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Design and comparison of two brushless DC drives for an electric propulsion system of solar-power unmanned aerial vehicles

Design and comparison of two brushless DC drives for an electric propulsion system of solar-power unmanned aerial vehicles
Author: Dong, Rong
Publisher: Universitätsverlag der TU Berlin
Total Pages: 130
Release: 2020-08-26
Genre: Technology & Engineering
ISBN: 379833126X

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The electrical propulsion system as the core component of solar-power Unmanned Aerial Vehicles (UAVs) for long duration flight requires high power density and stable drive technology. Brushless DC motors (BLDCM) with high power and torque density and control algorithms suitable for drive system are given preference for the application in UAVs. This dissertation is aimed at designing an improved BLDCM using only 4 interior magnet blocks to realize 8 poles compared to the conventional 8 magnet blocks structure. The performances of both BLDCM designs have been analytically determined and the motor models were verified through finite element software in ANSYS. Design and construction of the demonstrators of BLDCMs with the proposed and the conventional magnet structure have been carried out and a test bench for extensive performance comparison has been set up. Since the proposed magnet structure leads to a particularity of the magnetic circuit, the behavior of absolute and differential synchronous direct and quadrature inductances have been investigated by finite element model analysis and experiments. Efficiency maps were generated and thermal characteristics have been measured to gain a comprehensive understanding of the two motors. To reduce the uncertainty of sensor control for BLDCM, a high speed, good linearity analog isolation circuit to measure the voltages of 270 V DC voltage to realize sensorless control strategy has been designed. The circuit combines a PI controller with fast operational amplifiers with a built-in linearizing feedback photodiode loop of a linear optocoupler. A 3D stator model was built to analyse the mechanical resonance frequencies and possible excitation by the electromagnetic radial force leading to vibration and noise for the proposed and conventional rotor structure. Analytical calculation of natural mode frequencies has also been conducted to compare and validate the accuracy of FEM simulations and impact hammer testing experimental results. Das elektrische Antriebssystem als Kernkomponente von unbemannten Solarflugzeugen (UAVs, Unmanned Aerial Vehicles) für Langzeitflüge erfordert eine hohe Leistungsdichte und robuste Antriebstechnik. Bürstenlose Gleichstrommotoren (BLDCM) mit hoher Leistungs- und Drehmomentdichte sowie dafür angepasste Regelalgorithmen werden daher bevorzugt in UAVs eingesetzt. Diese Dissertation zielt darauf ab, einen verbesserten BLDCM mit nur 4 eingebetteten Magnetblöcken zu entwerfen, um 8 Pole zu realisieren im Vergleich zu der herkömmlichen Struktur mit 8 Magnetblöcken. Das Verhalten beider BLDCM-Designs wurde analytisch ermittelt und die Motormodelle mit Hilfe von Finite-Elemente-Software in ANSYS verifiziert. Design und Konstruktion der Prototypen mit der vorgeschlagenen und der herkömmlichen Magnetstruktur wurden durchgeführt und es wurde ein Prüfstand für einen umfassenden Leistungsvergleich aufgebaut. Da die vorgeschlagene Magnetstruktur zu einem Magnetkreis führt, bei dem die entgegengesetzten Pole keine Spiegelsymmetrie aufweisen, wurden die Längs- und Querinduktivität durch Finite-Elemente-Modellanalyse und Experimente absolut und differentiell untersucht. Weiterhin wurden Wirkungsgradkennfelder erstellt und das thermische Verhalten untersucht, um ein umfassendes Verständnis der beiden Motoren zu erhalten. Um das sensorbedingte Ausfallrisiko zu eliminieren, wurde eine schnelle analoge Isolationsschaltung mit hoher Linearität und Stabilität zur Messung der gepulsten Spannungen bei 270V Gleichspannung entwickelt, um eine sensorlose Steuerungsstrategie zu realisieren. Die Schaltung verwendet einen linearen Optokoppler mit integrierter Rückkopplungsfotodiode, sowie einen PI-Regler mit schnellen Operationsverstärkern im Rückkopplungspfad. Ein 3D-Statormodell wurde erstellt, um die mechanischen Resonanzfrequenzen und die mögliche Anregung durch die elektromagnetische Radialkraft zu analysieren, die zu Vibrationen und Geräuschen bei der vorgeschlagenen und herkömmlichen Rotorstruktur führt. Es wurde auch eine analytische Modalanalyse durchgeführt, um die Genauigkeit von FEM-Simulationen und experimentellen Ergebnissen mit dem Impulshammer zu vergleichen und zu validieren.


