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أخواني في الله أحضرت لكم كتاب Mechanical Design and Manufacturing of Electric Motors Second Edition Wei Tong
![كتاب Mechanical Design and Manufacturing of Electric Motors M_d_a_17](https://i.servimg.com/u/f61/15/36/74/14/m_d_a_17.jpg) و المحتوى كما يلي :
Contents Preface ( nd Edition) . xxv Preface ( st Edition) . xxix Author xxxiii List of Abbreviations xxxv Chapter Introduction to Electric Motors . History of Electric Machines . Motor Design Characteristics . Motor Torque . Static and Dynamic Torque . Motor Torque in Motor-Load System . . Continuous Torque . Peak Torque . RMS Torque . Stall Torque . . Cogging Torque and Reduction Methods . . Torque Ripple . Motor Speed . . Continuous Speed . . Peak Speed . Speed Ripple . . Torque Density . . Motor Power and Power Factor . Torque–Speed Characteristics . Mechanical Resonance and Resonant Frequency . Load-to-Motor Inertia Ratio . . Duty Cycle . Motor Efficiency . . Definition of Motor Efficiency . . IEC Standards on Efficiency Classes of AC Electric Motors . . Motor Insulation . . Motor Operation Reliability . . Classifications of Electric Motors . . DC and AC Motors . . Single-Phase and Three-Phase Motors . Induction and PM Motors . Synchronous and Asynchronous Motors . . Servo and Stepper Motors . Gear Drive and Direct Drive Motors . . Brush and Brushless Motors . Reluctance Motors . Radial Flux and Axial Flux Motors . . Rotary and Linear Motors . Open and Enclosed Motors . Housed and Frameless Motors . viii Contents . Internal Rotor Motor and External Rotor Motor . Specialty Electric Motors . . Explosion Proof Motor and Flame Proof Motor . . Submersible Motor . Ultrahigh-Speed Motor . . Motor Operating under Vacuum Environment . . Motor Operating under Nuclear Radiation Environment . . Piezoelectric Motor . . Motor Classification According to Power Rating . . Motor Design and Operation Parameters . Back EMF Constant, Ke . . Torque Constant, Kt . Velocity Constant, Kv . Motor Constant, Km . Mechanical Time Constant, τm . . Electrical Time Constant, τe . Thermal Time Constant, τth . Viscous Damping, Kvd . Sizing Equations . Motor Design Process and Considerations . . Design Process . . Design Integration . Mechatronics . Temperature Effect on Motor Performance . . Motor Failure Modes . . IP Code References Chapter Rotor Design . . Rotor in Induction Motor . . Wound Rotor . Squirrel Cage Rotor . Factors Affecting Resistance of Squirrel Cage Rotor . Double-Cage Rotor . . Casting Squirrel Cage Rotor . . Skin Effect . Induction Motor Design Types and Their Performing Characteristics . Permanent Magnet Rotor . . Discovery of Phenomenon of Magnetism . Permanent Magnet Characteristics . Permanent Magnet Materials . . Ferrite Permanent Magnets . Rare Earth Permanent Magnets . New Developments of Alternative PMs and Reductions of Reliance on Rare Earths . Magnetization . . Factors Causing Demagnetization . Maximum Operating Temperature . Permanent Magnet Mounting and Retention Methods Contents ix . Ring Magnets . . Corrosion Protection of Permanent Magnets . . Rotor Manufacturing Process . Lamination Materials . . Lamination Cutting . Lamination Surface Insulation . . Lamination Annealing . . Lamination Stacking . Rotor Casting for Squirrel Cage Motor . Heat Treatment of Casted Rotor . . Rotor Assembly . Rotor Machining and Runout Measurement . Rotor Balancing . Type of Unbalance . Rotor Balancing Machine . . Balancing Operation . . Interference Fit . Press Fit . Shrink Fit . Serration Fit . Fit with Knurling . Fit with Adjustable Ringfeder Locking Devices . Fit with Tolerance Rings . Stress Analysis of Rotor . Rotordynamic Analysis . . Rotor Inertia . . Motor Critical Speed and Resonance . . Rotor Burst Containment Analysis . Rotor Burst Speed . Energy in Rotating Rotor . . Kinetic Energy in Rotor . Elastic Potential Energy in Rotor . . Ratio of Potential Energy to Kinetic Energy of Rotor . Rotor Burst Containment Design . References Chapter Shaft Design . . Shaft Materials . Shaft Loads . Solid and Hollow Shafts . Shaft Design Methods . . Macaulay’s Method . Area–Moment Method . . Castigliano’s Method . Graphical Method . Engineering Calculations . Normal Stress for Shaft Subjected to Axial Force . . Bending Stress for Shaft Subjected to Bending Moment . . Torsional Shear Stress and Torsional Deflection . Lateral Deflection of Shaft . x Contents . Lateral Deflection due to Bending Moment . . Lateral Deflection due to Transverse Force . Lateral Deflection due to Shear Force . Shaft Design Issues . Shaft Design Considerations . Shaft Rigidity . . Critical Shaft Speed . . Shaft with Uniform Diameter . . Stepped Shaft . Dimensional Tolerance . . Shaft Runout . . Shaft Eccentricity . . Heat Treatment and Shaft Hardness . . Shaft Surface Finishing . Shaft Lead . Shaft Seal . . O-Ring Seal . Universal Lip Seal . V-Shaped Spring Seal . . Brush Seal . . PTFE Seal . . Spring-Energized Seal . Noncontact Seal . Diametrical Fit Types . . Stress Concentration . Torque Transmission through Mechanical Joints . Keyed Shafts . . Selection of Key Material . . Stress Analysis of Key and Keyseat . . Key Fit . Stress Concentration Factors of Keyed Shafts . Spline Shafts . . Advantages of Spline Shafts . . Type of Spline . . Stress Concentration Factors of Spline Shafts . Tapered Shafts . Fatigue Failure under Alternative Loading . . Shaft Manufacturing Methods . Machined Shaft . Forged Shaft . . Welded Hollow Shaft . . Shaft Measurement . . Shaft Misalignment between Motor and Driven Machine . Type of Misalignment . Correction of Shaft Misalignment . . Shaft Coupling . . Rigid and Semirigid Couplings . Flexible Couplings . Non-Contact Couplings . Oil Shear Couplings . References Contents xi Chapter Stator Design . Stator Lamination . Stator Lamination Material . Stator Lamination Patterns . . One-Piece Lamination . T-Shaped Segmented