Analysis of the dynamics of the linear-and-rotary-motion energy-conversion systems with active DC excitation
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The objective of the dissertation is to develop simplified analytical models for typical linear-motion and rotary-motion energy-conversion systems under active DC excitation without tedious numerical-simulation effort, and provide practical implementation of the models in optimal-design and thermal-protection aspects. The model of a vacuum automatic circuit recloser (a typical linear-motion system under DC excitation) is first developed in the form of a non-linear discontinuous eighth-order dynamic system. The model is then used to simulate the transient mechanical and electromagnetic performance during the opening and closing movements of the recloser. Such a model is not found in the literature. Although the model is based on certain simplifying assumptions, the result is validated by high-speed-camera measurements. In addition, the impact of key design variables is explored, based on which an improved recloser design is proposed, and helps to optimize capital and production costs without degrading performance. Further analytical investigation is carried out in modeling an inverter-fed induction motor (IM) (a typical rotary-motion system) with active DC injection. The IM is closed-loop controlled via two popular motor-control algorithms, namely, the direct-torque-control (DTC) algorithm and field-oriented-control (FOC) algorithm. Quantitative relationships between the changes of various machine variables during the active DC excitation are provided in the theoretical analysis. The developed DC-injection model is further simplified for practical implementation. The developed IM model under DC injection results in practical ways to excite a proper amount of DC current directly or indirectly into IM stator windings via different closed-loop motor-control algorithms. In a DTC motor-drive system, the modeling work makes it possible to excite the DC current indirectly inside the motor by superimposing a stator-flux-linkage-bias command in the flux-control loop or a torque-ripple command in the torque-control loop. The proposed flux-linkage-injection and torque-injection methods are the first novel efforts to implement the DC-signal-injection method in a DTC motor-drive system. In addition, the analysis carried out in a standard FOC drive system brings about an improved DC-current-injection approach: the torque ripple in this method is significantly mitigated compared to all existing DC-injection methods in FOC systems. The proposed DC-injection methods, either in a DTC or an FOC system, lead to a simple, low-cost, accurate, and non-invasive thermal-monitoring scheme for closed-loop-controlled IMs, where the stator temperature is indirectly estimated from stator resistance. Furthermore, considering inverter non-idealities, there is a challenge for a typical inverter drive to accurately estimate the DC component of motor terminal voltages. The existing methods are extended to provide a complete study of the real-time signal-processing technique for both DTC and FOC algorithms, and are finally implemented in a custom-built programmable motor-drive system. The experimental results demonstrate that the proposed technique gives accurate and robust stator-temperature estimation, regardless of the operating conditions and cooling modes. The analytical modeling method for the linear-motion and rotary-motion energy-conversion systems can be further extended to other power devices with similar mechanisms, and implemented in optimal design, control, and thermal-protection areas.