This paper analyzes the impact of manufacturing tolerances on the cogging torque of a 24-slot 28-pole tooth-coil-winding permanent magnet synchronous machine with a modular stator core (TCW-MPMSM). Dimensional tolerances and asymmetries associated with the modular topology are studied by means of finite element simulations in order to identify key parameters that increase the cogging torque above the expected values of a faultless machine. Among five selected dimensional parameters, it was found that angular displacement, radial displacement, and tooth–tip width deviations of the stator segments have the most significant impact on the cogging torque. Considering these three key parameters, a full-range tolerance analysis is carried out by means of a proposed superposition-based approach, evaluating all possible combinations of typical deviation values. It is concluded that the cogging torque increment, generated by tolerances, is relatively independent of the faultless tooth–tip width of the stator segments and the arc-to-pole ratio. Robustness of the TCW-MPMSM, regarding cogging torque generation, depends on both the tightness of the tolerances handled in the manufacturing process and the rated cogging torque: the lower the cogging torque of the ideal machine, the less robust is the machine and, therefore, manufacturing imperfections will be required to be tightened.
The research on DC-DC power converters has been a matter of interest for years since this type of converter can be used in a wide range of applications. The main research is focused on increasing the converter voltage gain while obtaining a good efficiency and reliability. Among the different DC-DC converters, the flyback topology is well-known and widely used. In this paper, a novel high efficiency modified step-up DC-DC flyback converter is presented. The converter is based on a N-stages flyback converter with parallel connected inputs and series-connected outputs. The use of a single main diode and output capacitor reduces the number of passive elements and allows for a more economical implementation compared with interleaved flyback topologies. High efficiency is obtained by including an active snubber circuit, which returns the energy stored in the leakage inductance of the flyback transformers back to the input power supply. A 4.7 kW laboratory prototype is implemented considering four flyback stages with an input voltage of 96 V and an output voltage of 590 V, obtaining an efficiency of 95%. The converter operates in discontinuous current mode then facilitating the output voltage controller design. Experimental results are presented and discussed.
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