Lamination . . Connected Segmented Lamination . . Two-Section Stator Lamination . Stator Lamination Integrated by Individual Teeth and a Yoke Section . Slotless Stator Core . . Slinky Lamination Stator Core . . Magnet Wire . Regular Magnet Wire . . Self-Adhesive Magnet Wire . . Litz Wire . Stator Insulation . Injection Molded Plastic Insulation . Slot Liner . Glass Fiber Reinforced Mica Tape . . Powder Coating on Stator Core . Manufacturing Process of a Stator Core . . Stator Lamination Cutting . Lamination Fabrication Process . . Lamination Annealing . . Lamination Stacking . Stator Winding . . Random Winding by Hand . . Coil Formation—Distributed Winding . Coil Formation—Concentrated Winding . . Coil Formation—Conductor Bar . Stator Encapsulation and Impregnation . Encapsulation . . Encapsulation Materials . . Encapsulation Process . Varnish Dipping . . Trickle Impregnation . Vacuum Pressure Impregnation . . Stator Design Considerations . Cogging Torque . Airgap . . Stator Cooling . Robust Design of Stator . Power Density Improvement . Mechanical Stress of Stator . References Chapter Motor Frame Design . Types of Motor Housing Based on Manufacturing Method xii Contents . Wrapped Housing . . Casted Housing . Casting Material . . Casting Process . . Pressure Casting . . Heat Treatment . . Machined Housing . . Stamped Housing . . Extruded Motor Housing . Motor Housing with Composite Materials . . Motor Housing Fabricated by D Printing and Other Additive Manufacturing Processes . . Frameless Motor . . Testing Methods of Casted Motor Housing . . Endbell Manufacturing . Casted Endbell . . Stamped Endbell . Iron Casting versus Aluminum Casting . . Machined Endbell . Forged Endbell . . Motor Assembly Methods . . Tie Bar . Tapping at Housing End Surface . Forged Z-Shaped Fastener . Rotary Fasteners . . Triangle-Base Rotating Fastener . Square-Base Rotating Fastener . . Butterfly-Base Rotating Fastener . Other Types of Fasteners . Cylinder-Base Fastener Locked with Retaining Ring . Cylinder-Base Fastener with Self-Locking Aperture . . Fastener Engaged with Housing from Housing Interior . . Self-Clinching Fastener . Fastening System Design . . Types of Thread Fasteners . . Thread Formation . . Fastener Preload . . Fastener-Tightening Process . . Tightening Torque . Thread Engagement and Load Distribution . . Common Types of Electric Motor Enclosures . Open Drip Proof Enclosure . Totally Enclosed Non-Ventilated Enclosure . . Totally Enclosed Fan Cooled Enclosure . . Totally Enclosed Air over Enclosure . Totally Enclosed Forced Ventilated Enclosure . Totally Enclosed Washdown Enclosure . . Explosion Proof Enclosure . . Anticorrosion of Electric Motor and Components . Surface Treatment Methods . . Electroplating Contents xiii . Electroless Plating . Physical Vapor Deposition . Inorganic Coating . . Phosphate Coating . Electropolishing . Nanocoating . Anticorrosion Treatment of Electric Motor . Hydrogen Embrittlement Issues . References Chapter Motor Bearing . Bearing Classification . Journal Bearing . Rolling Bearing . Ball Bearing . Roller Bearing . . Noncontact Bearing . Sensor Bearing . . Slewing Ring Bearing . Crossed Roller Bearing . Ball Screw . Bearing Design . Bearing Materials . . Bearing Internal Clearances . . Allowable Bearing Speed . . Bearing Fit . Prevention of Bearing Axial Movement . Bearing Load . Bearing Preload Arrangement . Radial and Axial Bearing Load . Load Distribution . Bearing Fatigue Life . Calculation of Bearing Fatigue Life . . Bearing Failure Probability Distribution . . Influence of Unbalance on Bearing Fatigue Life . . Influence of Wear on Bearing Fatigue Life . Influence of Internal Radial Clearance on Bearing Fatigue Life . . Bearing Failure Mode . Major Causes of Premature Bearing Failure . Lubricant Selection . . Improper Bearing Lubrication . . Lubricant Contamination . . Grease Leakage . Bearing Sealing and Bearing Shielding . . Excessive Load . . Internal Radial Interference Condition . Bearing Current . Impact of High Temperature on Bearing Failure . . Bearing Failure Associated with Motor Vibration and Overloading . Improper Bearing Installation and Bearing Misalignment xiv Contents . Vertically Mounted Motor . Bearing Noise . Bearing Selection . Bearing Type Selection Based on Load . . Bearing Type Selection Based on Speed . Selection of Bearing Size . . Bearing Performance Improvement References Chapter Motor Brake . . Fundamental Knowledge of Motor Brake . . Static and Dynamic Friction . Wear . . Kinetic Energy of Rotating Object . . Brake Friction Materials . Brake Operation Mode . . Key Design Parameters and Considerations in Brake Design . Braking Torque . . Brake Operation Time . Definitions of Various Brake Action Time . . Brake Response Time . . Actual Braking Time . Total Braking Time . . Braking Energy for Single Operation and Operation Frequency per Minute . Mean Heat Power . . Temperature Rise and Thermal Capacity Rating . . Factor of Safety . Brake Backlash . . Brake Noise . Maximum Sliding Speed . Reliability and Durability . Brake Operation Cycle . . Brake Mounting Arrangement . . Brake Size . Brake Integration with Electric Motor . . Brake Ingress Protection Rating . Accumulation of Brake Wear Particles . Classification of Braking System . Electromagnetic Brake . . Spring-Engaged, Electromagnetically Released Brake . Solenoid-Actuated Brake . Multiple Disc Friction-Blocking Brake . Eddy-Current Brake . . Magnetic Particle Brake . . Hysteresis Brake . . Permanent Magnet Brake . . Magnetorheological Brake . Piezoelectric Brake . Contents xv . Mechanical Brake . Compressed Air-Engaged, Spring-Released Brake . Spring-Engaged, Hydraulic Pressure Released Brake . Pneumatic Brake . . Hydraulic Brake . Oil Shear Brake . Regenerative Brake . . Brake Failure . . Overheating of Mating Friction Surfaces . . Excessive Wear on Friction Surfaces . . Failure due to