Modeling and control of power converters in weak and unbalanced electric grids

Modeling and control of power converters in weak and unbalanced electric grids
Author: Just, Hendrik
Publisher: Universitätsverlag der TU Berlin
Total Pages: 236
Release: 2021-11-25
Genre: Technology & Engineering
ISBN: 379833207X

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Grid converters increasingly affect power system operation due to the increasing share of renewable energy sources and less conventional power plants. This shift in power generation leads to converter-dominated weak grids, which show critical stability phenomena but also enable converters to contribute to grid stability and voltage support. This thesis presents critical parts of converter controls and describes models to assess their characteristics. These models are used to derive design criteria and dedicated stability analysis methods for grid converter controls. Der steigende Anteil an erneuerbaren Energien in den Energieversorgungsnetzen führt zur Verdrängung konventioneller Kraftwerke. Diese Entwicklung lässt umrichterdominierte und schwache Netzabschnitte entstehen, die kritischen Stabilitätsmechanismen unterliegen, allerdings auch ermöglichen, dass Umrichter aktiv zur Netzstützung und Netzstabilität beitragen können. Die vorliegende Arbeit beschreibt kritische Regelungskomponenten der Umrichter und deren Modellierung. Auf Basis der Modelle werden Auslegungskriterien für die Regelungen abgeleitet und dedizierte Stabilitätsanalysemethoden präsentiert.


Detection and characterization of Lithium plating

Detection and characterization of Lithium plating
Author: Long, Julian
Publisher: Universitätsverlag der TU Berlin
Total Pages: 260
Release: 2023-05-31
Genre: Technology & Engineering
ISBN: 3798332789

