Ph.D. Poster Day - Politecnico di Torino

Ph.D. Poster Day
Ph.D. candidate: Marco Cossale - 27827
2014 - First year
Dottorato di ricerca in Ingegneria Elettronica
XXIX Ciclo
Dipartimento di Energia
Tutor:
Prof. Andrea Cavagnino
Collaborators:
Prof. Aldo Boglietti – Politecnico di Torino
Prof. Radu Bojoi – Politecnico di Torino
Prof. Enrico Carpaneto – Politecnico di Torino
Prof. Alberto Tenconi – Politecnico di Torino
Dr. Shafiq Odhano – Politecnico di Torino
Dr. Silvio Vaschetto – Politecnico di Torino
Prof. Juliette Soulard – Royal Institute of Technology KTH Sweeden
Dr. Andreas Krings – Royal Institute of Technology KTH Sweeden
Ph.D. candidate Marco Cossale
2
Attended Classes
Class
CFU
Mark
Data
Come scrivere un articolo scientifico e come fare una
presentazione
4
sup
7/4/2014
Propulsione di veicoli elettrici ed ibridi
8
30
19/9/2014
Fondi competitivi per la ricerca: dall’idea alla scrittura del
progetto
2
sup
6/11/2014
Sistemi elettronici di potenza per la generazione
distribuita dell’energia
4
sup
TBR
Analysis and application of soft magnetic composites
2
sup
TBR
Controllo sensorless per macchine AC
5
Ph.D. candidate Marco Cossale
ongoing
3
Research context and motivation
Electrical machine design for energy saving and reduction of the CO2
emissions:
 Efficiency improvement of industrial electrical machines
IE3 premium efficiency induction motors
 Electrification of propulsion system in the field of “More Electric Transport”
Automotive - Belt Starter Generator for mini-hybrid powertrain
 Magnetic material and temperature assessment for high performance
machines
Practical investigation on Cobalt-Iron laminations for electrical machine
Transient thermal model for stator windings
Ph.D. candidate Marco Cossale
4
Addressed research questions – 1
 Electrification of propulsion system in the field of
“More Electric Transport”
Reference application
• City compact class
System configuration
• Mini-hybrid powertrain, Belt Starter Generator
• Internal combustion engine
• 0.9 liter, 60 kW, 140 Nm
Required functionalities
• Start/stop, regenerative braking,
• Generation, eBoost
• Integrated power electronic
DC power supply
•
48 V (LV 148)
Ph.D. candidate Marco Cossale
5
Adopted methodologies – 1
 Electrification of propulsion system in the field of
“More Electric Transport”
• Preliminary electromagnetic sizing
• Electromagnetic design refinement
• Equivalent circuit parameters
• Finite element analysis
• Thermal model
• Prototyping and testing
Ph.D. candidate Marco Cossale
6
Addressed research questions – 2
 Efficiency improvement of industrial electrical machines
Invesigated topology:
Totally Enclosed Fan-Cooled induction machine
Rated power:
15 - 200 kW
Actual Efficiency class:
IE1 – IE2
Ph.D. candidate Marco Cossale
7
Adopted methodologies – 2
 Efficiency improvement of industrial electrical machines
• Calibration of the analytical model according to the actual motor
• Energy balance and losses localization
• Propose of the new design based on the degree of freedom
- Low specific loss lamination material
- Stack length
- Rotor end-ring
- Winding
• Prototyping and testing
Ph.D. candidate Marco Cossale
8
Addressed research questions – 3
 Investigation of magnetic material and temperature assessment for
high performance machines
- Investigation of magnetic and energetic properties of cobalt-iron stator cores:
influence of annealing and manufacturing process
- Prediction of the winding thermal behavior during overload condition
Ph.D. candidate Marco Cossale
9
Adopted methodologies – 3a
 Practical investigation on Cobalt-Iron laminations
for electrical machines
• Magnetic characterization
• Specific iron losses
• Micrographic analyses
• FEM simulation
• Fringing effect study and correction
Ph.D. candidate Marco Cossale
10
Adopted methodologies – 3b
Transient thermal model for stator windings
• Experimental approah: steady state and transient
thermal test with DC supply current
• Simplified lumped parameter networks based on
phisical representation of the stator components
under the hypotesis of isothermal rotor and frame
Ph.D. candidate Marco Cossale
11
Novel contributions
 Design trade-off and demonstration of feasibility using multiphase
induction machine for mini-hybrid powertrain [1] [7]
 Manufacturing and annealing influences on magnetic property of cobaltiron stator core laminations [2] [3]
 Short-time thermal model for stator winding [4] [5]
 Methodology for the IPM Motor Magnetic Model Computation based on
Finite Element Analysis [6]
Ph.D. candidate Marco Cossale
12
Submitted and published conference papers
[1] R.Bojoi, A. Cavagnino, M. Cossale, A. Tenconi, “Multiphase starter generator for 48V Mini-hybrid
Powertrain: Design and Testing”, SPEEDAM, Italy, June 2014
[2] A. Krings, M Cossale, J Soulard, A. Boglietti, A. Cavagnino, “ Manufacturing Influence on the Magnetic
Properties and Iron Losses in Cobalt-Iron Stator Cores for Electrical Machines”, ECCE, Pittsburg, September
2014
[3] M. Cossale, A. Krings, J. Soulard, A. Boglietti, A. Cavagnino, “ Practical Investigations on Cobalt-Iron
Laminations for Electrical Machines”, ICEM, Berlin, September 2014
[4] A. Boglietti, E. Carpaneto, M. Cossale, A. Lucco Borlera, “ Stator Thermal Model for Short-Time Thermal
Transients”, ICEM, Berlin, September 2014
[5] A. Boglietti, E. Carpaneto, M. Cossale, A. Lucco Borlera, D. Staton, M. Popescu,” Electrical Machine First
Order Short-Time Thermal Transients Model: Measurements and Parameters Evaluation”, IECON, Dallas,
November 2014
[6] R. Bojoi, A. Cavagnino, M. Cossale, S. Vaschetto, “Methodology for the IPM Motor Magnetic Model
Computation based on Finite Element Analysis”, IECON, Dallas, November 2014
[7] R. Bojoi, A. Cavagnino, M. Cossale, A. Tenconi, S. Vaschetto, «Design Trade-off and Experimental
Validation of Multiphase Starter Generators for 48V Mini-Hybrid Powertrain”, IEVC, Italy, Dec. 2014 (in press)
Ph.D. candidate Marco Cossale
13
Submitted journal papers
[8] M. Cossale, A. Krings, J. Soulard, A. Boglietti, A. Cavagnino, “ Practical Investigations on Cobalt-Iron
Laminations for Electrical Machines”, Transaction on Industrial Application, in review R1
[9] A. Boglietti, E. Carpaneto, M. Cossale, S. Vaschetto , “ Stator Thermal Model for Short-Time Thermal
Transients”, Transaction on Industrial Application, in review R1
Awards
ICEM Brian J. Chalmers Best Paper Award with:
M. Cossale, A. Krings, J. Soulard, A. Boglietti, A. Cavagnino, “ Practical Investigations on Cobalt-Iron
Laminations for Electrical Machines”
ICEM Best Poster Presentation Award with:
A. Boglietti, E. Carpaneto, M. Cossale, A. Lucco Borlera, “ Stator Thermal Model for Short-Time Thermal
Transients”
Ph.D. candidate Marco Cossale
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Future work
 Test of the BSG supplied by inverter
 Implementation of the thermal model on the control strategy
 Feedback from the installation on a car demonstrator and design review
Ph.D. candidate Marco Cossale
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