Corrosion . . Runout of Friction Disc . Thermomechanical Fatigue . Brake Design and Selection Considerations . Dynamic Stopping Brake or Holding Brake? . . AC or DC Brake? . Braking Torque . . Overall Inertia of System . . Thermal Consideration in Brake Selection . Other Factors Affecting Brake Selection . References Chapter Servo Feedback Devices and Motor Sensors . . Encoder . Type of Encoder . . Optical Encoder . Magnetic Encoder . . Capacitive Encoder . . Inductive Encoder . . Absolute and Incremental Encoders . . Absolute Encoder . Incremental Encoder . . Resolution of Encoder . Rotary and Linear Encoder . Encoder Mounting . Resolver . . Type of Resolver . . Resolver Operating Parameters . Resolver Accuracy . Input Excitation Frequency, Voltage, and Current . . Phase Shift . Transformation Ratio . Winding Impedance . . Speed Ripple . . Null Voltage . Resolver Testing . . Test Equipment and Instruments . Determination of Resolver Position Error . Measurement of Transformation Ratio . . Measurement of Phase Shift . xvi Contents . Measurement of Velocity Ripple . Measurement of Resolver Impedance . Effect of Cable Length on Resolver Performance . Influence of Motor Brake on Resolver Performance . Influence of Mechanical Impacts on Resolver Performance . Hall Effect Sensor . . Linear Sensor . . Threshold Sensor . Proximity Sensor . . Inductive Proximity Sensor . Capacitive Proximity Sensor . Ultrasonic Proximity Sensor . Photoelectric Proximity Sensor . Other Motor Sensors . Force/Torque Sensor . . Temperature Sensor . Thermocouple . . Resistance Temperature Detector . . Thermistor . Monolithic Integrated Circuit Temperature Sensor . Infrared Thermometer . Vibration Sensor . . Current Sensor . Pressure Sensor . Magnetic Field Sensor . Improving Motor Sensor Performance . Mitigation of Electrical Noise . Suppression of Temperature Rise . . Utilization of Dual-Feedback Solution for Improving Motion Control Accuracy and Reliability . . Development of Innovative Sensor . Sensor Miniaturization—Microsensor and Nanosensor . Advanced Wireless Sensor Technology . . Smart Sensors . . Color-Changing Dye Sensor for Detecting Motor Condition . Sensor with Newly Developed Material . . Selection of Motor Feedback Devices and Sensors . . Cable Technology References Chapter Power Transmission and Gearing Systems . Characteristics of Gearing Systems . Gearing System Efficiency . . Gear Ratio and Torque Ratio . Inertia Matching . . Gear Tooth Profile . Backlash . . Gearing Stage . . Gear Lubrication Contents xvii . Gear Contact Ratio . . Temperature Rise and Thermal Effect on Gearing System Performance . . Compact Structure . Acoustic Noise . Operation Reliability . Types of Modern Gearing Systems . . Strain Wave Gearing System . Planetary Gearing System . Cycloidal Gearing System . Rotate Vector Gearing System . . Magnetic Gearing System . Continuously Variable Strain Wave Transmission . . Pulse Drive . . Abacus Drive . Circular Wave Drive . . Archimedes Drive . Spiral Cam Gearing System . . Clutch-Type Stepless Speed Changer . . Conventional Gearing Systems . . Spur Gear . . Helical Gear . . Bevel Gear . Spiroid Gear . . Helicon Gear . Worm Gear . . Comparison of Conventional Gearing Systems . . Gearhead and Gearmotor . Gearhead . Gearmotor . Failure of Gearing System . . Selection of Gearing System . References Chapter Motor Power Losses . . Power Losses in Windings due to Electric Resistance in Copper Wires . Eddy-Current and Magnetic Hysteresis Losses . Eddy-Current Loss . . Magnetic Hysteresis Loss . . Calculations of Eddy-Current and Magnetic Hysteresis Losses . Losses in Stator and Rotor Iron Cores . . Losses in PMs . . Power Losses in Other Core Components . Mechanical Friction Losses . . Bearing Losses . . Sealing Losses . Brush Losses . Windage Losses . . Windage Loss due to Rotating Rotor . . Taylor Vortex xviii Contents . Friction Factor . . Windage Loss Due to Rotating Rotor . . Windage Loss due to Entrance Effect of Axial Airgap Flow . Windage Loss due to Stator Surface Roughness . Energy Loss due to Fluid Viscosity . . Fan Losses . Ventilating Path Losses . Methods for Reducing Windage Losses . . Stray Load Losses . . Influence of Power Rating on Motor Power Losses References Chapter Motor Cooling . Introduction . . Passive and Active Cooling Techniques . . Heat Transfer Enhancement Techniques . Conductive Heat Transfer Techniques . . Conductive Heat Flux and Energy Equations . Encapsulation and Impregnation of Electric Motor . . Enhanced Heat Transfer Using High-Thermal-Conductivity Material . Using Self-Adhesive Magnet Wire for Fabricating Stator Winding . . Natural Convection Cooling with Fins . Cooling Fin . . Fin Optimization . Heatsinks Manufactured with Additive Manufacturing Process . . Applications of Various Fins in Motor Cooling . . Pin Fin Heatsink . . Thermal Interface Materials . Forced Air Cooling Techniques . Thermophysical Properties of Air . Direct Forced Air Cooling Techniques . Forced Air Cooling at End-Winding Regions . Forced Air Flowing through Internal Cooling Channels across the Motor . . Forced Air Flowing Over Motor Outer Surfaces . . Forced Air Flowing through Both Motor Outer and Inner Surfaces . . Air Jet Impingement Cooling . . Cooling with Hydrogen Gas . . Indirect Forced Air Cooling Techniques . . Indirect Forced Air Cooling with Heat Exchangers . . Indirect Forced Air Cooling via Indirect Evaporative Air Cooler . . Fan and Blower . . Fan Types . Forward-Curved, Backward-Curved, and Straight Blades of Centrifugal Fans . . Fan Performance Curve and Operation Point . . Fan Selection . Contents xix . Liquid Cooling Techniques . . Thermophysical Properties of Coolants . . Direct Liquid Cooling Techniques . . Direct Liquid Cooling of Bundled Magnet Wires . Spray Cooling . . Direct Liquid Cooling through Hollow Winding Coils/Conductors . Liquid Jet Impingement Cooling . Liquid Immersion