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Lithium plating is not only the most severe ageing mechanism in lithium-ion batteries (LIBs) but also becoming more and more important due the increasing presence of electric vehicles (EVs). In EVs the extreme conditions causing lithium plating, like very high charging currents and low environment temperatures, are much more prevalent than in consumer electronics. Due to the high number of factors that influence the plating process, ranging from the cell geometry to the chemical composition of the electrolyte, a deeper understanding of the plating process is still lacking. Without this knowledge it is hard to design cells in a plating resistant way, or to operate cells under the ideal conditions to minimize plating. This thesis aims at showing different methods to investigate the plating process on three different levels. The first method is on the cell level, investigating the behaviour of the whole cell during plating. It contains the analysis of the voltage and current profiles that show an atypical behaviour during plating. The focus of the analysis is on the current profile of the constant voltage (CV) phase during charging under low temperature conditions leading to plating. This current profile can be fitted with the Johnson-Mehl-Avrami-Kolmogorov (JMAK) function that describes the electrochemical deposition process of a metallic species on a surface. The resulting fitting parameters can be utilized to characterize the plating behaviour of the cell as well as better estimate the amount of plated lithium than commonly used methods. It can also potentially predict the future safety risk due to dendrite formation. In the second part the chemical composition of the surface electrolyte interface (SEI) is investigated using X-ray photoelectron spectroscopy (XPS). The composition as well as the mechanical properties of the SEI are strongly influencing the plating process and preliminary work has shown that plating is also changing the morphology of the SEI and increasing its thickness drastically. Cells under different conditions (plated, charged and discharged) as well as cells of different manufacturers have been probed using XPS. During the measurements an unwanted side effect of the experimental setup was discovered that lead to a migration of lithium to the surface of the sample and was distorting the measurement results. Regardless of the effect, it was possible to see that the SEI can have a very different composition in cells of different manufacturers and that plating not only changes the morphology but also the composition of the SEI. The unwanted side effect could furthermore be utilized to identify samples that were plated recently and could be used in further more controlled experiments to localize lithium depositions on plated samples. In the last part the particle structure of the anode surface of cells of different manufacturers was investigated using a watershed particle detection algorithm on laser scanning microscopy (LSM) images of the anode surfaces. The distributions of the particle sizes have then been compared to the capacity loss in plated cells. It was shown that the capacity loss correlates with parameters extracted from the particle size distributions. It is however necessary to create more data to verify this correlation. In summary this thesis utilized new methods to detect or characterize plating on different levels of magnification, from the cell level to the chemical composition. New approaches were found to predict a cells future plating behaviour, spatially localize plated areas on the anode and design cells in a plating resistant way. Lithium Plating ist nicht nur der Alterungsmechanismus in Lithium-Ionen-Batterien mit dem größten Kapazitätsverlust, sondern wird auch im Zuge der voranschreitenden Elektrifizierung des Personenverkehrs immer wichtiger. In Elektrofahrzeugen finden sich die extremen Zustände, wie niedrige Ladetemperaturen und hohe Ladestrome, unter denen Plating auftritt, deutlich häufiger als in Unterhaltungstechnik. Durch die Vielzahl von Parametern, von der Zellgeometrie bis hin zur Elektrolyzusammensetzung, die Plating beeinflussen, fehlt immer noch ein tieferes Verständnis des Plating-Prozesses. Ohne dieses Wissen ist es schwer, Zellen zu designen, die resistent gegen Plating sind oder Zellen unter optimalen Bedingungen zu betreiben um Plating zu minimieren. Das Ziel dieser Arbeit ist es, verschiedene Methoden aufzuzeigen, die die Untersuchung von Plating auf drei verschiedenen Ebenen ermöglichen. Die erste Methode untersucht das Gesamtverhalten der Zelle auf Zellebene. Hierbei wird das atypische Verhalten der Strom- und Spannunsprofile wahrend des Plating-Vorgangs analysiert. Der Fokus liegt dabei auf der Untersuchung der Konstantstrom-Phase bei niedrigen Temperaturen während der Ladung. Das Stromprofil dieser Phase kann mit der JMAK-Funktion gefittet werden, welche die elektrochemische Abscheidung eines Metalls auf einer Oberfläche beschreibt. Die resultierenden Fitting-Parameter können genutzt werden, um das Plating-Verhalten vorherzusagen und sind gleichzeitig eine bessere Abschätzung fur die Menge an geplatetem Lithium im Vergleich zu gängigen Methoden. Die Ergebnisse konnten außerdem helfen das Sicherheitsrisiko der Zelle bei Dendritenbildung vorherzusagen. Im zweiten Teil wird die chemische Zusammensetzung der SEI mittels XPS untersucht. Die Zusammensetzung, wie auch die mechanischen Eigenschaften der SEI, beeinflussen den Plating-Prozess stark und es wurde in vorhergehenden Arbeiten gezeigt, dass Plating auch die Morphologie und Dicke der SEI drastisch verändern kann. Zellen in verschiedenen Zuständen (geplatet, geladen, entladen), sowie Zellen verschiedener Hersteller wurden mit XPS untersucht. Während der Messungen wurde ein ungewollter Nebeneffekt des Messaufbaus entdeckt, der zu einer Migration von Lithium an die Oberflache der Proben geführt und die Messergebnisse verfälscht hat. Unabhängig von diesem Effekt war es dennoch möglich, zu zeigen, dass die SEI in Zellen verschiedener Hersteller stark unterschiedliche Zusammensetzungen haben kann und dass Plating nicht nur die Morphologie der SEI beeinflusst, sondern auch die chemische Zusammensetzung. Weiterhin konnte der ungewollte Nebeneffekt verwendet werden, um Proben zu identifizieren, die vor kurzem geplatet wurden und konnte in zukünftigen Arbeiten verwendet werden, um lokalisiert Lithium-Ablagerungen auf geplateten Proben zu identifizieren. Im letzten Teil wurde die Partikelstruktur der Anoden von Zellen verschiedener Zellhersteller mit Hilfe einer watershed-Partikeldetektion an LSM-Bildern untersucht. Die Verteilung der Partikelgrößen wurde mit dem Kapazitätsverlust gleicher Zelle durch Plating verglichen. Es wurde gezeigt, dass der Kapazitätsverlust mit Parametern, die aus den Partikelverteilungen extrahiert wurden, korreliert. Ein größerer Datensatz ist jedoch notwendig, um diese Ergebnisse zu validieren. Zusammenfassend hat diese Arbeit verschiedene neue Methoden aufgezeigt, um Plating auf verschiedenen Vergrößerungsebenen zu detektieren und zu charakterisieren. Neue Ansätze wurden gefunden, um das Platingverhalten von Zellen vorherzusagen, lokalisiertes Lithium auf der Oberfläche zu detektieren und Zellen platingresistenter designen zu können.


