This document summarizes the work of Dr. Howard Lovatt at CSIRO Material Science and Engineering on electric machine technology, including magnetic materials, machine design, power electronics, control systems, and innovative motor designs. It discusses permanent magnets, soft magnetic materials, finite element analysis, optimization of motors and generators, winding design, and various applications including high speed motors, actuators, pumps, and hybrid electric vehicles.

1. Applied Magnetics and Drives
Dr Howard Lovatt
CSIRO Material Science and Engineering
May 2009

2. Electric Machine Technology

3. Magnetic Materials
• Permanent Magnets
• sintered commercial magnets,
Nd2Fe14B, Sm2Co17, ferrites
• Novel shapes – wire and water
jet cutting
• polymer bonded magnets,
anisotropic HDDR (MQA-T
powder)
• Magnetically soft materials
• glassy metals
• powdered iron cores
• low-loss electrical steels
• rotational and high-
frequency losses

4. Machine Design – Motors and Generators
• Design of Induction, Switched Reluctance
and Permanent Magnet machines
• Machine design (magnetic circuit design)
using 2D and 3D finite element analysis.
• Optimisation
• objective function, (e.g. cost,
efficiency) is sought over key variables
subject to constraint of motor
specification (volume, torque etc)
• Circuit Analysis
• Novel Machine Topology
• slotless, ironless, axial flux, permanent
magnet reluctance

5. Machine Design – Motors and Generators
• Winding Design
• Magnetic Couplings
• Solenoids
• Magnetic separators
• Mechanical design of machine, and
solid modelling of machine and
power electronics (AutoDesk
Inventor)

6. Advantages of brushless rare-earth permanent
magnet motors
• High Efficiency - typically
greater than 90%
• Improved Reliability (no
brushes)
• High Torque-to-Weight
Ratio
• Increased Power-to-
Weight Ratio
• Reduced Dimensions -
Compactness
• Cool Operation
• Quiet Operation
• Possible Lower Cost

7. Power Electronics and Control
• Power electronic circuits
• Hardware: Analogue and digital
circuits design and prototype
• Software development for
microcontrollers, DSPs and PLDs
• Sensor and sensorless control
techniques
• Circuit simulation and modelling
• Matlab, Simulink and dSpace
platforms
• microAutoBox for automotive

8. Power Electronics and Control

9. Design for Manufacture
• Integration of motor and
controller
• Lamination production
• Use of existing stator or
housing
• Bearings, seals and cooling
• Testing
• loss separation
• thermal
• In-situ multi-pole
magnetisation
• design and construction
of multi-pole magnetising
fixture

10. Magnetic Separator

11. Solenoids
• Very low cost
• Constant force characteristic
• Uses DC
• Silent - plunger does not
impact on end stop
• Does not burn-out as
resistance constant in any
position

12. Innovative Motors - Motor and Sensorless
Controller
• 3-phase brushless pm
motor
• 740 W at 20,000 rev/
min
• high-efficiency >90%
• no magnetic
hysteresis losses
• 1 kW sensorless
controller

13. Permanent Magnet Generators: Cogeneration and
Wind

14. Innovative Motors - Wool Shear Motor
• Wool shearing hand-
piece motor
• Efficiency ~96%
• Slotless winding and
glassy metal stator
• Hand piece stays cool
• 150 W, 13,300 rpm,
(total losses 6 W)

15. Innovative Motors – High Speed
Motor
High-speed compressor motor
 Customer: Danfoss/Turbocor (US based but
formerly Multistack in Australia)
 Patents in ~15 countries
 Collaborators: CIP and UTS
 High-speed motor developed, ~50 kW, 50,000
rpm
 Won many international awards
US EPA Climate ASHRAE/AHR Expo Canadian Energy
Protection Award "Energy Innovation“ Award Efficiency Award

16. Innovative Motors - Actuator
• Valve actuator
• Customer:
• Transfield
• High-torque motor, 120 Nm
• Direct-drive (no gearbox)
• Mounted axially with valve

17. Innovative Motors - Oil-Well Mule
• Oil-Well Mule Motor
• Customer:
• ORAD Ltd
• Slotless winding
• 500 W, 92% efficient, 2-
pole Sm2Co17 rotor
• Operates at 150OC and at
500 atmospheres

18. Innovative Motors - Solar Powered Pump
• Rural/Agricultural
Pumps
• Customer:
• Mono Pumps
• Pumps twice as much
water in a day as
competitors
• Water filled 300 W,
>85% efficient
• Powered by the sun
through solar panels
• Bore-hole depths to
120 m and 100 mm
diameter
• Mechanically simple

19. Innovative Motors - Solar Car Motor
• Solar Car Motor
Ironless, axial flux, 98% efficient, 1.8 kW
(rated 3.6 kW), 1,060 rpm (100 kph), 16
Nm, Active mass 5 kg

20. Innovative Motors - Solar Car Motor

21. Innovative Motors - Switched Reluctance
Motors
• The Benefits
• Lowest production cost of all
electrical motors
• Ideal for applications in
domestic appliances and
vehicles
• Torque/Volume ratio
intermediate between Rare
Earth Permanent Magnet and
Induction motors
• Operate over wide speed range
• Mechanically robust design
suited to harsh environments

22. Innovative Motors - Switched Reluctance
Motors
Switched Reluctance Motor - circuit coupled FEA

23. Innovative Motors - Switched Reluctance
Motors

24. Hybrid Electric Vehicles
Holden ECOmmodore (parallel HEV)
aXcess Australia LEV (series HEV)

25. Hybrid Electric Vehicles

26. CSIRO Material Science and Engineering
Name Dr Howard Lovatt
Phone +61 2 9413 7412
Email howard.lovatt@csiro.au
Web www.csiro.au
Thank You
Contact CSIRO
Phone 1300 363 400
+61 3 9545 2176
Email enquiries@csiro.au
Web www.csiro.au