Cooling . . Indirect Liquid Cooling Techniques . Indirect Liquid Cooling via Cold Plates Attached to Motor Walls . Indirect Liquid Cooling via Helical Copper Pipes Casted in Motor Housing . Indirect Liquid Cooling with Cooling Channels on Casted Motor Housing . Indirect Liquid Cooling via Copper Pipe in Spacer . . Indirect Liquid Cooling through Stator Winding Slots . Indirect Liquid Cooling through Microscale Channels . Indirect Liquid Cooling via Heat Transfer Enhancement Device . Phase-Change Cooling Techniques . . Cooling with Heat Pipes . . Cooling with Vapor Chambers . . Evaporative Cooling . . Mist Cooling . . Radiative Heat Transfer . . Other Advanced State-of-the-Art Cooling Methods . . Micro Channel Cooling Systems . . Metal Foams . . Heat Transfer Enhancement with Nanotechnology . Nanofluid . Carbon Nanotube . NanoSpreader Vapor Cooler . . CarbAl Heat Transfer Material . . Ionic Wind Generator . References Chapter Motor Vibration and Acoustic Noise . Vibration and Noise of Electric Motor . Fundamentals of Vibration . Simple Harmonic Oscillating System . Damped Harmonic Oscillating System . Forced Vibration with Damping . Forced Vibration Due to Mass Unbalance . . Vibration Induced by Support Excitation . . Directional Vibration . . Electromagnetic Vibrations . . Unbalanced Forces/Torques Caused by Electric Supply . Broken Rotor Bar and Cracked End Ring xx Contents . Unbalanced Magnetic Pull Due to Asymmetric Airgap . Electromagnetic Force at Airgap . Asymmetric Airgap Due to Nonconcentric Rotor and Stator . Asymmetric Airgap Due to Elliptic Stator . . Asymmetric Airgap Due to Elliptic Rotor . . Asymmetric Airgap Due to Rotor Misalignment . . Asymmetric Airgap Resulting from Shaft Deflection . Nonuniform Airgap Due to Stator Slots . . Mutual Action Forces between Currents of Stator and Rotor . Vibration Due to Unbalanced Voltage Operation . Mechanical Vibrations . Misaligned Shaft and Distorted Coupling . . Defective Bearing . . Self-Excited Vibration . Torsional Vibration . . Vibration Measurements . Vibration Control . . Damping Materials . . Vibration Isolation . Magnetorheological Damper and Machine Mount . Tuned Mass Damper . Double Mounting Isolation System . Viscoelastic Bearing Support . . Self-Locking Fastener . Hard Lock Nut . Super Lock Nut and Super Stud Bolt . Self-Locking Nut . Jam Nut . . Serrated Face Nut and Bolt . . Nord-Lock Washer . Active Vibration Isolation and Damping . Measurements of Motor Vibration . . Fundamentals of Acoustic Noise . . Tonal Noise and Broadband Noise . . Sound Pressure Level and Sound Power Level . Octave Frequency Bands . Three Sound Weighting Scales . Averaged Sound Pressure Level . . Type of Noise . . Structure-Borne Noise . Airborne Noise . . Type of Aerodynamic Noise . . Noise Classification and Measurement in Rotating Electric Machine . Noise Type in Rotating Electric Machine . Mechanical Noise . . Electromagnetic Noise . Aerodynamic Noise . Acoustic Anechoic Chamber . Measurement of Motor Noise . . Acoustic Noise Field Measurement Contents xxi . Motor Noise Abatement Techniques . . Active Noise Reduction Techniques . . Passive Noise Reduction Techniques . . Blocking Noise Propagation Paths and Isolating Noise Sources . Using Noise-Absorbing Material . Motor Suspension Mounting . . Noise-Attenuating Structure . . Smoothing Ventilation Path . Selecting Low Noise Bearing . . Innovative Noise Abatement Methods . References Chapter Motor Testing . . Motor Testing Standards . . Testing Equipment and Measuring Instruments . Dynamometer . . Thermocouples and Other Temperature Measuring Devices . Control System . . Data Acquisition System . Torque Transducer . Power Quality Analyzer . . Power Supply . Motor Test Platform . . Testing Load Level . Testing Methods . Mechanical Differential Testing Method . . Back-to-Back Testing Method . Indirect Loading Testing Method . . Forward Short-Circuit Testing Method . Variable Inertia Testing Method . Off-Line Motor Testing . . Winding Electrical Resistance Testing . Megohm Testing . . Polarization Index Testing . High-Potential Testing . Surge Testing . Step-Voltage Testing . . Determination of Rotor’s Moment of Inertia . . Online Motor Testing . Locked Rotor Testing . . Motor Heat Run Testing . . Motor Efficiency Testing . Impulse Testing . Cogging Torque Testing . . Torque Ripple Measurement References xxii Contents Chapter Modeling, Simulation, and Analysis of Electric Motors . Computational Fluid Dynamics and Numerical Heat Transfer . . Strategies in Modeling and Performing CFD Analysis . . Rotating Flow Modeling . Porous Media Modeling . . Numerical Simulation of Motor Cooling . . Mathematical Formulations . Numerical Method . Case Study— D Thermal Analysis of Large Size Motor . Simulation of Two-Phase Flow and Heat Transfer . . Thermal Simulation with Lumped-Circuit Modeling . . Thermal Analysis Using the Finite Element Method . Rotordynamic Analysis . . Problem Description . . Bearing Support’s Stiffness and Damping . . Rotordynamic Modeling . Results of Rotordynamic Analysis . . Static and Dynamic Stress/Strain Analysis . . Static Analysis . Dynamic Analysis . Centrifugal Force-Induced Stress on PMs . Structural Analysis Using the Finite Element Method . . Shock Load . . Fatigue Analysis . Torsional Resonance Analysis . . Motor Noise Prediction . . Buckling Analysis . . Thermally Induced Stress Analysis . . Thermal Expansion and Contraction Analysis References Chapter Innovative and Advanced Motor Design . High-Temperature Superconducting Motor . . Radial-Flux Multirotor or Multistator Motor . Radial-Flux Multirotor Motor . Radial-Flux Multistator Motor . . Radial-Flux Brushless Dual-Rotor Machine . Radial-Flux Dual-Stator PM Machine . . High-Torque PM Motor with D Circumferential Flux Design . . Radial-Flux Dual-Rotor, Dual-Stator Motor . Radial-Flux Integrated Magnetic-Geared In-Wheel Motor . . Axial-Flux Multirotor or Multistator Motor . Single-Sided and Double-Sided Axial-Flux Motors . Multistage Axial-Flux Motor . . Yokeless and Segmented Armature Motors . . Energy Efficient Axial-Flux Yokeless Motor with Modular Stator . Axial-Flux Motor with PCB Stator . Hybrid Motor . . Hybrid Excitation Synchronous Machine Contents xxiii . Hybrid Hysteresis PM Synchronous Motor . Hybrid Motor Integrating RF Motor and AF Motor . Hybrid-Field Flux-Controllable PM Motor . Hybrid Linear Motor . Conical Rotor Motor . Transverse Flux Motor . Reconfigurable PM Motor . . Variable Reluctance Motor . PM Memory Motor . Variable Flux PM Memory Motor . . Pole-Changing PM Memory Motor . . Doubly Salient Memory Motor . Adjustable and Controllable Axial Rotor/Stator Alignment Motor . Piezoelectric Motor . . Advanced Electric Machines for Renewable Energy . Micromotor, Nanomotor, and Molecular Motor . Micromotor . . Nanomotor . Molecular Motor . References Appendix A: Advanced Interconnection Technology for Motors . Index Index abacus drive advantages gear ratio acceleration of gravity , accelerometer – AC motor , , , ; see also alternating current (AC) motor acoustic anechoic chamber acoustic blankets – , acoustic noise acoustic anechoic chamber active noise reduction – aerodynamic noise , airborne noise – , average sound absorption coefficient averaged sound pressure level A-weighting scale broadband noise B-weighting scale C-weighting scale electromagnetic noise , , – , field noise test mechanical noise – , noise abatement , – noise measurement , nonrotational aerodynamic noise octave frequency bands – rotating electric machines (see rotating electric machines) rotational aerodynamic noise sound power , – sound pressure , , structure-borne noise , – , tonal noise active cooling active noise reduction – active vibration damping , active vibration isolation systems , – additive manufacturing process , – direct metal laser sintering direct metal laser melting electron beam melting selective heat sintering selective laser melting selective laser sintering D printing , – , – aerodynamic noise , AF motors see axial-flux (AF) motors airborne noise – air cooling direct end-winding regions , , – , , – internal cooling channels jet impingement – motor inner surfaces motor outer surfaces , indirect heat exchangers , – , – , indirect evaporative air cooler thermophysical properties of air air density , specific heat – , thermal conductivity – , air density , airgap – , , – , , , , , , , , – , – , AF motor – asymmetries cylindrical circular rotor whirling – eccentricity – electromagnetic force – elliptic rotor – elliptic stator – nonconcentric rotor and stator – rotor misalignment shaft deflection , UMP – conical rotor motor – dynamic loss end flux density , , , – , hybrid motor , – inner nonuniform – , – , SRM noise – stator slots , outer reluctance – uniform – , , velocity components , windage loss – , axial airgap flow film divider – Taylor vortices , – tangential flow alnico magnet motors – , – , , – alternating current (AC) motors vs. DC motors efficiency classes – IM – (see also induction motor (IM) motor damping) PMMs – , power loss reactive power – servomotor – , – , – , , , – , , , single-phase motors – synchronous HTS motor three-phase motors , – , – , , , , , , , torque–speed characteristics – , – , Index aluminum–nickel–cobalt (alnico) – , – , , – ambient temperature – , – , , , , , , , – Ampère-Maxwell’s law angular acceleration – , – , angular contact ball bearings back-to-back arrangement – contact angle – cross section , face-to-face arrangement load analysis matched bearing performance – , , reverse loading conditions angular deceleration – angular displacement , – angular misalignment – , – angular momentum , , – , , , angular speed , – , – , , , , angular velocity , , , , , , , , angular vibration anticorrosion electroless plating technology electroplating , , – , electropolishing , hydrogen embrittlement , – inorganic and organic materials , , inorganic coating nanocoating phosphate coating , protective coating – , PVD , salt-spray test seals stainless steel thermally conductive paints thermal spraying process Archimedes drive (compound planetary drive) – advantages – applications gear ratio structure area-moment method asynchronous motors , A-weighting scale axial fan , axial-flux (AF) motors , , HTS motor , hybrid motor – torque density with PCB stator – yokeless and segmented armature (YASA) – axial-flux (AF) multirotor double-sided , – magnetic flux path , multistage machine rotor–stator–rotor structure , single-sided – slotless torus topology yokeless and segmented armature (YASA) – axial misalignment – , – , axial rotor/stator alignment motor – axial vibration , , back EMF constant (Ke) , – background noise level , backlash – , – , – , , , – , – , – , – , – , – , back-to-back testing method – ball bearing angular contact ball bearings – , , deep-groove ball bearings – , , – , , , – , radial ball bearing ball screw – bearing axial movement prevention , ball angular contact ball bearings – , , deep-groove ball bearings – , , – , , – , radial ball bearing ceramic hybrid , crossed roller – , clearance – , – , current – , – failure mode bearing currents – excessive load fishbone diagram grease leakage – high temperature impact improper installation and misalignment improper lubrication internal radial interference condition lubricant contamination lubricant selection motor vibration and overloading premature failure causes seals and shields statistical data vertically mounted motor – fatigue life calculation – determining factors failure probability distribution – internal radial clearance – unbalance influence – wear influence – fit , journal – load distribution , – , – lubrication , , – , materials , noise , noncontact – , performance improvement preload arrangement radial and axial bearing load , , – , , roller