The propulsion system of the electric-powered vertical take-off and landing aircraft requires a high level of performances, including power density, efficiency, noise vibration and harshness, and fault tolerance. Among many types of conventional electric motor, the outer rotor surface-mounted permanent magnet synchronous motor (SPMSM) is widely used for its high power density and low torque pulsation. However, these advantages are degraded when the multiphase winding is applied to secure the fault-tolerance characteristics. To overcome the limit of conventional motor topology, the dual stator permanent magnet synchronous motor with separately controlled dual three-phase winding is proposed. The advantages of the proposed topology are resulted from the feature of mechanical, electrical, and magnetic isolation. To maximize the distinctive feature, a design process considering separated current vector control (SCVC) method is established. A design example is presented to demonstrate the impacts of the proposed design process considering SCVC on the power density maximization, torque harmonic reduction, and efficiency improvement. Finally, the experimental verification is presented to validate the proposed design and control techniques.

This paper proposes a junction temperature estimation algorithm for the insulated gate bipolar transistor (IGBT) based on a power loss calculation and a thermal impedance model for inverter systems. The Simulink model was designed to calculate the power losses of power semiconductor devices and to estimate the junction temperature with a simplified thermal impedance model. This model can estimate the junction temperature up to the transient state, including the steady state. The parameters used to calculate the power losses, the thermal resistance, and the thermal capacitance were optimized for a given inverter to be tested for improving the accuracy. The simulation results and experimental measurement data were compared to verify the proposed junction temperature estimation algorithm. Finally, the algorithm was installed on the inverter controller, and the performance was verified by comparing the real time estimation result with the measured temperature.

Two algorithms have been extensively studied for motor control: Field Oriented Control (FOC) and Direct Torque Control (DTC). Both control algorithms use a Voltage Source Inverter (VSI) to drive a Permanent Magnet Synchronous Motor (PMSM). To prevent short-arm short-circuit accidents when driving PMSM using VSI, a dead time is used to turn off the TOP and BOTTOM switches of each arm at the same time. However, this dead-time technique causes an unexpected pole voltage to be applied to the PMSM on the VSI output voltage, causing distortion and resulting in control nonlinearity. The disturbance voltage that causes nonlinearity is difficult to measure directly with the sensor. Therefore, this paper analyzes the nonlinearity of the controller due to the distorted voltage caused by the dead time during PMSM operation using the DTC algorithm and predicts the distorted output voltage using the extended Kalman Filter (EKF) to improve control stability. As a result, The algorithm proposed in this paper has verified the improvement of torque ripple and stator flux ripple through experiments and simulations.

Surface-mounted permanent magnet synchronous motors (SPMSMs) usually adopt a retaining sleeve for ultrahigh-speed (UHS) applications. The retaining sleeve usually has high electrical conductivity and cannot be segmented. Accordingly, the rotor eddy current loss is high. Moreover, the higher the eddy current loss, the higher is the rotor temperature. Therefore, the rotor eddy current loss should be considered in the design stage. However, the eddy current loss is generally calculated through three-dimensional finite-element analysis (3-D FEA) and considered cumbersome because of the high computation time. This article proposes a simple estimation method for the rotor eddy current loss of a UHS SPMSM according to the motor size. In this study, the mechanically stable cross-sectional structure of the rotor was fixed, and a formula for predicting the eddy current loss of the rotor based on motor size was devised. In this method, the basic electromagnetic formula for eddy current and the frozen permeability method were utilized. The proposed method was validated via comparisons with the results of 3-D FEA.

This paper proposes a resolver offset calibration algorithm that can detect offset with high precision just by configuring a very simple experimental environment. This use of a simple experimental environment holds a great advantage for large-capacity permanent magnet synchronous motors (PMSMs) that require substantial resources to configure an experimental environment, such as EV traction motors. The proposed algorithm is designed based on the PMSM voltage equation. The algorithm is first verified for its validity through simulation with Simulink. Subsequently, it is implemented based on the C-language and installed on an inverter for verification experiments. The implemented algorithm is very simple and requires little execution time and memory. The error in the calibrated offset is experimentally found to converge within 3-bits based on 12-bits (the resolution of the commonly used RDC), and the results have very little deviation.

The performance of motors can vary considerably, depending not only on the design but also the manufacturing process. In particular, for motors used in systems wherein vibration and noise are important, the characteristics of the motors change according to the manufacturing method; hence, it is essential to study the effect of the manufacturing process on the characteristics of motors. In this study, motors with a connected core and segmented core are compared and analyzed; particularly, the motors are intended for use in a brake system. The general strengths and weaknesses of each core type are determined, and the electrical and mechanical properties of the motors are analyzed through finite element analysis (FEA). The motors are applied to an integrated brake system that does not employ a vacuum booster, and motors with each type of core are fabricated and tested to verify their characteristics. Finally, the analysis results obtained using FEA and the test results are compared and analyzed to evaluate the validity of this study.