employed in variable speed industrial applications due to their simple and rugged structure, low cost, and high reliability. The rotor has no windings, magnets, or squirrel-cage winding, but is constructed from a stack of salient-pole laminations. This structure can withstand high mechanical stress, especially fit for the high speed requirements and adapt to the harsh environment. Therefore, SRM is considered the motor which has the advantage in the field of aerospace, high speed manufacturing of high speed / super high speed applications.
This dissertation focuses on basic research for the theory and application of high speed SRM system, in order to lay the foundation for the high speed SRM system design and engineering application. Based on the extensive and in-depth understanding of the outcomes in the past, some breakthrough have been made toward the multi-parameter integrated design, main circuit of power converter, application specific integrated circuit, and other core technology. At the mean time, some systematic study have been conducted toward the mechanism, prototype design, experiment and engineering applications, and a experimental platform of the high speed SRM has been built.
In terms of the operational features of the high speed SRM, a multi-parameter integrated design method has been developed in this paper, on the basis of regular electromagnetic design process and the finite element calculation of multi-physics field, including the electromagnetic, core loss, stress, rotor vibration, etc. The method comprises of electromagnetic design, loss calculation, the structural stress analysis, rotor dynamic analysis. At the same time, three high speed SRM experimental prototypes were successfully developed, laying the theoretical foundation for SRM prototype designing. Taking into account the need for the experiment and research of high speed prototype, much theoretical and experimental research have been conducted toward key techniques such as electromagnetic performance optimization, rotor structure stress and dynamic performance analysis, iron and windage loss calculation, etc.
In the dissertation, the advantages and disadvantages of some typical main circuit of SRM power converter, such as the asymmetrical half-bridge, split-phase main circuit is analyzed, and the influence to the SRM commutation performance brought by the topology of the typical power converter have also been discussed. On the basis of the topology of the conventional double-switch asymmetrical half-bridge main circuit, a three-switch asymmetrical half-bridge topology is proposed which could enhance the motor commutation performance. Meanwhile, the simulation analysis and comparison experiment was conducted between the double-switch and the three-switch main circuit based on a experiment prototype.
An application specific integrated circuit (ASIC) of SRM named SR3P10K07A was designed, which is the first integrated circuit for the SRM control in our country. The specific design process and the detailed information of the implementation algorithms of every function block have been introduced in this paper. Then the logic function of this chip has been verified on the basis of the hard-ware circuit. Based on the SR3P10K07A, a common set of SRM digital controller was designed and developed in this dissertation, the successful application to several high speed SRM have proved the feasibility of this chip.
In addition, the experiment research and engineering application was initiated toward three high speed SRM prototypes in this dissertation. The experiment result shows the maximum speed of the prototypeⅠachieve 136,000r/min. As a high speed prime motor, the prototypeⅠhave acquired the successful application in the air-bearing performance test platform developed by the Micro Engine Institute of NUAA. Meanwhile, a no-load experiment was made to conventional salient rotor and cylindrical composite salient rotor respectively based on the prototypeⅡ, and the comparison of the windage loss was made toward this two different rotor structure. The prototypeⅢhave a successful application in the high speed computerized numerical control engraving machine NRT40M produced by the CHANGZHOU NEW ROUTER NC MACHINERY CO., LTD.
引文
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