How to Market and Exhibit Properly

Graeme Jenner, Integral Marketing Ltd – UK

Most USA Electronic/Electrical Exhibitions are declining year after year.  Old habits need to change and a new mode of  thought  is required.  There is far more to exhibiting than just turning up and putting your wares on display.  Come and learn how to exhibit.

Adjustable, Integrated Inductors and Transformers

James J. Wang, Power Gold LLC, 3131 East Muirwood Drive, Phoenix, Arizona  85048   USA

Two to 16 inductors will fit onto IC chip and inside 1mm thin package.  Adding ferrite core, 50nH to 500nH inductors are formed.  With permalloy cores, 2 micro-Henry inductors are realized.  Inductors are tiny at 1x2x0.25 mm (40x80x1 mil) or smaller.  One can layout primary coil on one side and secondary coil on the opposite sides of rectangular core to create on-chip transformer. 

          Designers can shrink and reduce cost.  Ball bond directly on top of ICs having electroplated, metal line segments to form toroids or rectangular inductors.  Both thick electroplated metal and wire bonding are low cost, production processes.  Adding more inductors on-chip becomes cheaper than 0402 SMD chip inductors.  Moore’s law suggests wafer fabs plus packaging technologies advance such that ICs shrink and cost drops with each successive generation.  Integrating onto silicon wafer will become smaller, more reliable and cheaper.   

Novel Gold Inductors™ were fabricated on-chip and tested.  Electrical characterizations will be presented.  One can design and integrate inductors into PCB or even inside packaged ICs.  Furthermore, inductors can be trimmed.  Exploit precise semiconductor design and process.  Miniature hand-held electronics and medical devices will benefit from shrink.  Aerospace and automotive products will reduce weight and increase ruggedness. 

Contact less Backbones for Industrial automation

Hans-Peter Schmidt, UAS Amberg-Weiden, Faculty of Electrical Engineering and Information Technology, Kaiser-Wilhelm-Ring 23, D-92224 Amberg, Germany

In industrial automation rail mounted devices are commonly in use. Also devices distributed across the shop floor are found in most of the applications. Power and data feeds are usually cabled with electric contacts. We investigate contact less energy and data transfer for such devices. The main focus lies on contact less systems with cable like structures. The power range under consideration is in the order of some Watts. While studying inductive and capacitive coupling, we consider here only inductive coupling. 

For design and optimization detailed 3 D calculations are carried out. Vectorfield calculations were carried out with respect to flux linkage and stray fluxes, power losses and efficiency. Calculations span the frequency range from DC to some 100 kHz. Special care is taken to account for losses such as arising from eddy currents. Optimization runs yield parameters for geometry as well as for electrical and electronic design.

To verify results of the simulations we devise a field measurement. It comprises sensors for three dimensional measuring of the magnetic fields. Its sensor head is positioned with respect to the three axes via a computer control. The sensor head itself consists of three perpendicular arranged hall sensors. Calibration is accomplished via built to purpose Helmholtz coils. For a full 3 D measurement of the magnetic flux including orientation and field strength the sensor head is positioned along the axes.

Results from calculations and measurements are given for a ferrites structures and high μ metal foils.  

Design Workshop for AC Induction Machines for Inverter Operation

James R. Hendershot,  Infolytica Corp – Canada

Download the "Motor Solve - Design Software for Electric Machines" PDF - Here 

Jim Hendershot, an IEEE Fellow, holds a B.S in Physics from Baldwin Wallace College in Berea Ohio. He specializes in the design and analysis of both electro-magnetic and permanent magnet devices as well as teaching design courses and workshops.

Efficient Machine Design Using a Finite Element-Based Software Tool

Hussam Maleh, Kousseil Ben Ahmed, Ahmed Khebir, ElectroMagneticWorks Inc., Montreal, Canada

A finite element-based software tool, EMS, offering a high degree of versatility in streamlining the design phase of electromechanical devices, is presented. This general purpose package employs a highly accurate field-based simulation technique inside a CAD environment, SolidWorks, which makes the analysis of a wide variety of devices readily accessible to the practicing engineer. Some devices, namely, a magnetic coupling device, a brushless DC motor, and a three-phase transformer are selected to illustrate this design solution. Features such as the use of multiple configurations and studies, to evaluate design variations, or to carry out sensitivity analysis, and coupling of electrical and thermal analyses are illustrated using the aforementioned devices. Recommendations for the practicing engineer on the use of such a package are presented.

Transmitter & Receiver Coil Design for Open Area Concealed Weapon Detection System

Prasanta Pati. Researcher, Research Office CE2-14, Canalside East Building, School of Computing & Engineering, University of Huddersfield, Queensgate, Huddersfield HD1 3DH, UK

People carrying guns, knives and other threat metal objects are threat to public security. Detection of threat metal object in a crowded open area environment is always an important issue for public safety. Conventional metal detector and image scanners lack the ability to detect threat items in large area. In order to design a large area threat object detection system, it is important to design transmitter and receiver coils to illuminate the detection space. Transmitters and receiver coils array are designed in an array for this large area metal detection system. The optimum design of transmitter and receiver coils leave no space for hotspots (area of high sensitivity) or dead zones (area of low sensitivity) in the system. The transmitter coils has been modelled and analysed in Opera 3D electromagnetic simulation software. This new coil design would help to design large area detection system for large open area environment. The system could be used in corridor of an airport, entrance to apartments, schools, colleges, military checkpoints etc.

