Brushless Wound-Field Synchronous Machine Topology with Excellent Rotor Flux Regulation Freedom

This paper presents a nine-switch inverter for brushless operation of wound-field synchronous machines with excellent rotor flux regulation freedom. The manufacturing cost of permanent magnet machines is high due to the instability of rare-earth magnet prices in the global market. Moreover, conventional wound-field synchronous machines (WFSMs) have problems with their rotor brushes and slip-ring assembly, wherein the assembly starts to malfunction in the long run. Furthermore, recently, some brushless WFSM topologies have been investigated to eliminate the problems associated with rotor brushes and slip rings, but they have either a high cost due to a double-inverter, or low flux regulation freedom due to a single inverter (−i_d). The proposed nine-switch topology achieves a low cost by using a single inverter with nine switches and excellent flux control through three variables (−i_d, i_q, and i_f), making it highly suitable for wide-speed applications. In the proposed topology, the machine’s armature winding is divided into two sets of coils: ABC and XYZ. A 12-slot and 8-pole machine stator is wound with armature winding coils ABC and XYZ, creating six terminals for injecting currents and two neutrals from each ABC and XYZ coil set. The current to the ABC and XYZ coils is supplied by a nine-switch inverter. The inverter is specially designed to supply rated currents to the ABC winding coils and half of the rated current to the XYZ winding coils. The number of turns of the ABC and XYZ winding coils are kept the same so they produce the same winding function. However, the current in the XYZ winding coils is half compared to that of the ABC winding coils, which creates an asymmetrical airgap magnetomotive force (MMF). The asymmetrical airgap MMF contains two working harmonics, i.e., fundamental MMF for torque production and an additional sub-harmonic MMF component for rotor field brushless excitation. The rotor field is controlled by the difference in current of the two armature winding coils: ABC and XYZ. The proposed topology is validated through theoretical analysis and finite element simulations of electromagnetic and flux regulation. A 2D finite-element analysis is performed to verify the idea. The proposed topology is capable of establishing a 9.15 A dc current in the rotor field winding coil, which consequently generates a torque of 7.8 N·m with a 20.30% torque ripple. Rotor field flux regulation was analyzed from the stator ABC and XYZ coils current ratio ζ. The ratio ζ is analyzed as 2 to 1.3; subsequently, the inducted field currents were 9.15 A dc to 4.8 A dc, respectively.