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Nowadays, to simplify manufacture process and improve fault-tolerant capability, more and more modular electrical machines are being applied in industrial areas. The purpose of this paper is to investigate a novel modular single-sided flat permanent magnet linear synchronous motor (PMLSM), which adopts segmented armature with the required flux gaps between segments to enhance the performance.

Using 2D finite element analysis, the performances, such as open-flux linkage, back-EMF, average thrust force, thrust ripple, etc., are compared in different values of flux gaps, as well as different slot/pole number combinations (mainly odd numbers of poles). Finally, to show the difference of linear motor from rotary one, the detailed comparison is made between modular PMLSM and rotary PMSM.

Due to flux gaps, it is found the electromagnetic performances are worsened along with flux gap width increasing to modular PMLSMs having slot number higher than pole number, but some aspects of performances such as winding factor, open-circuit flux linkage, back-EMF and average thrust can be improved to those having slot number lower than pole number. Due to the end effect of linear format, the thrust ripple is not significantly improved.

It is concluded the proper flux gaps can be chosen to improve the performance of PMLSM with certain slot/pole combinations. A new structure of 12-slot-13-pole (hereinafter referred to as 12s/13p) PMLSM with fractional slot and alternative-teeth wound winding is designed.

Permanent magnet linear synchronous machines (PMLSMs) have large thrust ripple due to the longitudinal end effect caused by the finite length of the armature compared with rotary machines. The purpose of this paper is to analyze the influence of electric loading on thrust ripple performances based on a 12 slots/14 poles (12S/14P) PMLSM. Furthermore, the method of skewed PMs to reduce thrust ripple is investigated based on multi slices 2D finite element (FE) models.

The thrust ripple of PMLSM under open-circuit condition results from the slotting and the longitudinal end effects. Therefore, periodical model has been designed to clarify the effect of the longitudinal end effect. Under on-load condition, the thrust ripple increases and exhibits an effective component of thrust force. To analyze the thrust ripple under on-load condition, frozen permeability (FP) technique is employed. In addition, the method of skewed PMs is analyzed in this paper to obtain more smooth thrust force performance. The effectiveness of skewing accounting for skew angles, step skew numbers and slot/pole number combinations was highlighted.

The longitudinal end effect dominates the thrust ripple of PMLSM in both cases, i.e., open-circuit and on-load conditions. Under on-load condition, the second harmonic component of thrust ripple related to flux linkage harmonics increases significantly. Moreover, the effectiveness of skewed PMs is largely reduced with the increase of magnetic saturation. At last, a proper skew angle and step skew number are obtained for the conventional PMLSM with fractional-slot winding.

By 60 electrical degrees and two or three step skewed PMs, the thrust ripple can be decreased to a tolerable limite for conventional PMLSM. The thrust ripple harmonics contributed by longitudinal end effect and flux linkage harmonics are analyzed, respectively, which is beneficial to exploring other techniques such as adding end auxiliary teeth to obtain lower thrust force pulsation.

With the popularization of permanent magnet linear synchronous machines (PMLSMs) in recent years, the temperature rise has attracted increasingly attention since excessive heat generated in the windings could deteriorate the electromagnetic performance. In order to solve this problem, adopting water-cooled system is an effective method. The purpose of this paper is to investigate a 12-slot/11-pole (12S/11P) water-cooled double-sided PMLSM, which adopts the all teeth wound concentrated winding and shifted armature ends.

Based on 2D finite element analysis (FEA), the thermal performances, such as temperature distribution, the optimization of water flow rate and the influence of demagnetization, are investigated under the condition of continuous duty. Then the maximum current density and average thrust force are calculated for PMLSMs with or without water-cooled system. Finally, the detailed comparison is made between single-sided PMLSM and double-sided PMLSM.

With water-cooled system, the thermal performance of PMLSM can be improved, such as an efficient decrease of temperature rise, restriction of permanent magnet demagnetization and a dramatic increase of the maximum thrust force. It is found that the water flow rate has a significant impact on temperature rise, which can be optimized according to demands.

Electromagnetic and thermal coupled analysis is proposed in this paper. It can approximately predict thermal performance and save the manual iteration time at the same time. This method also can provide as a reference of thermal analysis for other PMLSMs.