Evaluation of Hybrid-electric Propulsion Systems for Unmanned Aerial Vehicles

Evaluation of Hybrid-electric Propulsion Systems for Unmanned Aerial Vehicles
Author: Jay Michael Todd Matlock
Publisher:
Total Pages:
Release: 2019
Genre:
ISBN:

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The future of aviation technology is transitioning to cleaner, more efficient and higher endurance aircraft solutions. As fully electric propulsion systems still fall short of the operational requirements of modern day aircraft, there is increasing pressure and demand for the aviation industry to explore alternatives to fossil fuel driven propulsion systems. The primary focus of this research is to experimentally evaluate hybrid electric propulsion systems (HEPS) for Unmanned Aerial Vehicles (UAV) which combine multiple power sources to improve performance. HEPS offer several potential benefits over more conventional propulsion systems such as a smaller environmental impact, lower fuel consumption, higher endurance and novel configurations through distributed propulsion. Advanced operating modes are also possible with HEPS, increasing the vehicle's versatility and redundancy in case of power source failure. The primary objective of the research is to combine all of the components of a small-scale HEPS together in a modular test bench for evaluation. The test bench uses components sized for a small-scale UAV including a 2.34kW two-stroke 35cc engine and a 1.65kW brushless DC motor together with an ESC capable of regenerative braking. Individual components were first tested to characterize performance, and then all components were assembled together in a parallel configuration to observe system-level performance. The parallel HEPS is capable of functioning in the four required operating modes: EM Only, ICE Only, Dash Mode (combined EM and ICE power) as well as Regenerative Mode where the onboard batteries get recharged. Further, the test bench was implemented with a supervisory controller to optimize system performance and run each component in the most efficient region to achieve torque requirements programmed into mission profiles. The logic based controller operates with the ideal operating line (IOL) concept and is implemented with a custom LabView GUI. The system is able to run on electric power or ICE power interchangeably without making any modifications to the transmission as the one-way bearing assembly engages for whichever power source is rotating at the highest speed. The most impressive of these sets of tests is the Dash mode testing where the output torque of the propeller is supplied from both the EM and ICE. Working in tandem, it was proved that the EM was drawing 19.9A of current which corresponds to an estimated 0.57Nm additional torque to the propeller for a degree of hybridization of 49.91%. Finally, the regenerative braking mode was proven to be operational, capable of recharging the battery systems at 13A. All of these operating modes attest to the flexibility and convenience of having a hybrid-electric propulsion system. The results collected from the test bench were validated against the models created in the aircraft simulation framework. This framework was created in MATLAB to simulate the performance of a small UAV and compare the performance by swapping in various propulsion systems. The purpose of the framework is to make direct comparisons of HEPS performance for parallel and series architectures against conventional electric and gasoline configuration UAVs, and explore the trade-offs. Each aircraft variable in the framework was modelled parametrically so that parameter sweeps could be run to observe the impact on the aircraft's performance. Finally, rather than comparing propulsion systems in steady-state, complex mission profiles were created that simulate real life applications for UAVs. With these experiments, it was possible to observe which propulsion configurations were best suited for each mission type, and provide engineers with information about the trade-offs or advantages of integrating hybrid-electric propulsion into UAV design. In the Pipeline Inspection mission, the exact payload capacities of each aircraft configuration could be observed in the fuel burn versus CL,cruise parameter sweep exercise. It was observed that the parallel HEPS configuration has an average of 3.52kg lower payload capacity for the 35kg aircraft (17.6%), but has a fuel consumption reduction of up to 26.1% compared to the gasoline aircraft configuration. In the LIDAR Data collection mission, the electric configuration could be suitable for collection ranges below 100km but suffers low LIDAR collection times. However, at 100km LIDAR collection range, the series HEPS has an endurance of 16hr and the parallel configuration has an endurance of 19hr. In the Interceptor mission, at 32kg TOW, the parallel HEPS configuration has an endurance/TOW of 1.3[hr/kg] compared to 1.15[hr/kg] for the gasoline aircraft. This result yields a 13% increase in endurance from 36.8hr for gasoline to 41.6hr for the parallel HEPS. Finally, in the Communications Relay mission, the gasoline configuration is recommended for all TOW above 28kg as it has the highest loiter endurance.