cylindrical roller – , tapered roller – , thrust , slewing ring – Index selection based on load based on speed selection factors – size sensor speed , bearing clearance – bearing currents – , – bearing failure mode bearing currents – excessive load fishbone diagram grease leakage – high temperature impact improper installation and misalignment improper lubrication internal radial interference condition lubricant contamination lubricant selection motor vibration and overloading premature failure causes seals and shields statistical data vertically mounted motor – bearing failure probability – bearing fatigue life calculation – determining factors failure probability distribution – internal radial clearance unbalance influence – wear influence – bearing fit , bearing load , , , – bearing losses ball bearing structure friction torque , total frictional moment , total power loss bearing noise , , bearing speed , bearing stress , bending moment , – , – , – , , , bending stress compressive and tensional stresses single-section shaft , – , stepped shaft , – , – , black oxide , BLDC motor see brushless DC (BLDC) motor blower , , bolt–nut fasteners – brake backlash – , – , braking torque – , – , – , , blocking – eddy-current – , electromagnetic factor of safety , – friction material ceramic – full metallic non-metallic semi-metallic hydraulic hysteresis , inertia , – , – , ingress protection (IP) rating – kinetic energy – , , magnetic particle/powder magnetorheological (MR) – maximum sliding speed mean heat power mechanical mounting arrangement multiple disc friction-blocking noise oil shear operation cycle operation mode operation time actual braking – , actual torque build-up – armature engage – armature pull-in , brake cycle brake response braking effective brake release , effective engagement hold initial delay response torque build-up torque decaying , total braking total brake release permanent magnet (PM) piezoelectric-actuated pneumatic powder (particle) , Prony regenerative reliability and durability solenoid-actuated spring-engaged thermal capacity rating – temperature rise torque – wear – wear power loss brake failure corrosion – excessive wear overheating runout thermomechanical brake selection backlash – , braking torque , , , cost dynamic stopping , holding , lifetime , – mounting configuration , overall inertia precise positioning capability Index brake selection (cont. ) size – thermal considerations broadband noise broken rotor bar , brushed DC PM field motors brushless DC (BLDC) motor , – , brushless double-rotor machine (BDRM) – brushless motors , brush losses brush motors , brush seal flexible silicone rubber – Kevlar fibers , – , wire bristles buckling analysis , , butterfly-base rotating fastener – B-weighting scale Campbell diagram , carbon emission carbon equivalent (CE) carbon fiber , , carbon fiber reinforced polymer (CFRP) , carbon steel cold-rolled or hot-rolled carbon steel heat treatment process , low-carbon, medium-carbon, and high-carbon steels mechanical and thermal properties Carter factor casted endbell – casted housing aluminum , casting materials properties die casting – EPC , graphite – gray iron graphite iron gravity fed process heat treatment iron material melting temperature molten material permanent-mold casting pressure casting – pressure fed process sand casting servomotor steel casting – testing methods – Castigliano’s method – casting copper rotor – , – die , endbell manufacturing – full-mold heat treatment iron vs. aluminum lost-foam low-pressure material properties permanent-mold pressure sand squirrel cage rotor , steel – cast iron technique centrifugal fan backward-curved blade fans – forward-curved blade fans – helical impeller design straight blade radial fans – ceramic bearings , CFD see computational fluid dynamics (CFD) CFPR see carbon fiber reinforced polymer chassis dynamometer chemical vapor deposition (CVD) circular wave drive (CWD) gear ratio structure – cloud-based data storage and transmission system clutch-type stepless speed changer – speed change ratio structure – CMM see coordinate measuring machine (CMM) CNC see computer numerical control (CNC) coefficient of thermal expansion (CTE) – , , , , – aluminum , carbon steel CarbAl thermal material copper , ductile iron gray iron , linear, area, and volumetric thermal expansions – stainless steel cogging torque analytical methods – effective driving torque nocurrent torque reduction techniques drive current waveform modulation flux linkage magnet pole arc magnet segmentation skewed permanent magnets – skewed stator teeth – slot number per pole Soleimani’s rotor structure stator–rotor airgap – step-skewed permanent magnets slotless stator core , testing torque ratio , vibration and acoustic noise cold forging , – endbell impression-die forging phosphate coating , serration fit cold plates , – , – cold rolled lamination steel composite material , – , compound motor compound-structure permanent magnet synchronous machine (CS-PMSM) – Index compressive strength , computational fluid dynamics (CFD) , , , , , – , – , – , advantages , – modeling and performing strategies – numerical simulation, motor cooling continuity equation energy/heat equation flowrate – , fluid meshing fundamental laws of physics large-scale elevator motor momentum equations pressure distribution , pressure drop data pressure vs. flowrate solid meshing temperature-dependent properties , temperature distribution – temperature vs. flowrate D velocity field , turbulence model – winding insulation porous media modeling – rotating flow modeling – mixing plane model MRF model sliding mesh method SRF method Taylor–Couette flow – , – , computer numerical control (CNC) , , , , , , , concentrated winding , conduct bar coil formation – conduction , , – , , , , , direct cooling technique , enclosed motor FEM analysis , FVM indirect cooling technique , nanofluid passive cooling mode silicon steel lamination thermal interface material thermal network conductive heat transfer , , carbon nanotube conductive heat flux encapsulation and impregnation , energy equations high-thermal-conductivity materials , self-adhesive magnet wires conductor bar in casted rotor , – , fatigue stress heat treatment skin effect – conical rotors nonuniform airgap rotor–stator structures uniform airgap containment design loading model debris accumulation model debris deflection model maximum compression and shear strain energy minimum perforation energy minimum thickness, containment shell – residual energy rotor burst tests and FEMs continuity equation , control active , , passive , control loop close – open – control system , – , , , , – , , , – , – , – , , , , dynamometer , end play – motion , , , , , , coolants , , , – , – , , – , , , – , cooling active , air (see air cooling) evaporative , – fin , (see also fin cooling) hydrogen gas , – HTS motor – immersion , – , internal channels , – jet impingement air jet impingement – liquid jet impingement – liquid (see liquid cooling) liquid immersion , , – , microchannel , – mist , passive , phase-change (see phase-change cooling) spray (see spray cooling) through hollow winding coils/conductors – coordinate measuring machine (CMM) , copper rotor – , – core losses see eddy-current losses; magnetic hysteresis losses corrosion resistance aluminum coating protection – electroless plating electroplating , – , – , electropolishing , ferrite PMs , forged shafts Inconel alloys , , inorganic coating nanocoating physical vapor deposition phosphate coating , stainless steel , , – , , , , coupled rotor unbalance – Index coupling flexible bellow double flex geared – grid – jaw Oldham roller chain – spiral beam Thompson (universal joint) noncontact labyrinth , – magnetic – , PM eddy-current – oil shear – rigid – , semirigid – crack/cracking , cast iron end rings fatigue , hydrogen-induced microcracks , microscale quenching stress concentration , stress corrosion – welding process critical speed damped , – mechanical resonance and resonant frequency and resonance definitions fourth-order frequency equation motion equation natural frequencies , – , , – , – physical and rotordynamic analytical model – Rayleigh–Ritz and Dunkerley methods , two-degree-of-freedom model , shaft design – undamped , – cross-flow fan – CTE see coefficient of thermal expansion (CTE) cumulative distribution function (CDF) CVD see chemical vapor deposition (CVD) CWD see chemical vapor deposition (CVD) C-weighting scale cycloidal gearing system advantages – disadvantages efficiency gear ratio structure – cylinder-base fastener – cylindrical roller bearings – , damped harmonic oscillating system damper magnetorheological mechanical single-degree-of-freedom system spring-damper system TMD (see tuned mass damper (TMD)) damping AC motors active vibration and bearing support stiffness forced vibration dynamic equation of motion , nonhomogeneous second-order differential equation phase angle variations , – single-degree-of-freedom system steady-state response transient response materials – , viscoelastic material , viscous – , – damping ratio – , – , – , – , , Darcy–Weisbach friction factor data acquisition systems , DC motors see direct current (DC) motors DDR motors see direct drive rotary (DDR) motors deep-groove ball bearings – , , – , , , – , delta connection design constant back EMF time constant (Ke) , – electrical time constant (τe) mechanical time constant (τm) – motor constant (Km) thermal time constant (τth) torque constant (Kt) velocity constant (Kv) viscous damping (Kvd) design for assembly (DFA) design for manufacturing (DFM) design integration design process design optimization electromagnetic design flowchart mechanical design prototype motor , rotordynamic analysis , – subsystem/component approach system approach – thermal analysis – DFA see design for assembly (DFA) DFM see design for manufacturing (DFM) diameter inner , , , , , – , outer , , , – , , die casting , – , – , – , – die casting copper motors digital signal , digital signal processor (DSP) direct current (DC) motors , – , – , – , , , vs. AC motors , brush AF motor brushless AF motor – Index brushless motor , , brush motor , motor constant (Km) motor torque – , – servomotor torque–speed characteristics types of – direct drive rotary (DDR) motors , , – advantages cartridge DDR motors – vs. conventional servo systems frameless DDR motors , – hollow shafts , housed/frameless – direct drive system equivalent motor-load model , mechanical resonance and resonant frequency TFM direct forced air cooling end-winding regions internal cooling channels jet impingement – motor outer and inner surfaces motor outer surfaces – directional vibration direction of rotation (DIR) , , , – direct liquid cooling bundled magnet wires jet impingement – spray cooling – , direct loading vs. indirect loading testing direct numerical simulation distributed winding double mounting isolation system doubly salient permanent magnet (DSPM) motor PM memory motor airgap flux control dual magnet temperature stability topology – VRM DSPM motor see doubly salient permanent magnet (DSPM) motor ductile iron , – , duty cycle – , , , – , dynamic load , , , dynamic rotor unbalance – dynamometer brake power (Pb) chassis control system eddy-current brake – electric motor/generator hydraulic brake hysteresis brake inertia brake mechanical friction brake powder brake water brake eccentricity – , – , – , , asymmetrical airgap – dynamic , static mass – , rotor , shaft , UMP , eddy-current brake dynamometer – eddy-current losses , – , , , – , Ampère-Maxwell’s law divergence theorem FEA tools Gauss’s law lumped circuit approach Maxwell’s equations , in permanent magnet motors in stator and rotor cores – eddy-current probes EDM see electrical discharge