Harmonic Calculation of Magnetization Current

N. Miteva, Department of Electrical Engineering, Ariel University Center of Samaria
M. Slonim, Department of Electrical and Computer Engineering, Ben Gurion University, Beer Sheva, Israel
A. Braunstein, Department of Interdisciplinary studies, Tel Aviv University, Tel Aviv, Israel

Transformers or coils with ferromagnetic cores are widely used in the power system and in power electronic converters. Their no-load magnetization currents are non-sinusoidal under sinusoidal input voltage because of the hysteresis. The current harmonics calculation is important in engineering practice for estimating the harmonics distortion influence. A new approach for a qualitative analysis and an analytical estimation of the harmonics of a measured magnetization current is presented in this article.  The method based on the physical explanation of the current waveform. It is shown that due to hysteresis the main harmonics of current are the basic and the third. It is also proved that the current’s third harmonic always decreases while its basic harmonic increases. This allows fast, easy and accurate calculation of the basic and the third harmonics of the magnetization current of any practical circuit with hysteresis. The results of the calculations are compared with the experimental results. A favorable matching is observed.

PM Synchronous Motors, an Alternative to Induction Motors for High Efficiency Applications

Recent legislation in the USA, Europe and China has been defined with the objective of setting new standards for the production of energy efficient motors. Some of the standards have already become effective; others will come into effect within a few years. It is already apparent that the standards will be difficult to meet with current asynchronous motor designs. This paper discusses various possible solutions in providing compliance with the new standards. Traditional induction motors require more volume to generate the same output, however, this is a limited solution and is not possible for many applications. In contrast, permanent magnet (PM)synchronous motors comply with the specified efficiencies without volume increase and provide a better solution. New applications are often realized with inverters. In these cases, PM synchronous motors are a good solution as well. The guidelines for the development of such a series are explained.

PM synchronous motors with embedded magnet blocks are best suited to meet all requirements and they offer great flexibility for range of applications. The newly designed series covers diameters between 120 and 300mm. It can be extended to cover smaller or larger diameters as well. The results are illustrated using the example of a 5,5HP (170mm diameter) motor.

Session 5 - Technical Workshop - Power Inductors & Transformers **

Power Inductors & Transformers – Electromagnetic Principles & Basic Magnetic Theory of Operations

Course Outline:

Introduction:

•        Brief history
•        Simple definition
•        Type of Inductors & Transformers
•        Difference between Inductor & Transformer

Basic Magnetic Theory:

•        Magnetic field, flux, flux density
•        Magnetic Field principles
•        Laws governing magnetic behavior – Faraday’s, Ampere, Lenze’s….
•        Transformation – electric characteristics of magnetic device
•        Magnetic units - Permeability, Permeance, Reluctance, Inductance….
•        System of Units – CGS and SI

Electromagnetic Principles &  Transformer:

•        Electromagnetic principles applied to transformer
·       Working of Inductors and Transformers
·       Manufacturing challenges
 

Samir Kagalwala has a unique combined experience in manufacturing and design of Wire Wound Components in Power Electronics. In over 30 years in the industry, he has set up magnetic manufacturing facilities, resolved short term and long term manufacturing issues meeting internal and external customer needs and bridged Design and Manufacturing for improved products and customers’ satisfaction. He developed design rules and guidelines for manufacturing and helped increase manufacturing professionals’ understanding of the design criteria. He worked for Philips Electronics, Motorola and Zenith Electronics in various capacities.

Impact of Rotor Bar Bridge on Torque Generation in Integral Horsepower Machines

Howard W Penrose, Ph.D., CMRP and Zachary Zych, Vice President, Dreisilker Electric Motors, Inc., Engineering and Reliability Services

The impact of rotor bar bridges in closed slot rotors has been simulated using finite element analysis and single phase equivalent circuit methods in 60Hz sinusoidal environments.  In this paper, we will discuss a study on a 455 horsepower, 90Hz machine utilizing a rotor with a thick bridge then the impact on torque development once the outer diameter of the rotor was turned down, reducing the thickness of the bridge.  The research performed allowed for optimizing bridge thickness based upon machine speed for optimal torque development.

Adhesive Potting and Encapsulating for Explosion Proof Motors

Joel F. Nashett, Market Development Engineer, Technical Customer Service, Henkel Loctite Corporation, 1 Henkel Way, Rocky Hill, CT

December 11, 2010 is a critical date for many electric motor manufacturers.  On this date all electric motor manufacturing companies that produce explosion proof models for use in hazardous environments will be required to fully meet Underwriters Laboratories UL 674 requirements.   In addition, the Energy Independence and Security Act (EISA) has created new efficiency standards for many electric motors, effective December 19, 2010.  A full review of electric motor designs and the components used in a motor must be carefully reevaluated to meet efficiency requirements and fully comply with the UL explosion proof listing.  Adhesives play a critical role in the successful design of an explosion proof, UL 674 compliant motor.  Several new potting materials have been formulated to enable electric motor companies to pot connectors and wire junctions that need to withstand the harsh environments these motors may be exposed to in their service life.