Modeling and Test of the Efficiency of Electronic Speed Controllers for Brushless DC Motors

Modeling and Test of the Efficiency of Electronic Speed Controllers for Brushless DC Motors
Author: Clayton Green
Publisher:
Total Pages: 83
Release: 2015
Genre: Brushless direct current electric motors
ISBN:

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Small electric uninhabited aerial vehicles (UAV) represent a rapidly expanding market requiring optimization in both efficiency and weight; efficiency is critical during cruise or loiter where the vehicle operates at part power for up to 99% of the mission time. Of the four components (battery, motor, propeller, and electronic speed controller (ESC)) of the electric propulsion system used in small UAVs, the ESC has no accepted performance model and almost no published performance data. To collect performance data, instrumentation was developed to measure electrical power in and out of the ESC using the two wattmeter method and current sense resistors; data was collected with a differential simultaneous data acquisition system. Performance of the ESC was measured under different load, commanded throttle, bus voltage, and switching frequency, and it was found that ESC efficiency decreases with increasing torque and decreasing bus voltage and does not vary much with speed and switching frequency. The final instrumentation was limited to low-voltage systems and error propagation calculations indicate a great deal of error at low power measurements; despite these limitations, an understanding of ESC performance appropriate for conceptual design of these systems was obtained.


Science Abstracts

Science Abstracts
Author:
Publisher:
Total Pages: 1360
Release: 1995
Genre: Electrical engineering
ISBN:

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Permanent Magnet Synchronous and Brushless DC Motor Drives

Permanent Magnet Synchronous and Brushless DC Motor Drives
Author: Ramu Krishnan
Publisher: CRC Press
Total Pages: 685
Release: 2017-12-19
Genre: Technology & Engineering
ISBN: 1351837370

