臺灣博碩士論文加值系統

在世界能源短缺及人本科技至上的時代，工具機在所有的科技中仍然是基礎的重要工程。傳統的工具機在高扭力操作下，往往因為龐大的慣量和複雜的機構，使得難度高加工的精度受到很大的限制；尤其在造型上複雜且特殊產品上，可以提供複雜曲面要求的多軸工具機將取代傳統的工具機成為加工機的主流。對多軸工具機來說，馬達本體主宰整個機械的傳動系統，本論文研發的新型直接驅動工具機扭力馬達將超越傳統工具機加工的限制，進而提升工具機的伺服性能以方便產品的大量生產。
本論文研究目標在於完成一個完整的直驅式工具機馬達設計與製造流程。首先，從設計觀點，由建立扭力馬達的設計方程式開始，利用最佳化程式針對特定的目標和規格需求來提升馬達的性能。接下來使用控制的方法，研發出最佳的驅動電流波形再加上最適合的偏移角(shift angle)，使得馬達的力矩與效率再一次的提升。根據馬達雛型的製作和測試結果，我們提出的設計流程可以優化馬達的各部特性，且性能亦符合規格的要求。本研究對新型扭力馬達所提出的設計與控制技術已經移轉至一間在世界頗具盛名的工具機公司。

Machine tools are most important and fundamental in the industry, especially at present, where there are great concerns about energy shortage and human-centered technologies. Traditional machine tools indirectly driven by conventional motors do not always operate efficiently, due to their mass moment of inertia and complexly coupled mechanisms. Today, a new competitive environment is emerging and forcing the evolution of machine tools for increasing efficiency over a wide range of operation. A directly driven torque motor has become a promising solution to the next-generation multi-axis machine tool, for its flexibility and intelligence in mass production.
This thesis introduces a systematic design and control procedure of torque motor for the next-generation machine tools that operate with high torque and low ripples. From the design perspective, the optimal design of motor geometry maximizes the output torque and efficiency; it also minimizes the cost under various constraints of size, materials and power sources. From the control perspective, an optimal current control waveform with an optimal shift angle in each phase is determined in order to increase more output torque. A prototype is fabricated, and the experimental results not only show that the motor meets all the performance requirements, but also prove the reliability of the proposed design procedure. The design and control technology of this novel torque motor has been transferred to a world-class prestigious machine tool company.

Contents
中文摘要 I
Abstract II
List of Tables VII
List of Figures VIII
Nomenclature XIII
Chapter 1 Introduction 1
1.1 Introduction 1
1.2 Example Applications 3
1.3 Performance Comparison for Different Motor Structure 6
1.4 Motivation 7
1.4.1 Geometric design 8
1.4.2 Controller design 9
1.5 Objectives and Proposed Design Method 10
1.5.1 Ring motor design 10
1.5.2 Direct-drive mechanism with low ripple 11
1.5.3 Water cooling 11
1.6 Organization of the Thesis 11
Chapter 2 Preliminary Design 15
2.1 Introduction 15
2.2 Design Process 15
2.3 Deign Specifications 17
2.4 Determination of the Winding Type 18
2.5 Determination of the Number of Slots and Poles 21
2.6 Comparison of Different Slot and Pole Numbers 28
2.6.1 Motor type with 72slots and 48 poles 28
2.6.2 Motor type with 60 slots and 50 poles 29
2.6.3 Motor type with 48slots and 44 poles 31
2.7 Performance Test with Different Slot/Pole Numbers 33
2.7.1 Torque ripples analysis 33
2.7.2 Torque production analysis 34
2.7.3 Summary 36
Chapter 3 Optimal Design of Motor Geometry 39
3.1 Introduction 39
3.2 Geometry Description 39
3.3 Sinusoidally Excited Magnet Shape Design 41
3.3.1 Magnetic potential definition 42
3.3.2 Sinusoidal excited magnet Arc shape design [12] 43
3.3.3 Comparison among different magnet shapes 46
3.4 Construction of Magnetic Circuit Model 47
3.4.1 Magnetomotive force distribution 48
3.4.2 Air gap distribution 50
3.4.3 Flux density distribution in the air gap 52
3.4.4 Torque equation 53
3.5 Calculation of Other Objective Function 54
3.5.1 Ohmic loss [29] 54
3.5.2 Core loss [29] 56
3.5.3 Phase inductance 58
3.5.4 Maximum speed of rotation 64
3.6 Sensitivity Analysis 66
3.7 Multi-Functional Optimal Design 82
3.8 Optimal Design Process 84
3.9 Final Element Analysis 89
3.9.1 Motor performance refinement 91
3.9.2 Verification of magnetic circuit by FE analysis 95
3.10 Thermal Analysis 97
3.10.1 Air cooling (free convection) 101
3.10.2 Water cooling 103
3.11 Motor Performance Display 108
Chapter 4 Optimal Current Waveform 111
4.1 Introduction 111
4.2 Motor Drive Topology 111
4.2.1 Rectangular current 112
4.2.2 Sinusoidal current drive 114
4.3 Optimal Current Waveform 116
4.3.1 Analysis of torque production 116
4.3.2 Optimal Current Waveform 118
4.4 Ideal Current Shift Angle 119
4.5 Design Model Analysis 121
4.6 Control Structure 125
4.7 Determination of Motor Variables 127
4.7.1 Torque constant and back EMF constant 127
4.7.2 Equivalent inductance and resistance 130
4.7.3 The mass mount of inertia 131
4.8 Control System Structure 131
4.9 Torque Calculation Above Base Speed 133
4.9.1 The block for the limitation of input current [48] 134
4.9.2 Input current waveform with limitation 135
4.9.3 The block for torque equation 136
Chapter 5 Machine Insulation and Fabrication 139
5.1 Introduction 139
5.2 Motor Insulation 139
5.2.1 Insulation system application 139
5.2.2 Random-wound motor 140
5.2.3 Form-wound motor 142
5.2.4 Material selection and insulation design 144
5.3 Machine Fabrication 146
5.3.1 Arrangement of stator and rotor 146
5.3.2 Mount of highly rigid bearing 147
5.3.3 Motor housing 150
Chapter 6 Experiment and Discussion 153
6.1 Introduction 153
6.2 Modification of Prototype 153
6.2.1 Axial length modification 153
6.2.2 Winding layout modification 154
6.3 Experimental Instrument 156
6.4 List of experiments 161
6.5 Back EMF Experiment 164
6.6 Temperature Experiment 167
6.7 Motor Performance Experiment 171
6.8 Comparison and Discussion 184
Chapter 7 Conclusion and Future Work 189
7.1 Conclusion 189
7.2 Future Work 191
References 193
Appendix A 198
Appendix B 204
Appendix C 205

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