The essence of vacuum dispensing for high-voltage substrates

Inductive, coiled wire components are often used in harsh environments and are exposed to high temperature changes. Therefore they need to have a high mechanical resistance against vibrations and need to be protected against humidity. A very important specification is always the high-voltage insulation when used in expensive electronical devices. 

To cope with all these requirements a high-quality state-of-art coiled wire component has to be encapsulated in appropriate formulated cast resin material. Of course, simply pouring potting material over a coil will not give the expected results; as for many reasons the resins are filled with solid materials and show a fairly high viscosity, they will not enter in the tiny gaps between the wires and the coil will not be soaked completely with material – even worse, air is trapped in the coil and finally lowers the high-voltage resistance and leads to cracks and mechanical damage of the component through thermal and mechanical stress. 

To ensure an absolutely air bubble free penetration of wire coils, the material preparation, feeding and potting process must be performed in a vacuum environment. 

Advantages of vacuum aided potting of inductive, coiled wire products: Optimal homogenized, degassed and absolutely air bubble free material, protected from all environmental influences; No trapped air in the coils, no air bubbles or voids included in the product; Highest possible high-voltage insulation; Excellent mechanical protection and thermal management; Outstanding product quality, high customer value for low production costs; Most competitive price / performance ratio – easy customer acquisition and retention.

Outsourcing the manufacturing off-shore is not new. However, it has dramatically accelerated in last decade of twentieth century and it continues going into twenty first century. Advancements in computer and internet technologies are helping the acceleration.

The greatest pro of the outsourcing off-shore, the enticing cost saving, is not without cons. It has its own tough challenges. However as long as there is a cost saving, the outsourcing will prevail and, we must find a way to manage the opportunity. Managing is not difficult if done right.  In a country where you drive on left side of the road, the rule of the road is ‘left is right and right is wrong’! As long as you understand it right and respectfully follow, you succeed avoiding accidents and a possible financial disaster.  

Benefit from presenter’s hands on experience to gain insight into the best practices in outsourcing of magnetics off-shore.

Axial Flux interior permanent magnet BLDC motor for automotive applications

Sreeju S Nair, Member R &D, TVS Motor Company, P.B.No.4, Harita , Hosur-635109, Tamil Nadu, India

A multi objective optimal design of an axial flux BLDC motor is presented to achieve a high torque-to-weight ratio and motor efficiency and is suitable for the automotive applications. First the motor is modeled in magnetic circuits, and designed to meet the specifications of an optimization scheme, subject to constraints, such as limited space, current density, flux saturation and driving voltage. Finite element analyses are then carried out for the proposed 8 pole, 24 slot combination to obtain the electromagnetic characteristics of the motor for modification and verification of the preliminary design. Thus a 1/8th of the model is made in Cedrat-FLUX 3D software for FE analysis. The air gap is varied to achieve the required flux density in the air gap and to prevent saturation of the core while loading the motor. A winding scheme is proposed to attain low resistance and hence to reduce the loses. The proposed magnet shaping in order to achieve triangular flux linkage and thus a trapezoidal back EMF too is studied by using FEM analysis. The shape of the magnet helps to reduce cogging torque imposing that the stator slot skewing is not necessary, which simplifies the manufacturing of the stator. The FE simulation is done in the generation mode of the motor to attain the hall sensor positions for motoring mode operation. A three phase bride circuit is made and coupled with the machine model in Flux for loading. For optimal phase excitations, the motor presents good efficiency and output torque with smaller ripple, and becomes a promising solution for the electric/hybrid motorcycle of required specifications.

Partial Discharge in insulation Voltage Endurance Test (V.E.T) for High Voltage Turbo Generator   

Amir Firoozshahi, Islamic Azad University-Damavand branch, Tehran, Iran

The use of mica based insulation and its application in high voltage machines has been improved and optimized within the last 50 years and it has reached a level where further improvements seem difficult to achieve. The purpose of the Voltage Endurance Test (in this paper) is to determine the Partial Discharge Parameter of stator winding bar insulation for a 160 MW Turbo Generator (U rated=15.75 kV). The insulation was produced on the basis of «impregnated tapes» (Resin-Rich)

process. The test Samples are sections of the actual bar used in the 160 MW Turbo Generators. The Partial Discharge was measured before VET and compared with values during voltage endurance test. Four Samples were tested in a furnace with air mixing, equipped with a high-voltage input. The bar insulation temperature was maintained at a level of 100 °С. The Sample temperature was measured with the help of 24 thermocouples. Sample lifetime at V.E.T. is shown in this paper. This paper presents results of the Insulation voltage endurance test (V.E.T.)