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Despite two decades of massive strides in research and development on control strategies and their subsequent implementation, most books on permanent magnet motor drives still focus primarily on motor design, providing only elementary coverage of control and converters. Addressing that gap with information that has largely been disseminated only in journals and at conferences, Permanent Magnet Synchronous and Brushless DC Motor Drives is a long-awaited comprehensive overview of power electronic converters for permanent magnet synchronous machines and control strategies for variable-speed operation. It introduces machines, power devices, inverters, and control, and addresses modeling, implementation, control strategies, and flux weakening operations, as well as parameter sensitivity, and rotor position sensorless control. Suitable for both industrial and academic audiences, this book also covers the simulation, low cost inverter topologies, and commutation torque ripple of PM brushless DC motor drives. Simulation of the motor drives system is illustrated with MATLAB® codes in the text. This book is divided into three parts—fundamentals of PM synchronous and brushless dc machines, power devices, inverters; PM synchronous motor drives, and brushless dc motor drives. With regard to the power electronics associated with these drive systems, the author: Explores use of the standard three-phase bridge inverter for driving the machine, power factor correction, and inverter control Introduces space vector modulation step by step and contrasts with PWM Details dead time effects in the inverter, and its compensation Discusses new power converter topologies being considered for low-cost drive systems in PM brushless DC motor drives This reference is dedicated exclusively to PM ac machines, with a timely emphasis on control and standard, and low-cost converter topologies. Widely used for teaching at the doctoral level and for industrial audiences both in the U.S. and abroad, it will be a welcome addition to any engineer’s library.


Design and Programming of the Software to Control the Sensor and Sensorless BLDCM of the Electrical Propulsion System for the Solar Aircraft

Design and Programming of the Software to Control the Sensor and Sensorless BLDCM of the Electrical Propulsion System for the Solar Aircraft
Author: Pablo Armero Almazán
Publisher:
Total Pages:
Release: 2013
Genre:
ISBN:

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A Brushless Direct Current (BLDC) machine and converter are applied for the electric propulsion system of the solar aircraft. BLDC motors are electronically commutated instead of mechanically, as Direct Current (DC) motors do, so the position of the rotor must be known to do the commutation at the right moment. The control of BLDC motors can be done in sensor or sensorless mode. being the use of Hall-effect sensors the most widespread use inside the sensored control. The use of the hall sensors divide a complete revolution of the motor in 6 sectors, where in each sector only two phases are conducting (block commutation, trapezoidal control). However, considering the complexity of the high altitude, the electrical propulsion system cannot work properly if the hardware of the Hall sensors is broken. Therefore a sensorless control is necessary. The BLDC motor provides an attractive candidate for sensorless operation because the nature of its excitation inherently offers a low-cost way to extract rotor position information from motor-terminal voltages. The implemented sensorless technique consists of sampling the non-fed phase voltage and comparing it to half of the DC-link voltage to detect the zero crossing point. The most important part of the sensorless control is the sample of the non-fed phase, so the software must synchronise the sample with the PWM signal and apply the necessary delays in order to avoid commutation spikes and execute a correct BEMF measure. The software must be able to control the motor in both sensored or sensorless mode and to change from one to the other if an error occurs, so the code has to be compatible between the two modes.


Permanent Magnet Brushless DC Motor Drives and Controls

Permanent Magnet Brushless DC Motor Drives and Controls
Author: Chang-liang Xia
Publisher: John Wiley & Sons
Total Pages: 306
Release: 2012-04-24
Genre: Technology & Engineering
ISBN: 1118188365

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An advanced introduction to the simulation and hardware implementation of BLDC motor drives A thorough reference on the simulation and hardware implementation of BLDC motor drives, this book covers recent advances in the control of BLDC motor drives, including intelligent control, sensorless control, torque ripple reduction and hardware implementation. With the guidance of the expert author team, readers will understand the principle, modelling, design and control of BLDC motor drives. The advanced control methods and new achievements of BLDC motor drives, of interest to more advanced readers, are also presented. Focuses on the control of PM brushless DC motors, giving readers the foundations to the topic that they can build on through more advanced reading Systematically guides readers through the subject, introducing basic operational principles before moving on to advanced control algorithms and implementations Covers special issues, such as sensorless control, intelligent control, torque ripple reduction and hardware implementation, which also have applications to other types of motors Includes presentation files with lecture notes and Matlab 7 coding on a companion website for the book