machining (EDM) effective thermal conductivity – , effective viscosity efficiency gearing system , motor (see motor efficiency) power transmission electrical discharge machining (EDM) electrical interconnect technology insulation displacement connection (IDC) technology – press-fit technology – electrical system , electrical time constant (τe) electric generator electric motor/generator dynamometer electric motors AC motors , , , AF motors – , , – , – , – , brush and brushless motors characteristics duty cycle – , , efficiency (see motor efficiency) insulation (see motor insulation) load-to-motor inertia ratio – mechanical resonance and resonant frequency (see mechanical resonance and resonant frequency) operation reliability , , , , , , power and power factor speed (see motor speed) torque (see motor torque) closed loop and open loop control systems components , , , – , , , , , , , , , , , , , – , , , , , , , – , , , , , – , DC motors , – , – , , DDR motors cartridge DDR motors – vs. conventional servo systems frameless DDR motors , – housed/frameless – Index electric motors (cont. ) design and operation parameters back EMF constant (Ke) , – electrical time constant (τe) mechanical time constant (τm) – motor constant (Km) thermal time constant (τth) torque constant (Kt) velocity constant (Kv) viscous damping (Kvd) design integration , design process design optimization , flowchart mechanical design – multidisciplinary design optimization prototype motor subsystem/component approach system approach – enclosed motor , , , failure modes gear drive motors history induction motors (IMs) , – , – , – , , , , , , , IP code linear motor – , mechatronics open motor permanent magnet motors (PMMs) , – , , , , , power rating classification reluctance motors , RF motors , , , rotary motors , – , servomotors , – , , – , , – , , , , , , single-phase motors – sizing equations – , – specialty electric motors explosion proof flame proof operating under vacuum environment operating under nuclear radiation environment piezoelectric submersible ultrahigh speed stepper motors – synchronous and asynchronous motors three-phase motors – , electroless plating technology electromagnetic force (EMF) , , , , – , airgap – axial vibration , back EMF , – , , constant , – sinusoidal , trapezoidal , electromagnetic noise , , – , electromagnetic vibration – two-pole motors unbalanced vibration and acoustic noise electromagnetic vibrations – airgap asymmetries cylindrical circular rotor whirling – eccentricity – electromagnetic force – elliptic rotor – elliptic stator – nonconcentric rotor and stator – rotor misalignment shaft deflection UMP – broken rotor bars – cracked end rings mutual action forces nonuniform airgap unbalanced forces/torques unbalanced voltage operation electroplating , – , electropolishing , elliptic rotor – elliptic stator – EMF see electromagnetic force (EMF) encapsulation , , materials – partial and total encapsulation – , process thermoplastics thermoset plastics trickle impregnation varnish dipping void-free vacuum pressure impregnation (VPI) primary process – vs. solvent varnishes tank, large electric motors enclosed motor , , , encoder absolute , – , – , capacitive – , incremental , – , – , inductive – , linear , magnetic – , – optical , resolution multiplication rotary , selection factors – accuracy compact size cost electrical noise immunity energy consumption magnetic field immunity maintainability operating temperature range operation reliability and stability output signal repeatability response time resolution service life structure ruggedness tolerance to vibration and shock loading Index endbell casted endbell forged endbell iron casting vs. aluminum casting machined endbell stamped endbell epoxy resins , , evaporative air cooler evaporative cooling , – evaporative pattern casting (EPC) , excitation frequency , – , – , – , exciting force , , , , , attenuation harmonic self-excited vibration system vibration isolation exponential Weibull distribution – extra-large motors extruded aluminum motor housing – factor of safety bearing braking system , electric machine crushing failure – , motor motor components , rotor shaft design , shear failure – , failure mechanism crushing – shear – , mode bearing (see bearing failure mode) motor winding failures , fan axial fan , , centrifugal fan backward-curved blade fans – forward-curved blade fans – helical impeller design straight blade radial fans – cross-flow fan – heatsink-impeller law volumetric airflow static pressure power mixed-flow fan , – performance curve and operation point , – , selection , Fanning friction factor fan performance curve , – , Faraday’s law of induction , – fasteners cylinder-base fastener forged Z-shaped fastener loading distribution preload rotary fasteners butterfly-base rotating fastener – square-base rotating fastener triangle-base rotating fastener self-clinching fastener self-locking fastener hard lock nut jam nut Nord-lock washer self-locking nut serrated face nut and bolt super lock nut super stud bolt thread engagement and load distribution tightening factor tightening load tightening process – , tightening torque , fast fourier transform (FFT) fatigue analysis , , – fatigue failure , , , , , – , – FEA see finite element analysis (FEA) FEM see finite element method (FEM) ferrite permanent magnets FDM see finite difference method (FDM) fin cooling fin optimization design parameters fin height vs. overall thermal resistance fin ratio vs. overall thermal resistance plate-fin efficiency thermal model on motor endbell motor frame with external and internal fins oblique plate fins pin-fin heatsink (see pin-fin heatsink) plate fins , – , – , – , stator lamination fins – finite element analysis (FEA) , , – , , , – , , , , , hybrid linear motor hysteresis and eddy-current losses results
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