Brushless Doubly-Fed Reluctance Machine

Rotor Design

Andrew M. Knight Robert E.Betz

Department of Electrical and Computer Engineering School of Electrical Engineering and Computer Science
University of Alberta University of Newcastle
Edmonton, AB, Canada Callaghan, NSW, Australia
[email protected] [email protected]

William K. Song and David G. Dorrell

School of Electrical Engineering
University of Technology Sydney
Sydney, NSW, Australia
[email protected] and [email protected]

Abstract— This paper investigates the rotor design factors that

impact the performance of brushless doubly-fed reluctance
machines (BDFRMs). The performance of the BDFRM relies
on the ability of the rotor structure to modulate stator
magnetic fields so that magnetic coupling occurs between
stator windings that do not otherwise interact. This paper
investigates those factors that create the desired magnetic
coupling and those that can cause undesirable magnetic
performance. Theoretical analysis is compared to test results
from an early prototype BDFRM and then applied to the
design of a new BDFRM. New designs are explored using
Finite Element Analysis. A prototype, based on these
investigations is under construction.
Fig. 1 Schematic diagram to illustrate the supply connection of a
BDFRM, with two stator windings, coupled via a rotor reluctance.
I. INTRODUCTION
Brushless doubly-fed machines (BDFMs) are a class of The publications on BDFMs largely fall into two categories,
electrical machine with two stator winding sets. Control of those that use a nested-loop rotor cage-like structure to create
power flow between the windings and the rotor shaft occurs linkage between stator windings (BDFIM) and those that use
through the rotor design, which modulates the magnetic rotor reluctance (BDFRM). This paper addresses issues in
coupling between the stator windings. A schematic diagram the design of brushless doubly-fed reluctance machines
of the connection of a brushless doubly-fed reluctance (BDFRMs) in an attempt to illustrate the factors which
machine (BDFRM) is presented in Fig. 1. positively and negatively influence BDFRM operation. The
recent research into BDFRMs has shown that they may be
The BDFM has its origins in the Cascade Induction
capable of operating with high efficiency and torque density
motor, an idea which is almost 100 years old [1] [2]. Interest
[19][20][21]. The work presented in [20] and [21] has shown
in brushless doubly-fed machines increased again in the
that theoretically, a segmented rotor (with rotor flux guides
1990s [3]-[7] and 2000s [8]-[19]. In the last two years,
and ducts) offers better coupling between stator windings
interest in this type of machine has again increased rapidly,
than when a salient pole rotor is used. Earlier research [16]
A search for “brushless doubly-fed” in IEEE Xplore returns
has shown that an axially laminated structure is subject to
over 50 publications from 2011 up to the time of writing in
excessive eddy current losses in the rotor laminations. This
2012. Examples of these publications include [20]-[27].
fact has been recognized previously with synchronous
Despite this interest, there are still few BDFMs in operation.
reluctance machines, with many designs using a radially
laminated rotor with appropriate design of flux guides which
This work is sponsored by the Australian Research Council, grant number offers desirable performance with affordable manufacturing
DP1096356. The authors are grateful for this support.

978-1-4673-0803-8/12/$31.00 ©2012 IEEE 2308

[28][29]. Unlike synchronous reluctance machines, there is positive frequency, the rotor speed and motor output power
little published information about appropriate design of will increase as power flows from the variable frequency
radially laminated rotors for a BDFRM. This paper aims to supply into the machine through the secondary winding. If
address this issue. the secondary winding supply is adjusted to a negative
frequency (against the direction of rotation), the rotor speed
II. PRINCIPLES OF OPERATION decreases and the secondary winding will regenerate.
All BDFMs, whether of the BDFIM or BDFRM variety,
operate under a similar principle. Two stator windings are III. IDEAL ROTOR ANALYSIS
wound with differing pole numbers. If the rotor has no The rotor of a BDFRM should have a high saliency ratio.
saliency or there is no rotor winding, there should be no Past research has considered axially laminated machines
coupling between the two stator windings. However, BDFMs [12], salient pole machines [22], and ducted (or
are built with rotors that are specifically designed to create “segmented”) rotor designs [19]. A segmented rotor structure
coupling between these stator windings. In the case of a is similar to the rotor design for a synchronous reluctance
BDFIM, a rotor winding is designed such that it has machine and an idealized design is illustrated (for a 4–pole
magnetic coupling with both stator windings, indirectly rotor) in Fig. 2.
resulting in coupling between the stator windings. In a
BDFRM, a reluctance structure is used to directly couple the
two stator windings. It is an opinion of the authors that an
appropriately designed BDFRM may offer higher efficiency
than a BDFIM, due to the fact that the BDFRM does not
suffer from rotor winding losses.
In this paper, one stator winding is referred to as the grid
winding, and is directly connected to the line supply without
control. The other winding which is controlled with a
variable speed drive is called the secondary winding. This
arrangement is shown in Fig. 1. Coupling between the stator
windings of BDFM occurs under the following constraints
[11]. Fig. 2 Illustration of an idealized segmented rotor

pg + ps ωg + ωs In the idealized case, the ducted rotor design may be

pr = ωm = (1) thought of as a flux guide. Linearizing the geometry of Fig. 2
2 pr results in the geometry shown in Fig. 3. Note that the
mathematical analysis of an ideal ducted rotor is similar to
⎛ p − ps ⎞ ⎛ ωg − ωs ⎞ that of an ideal axially laminated rotor .
pr = ± ⎜ g ⎟ ωm = ± ⎜ ⎟ (2)
⎝ 2 ⎠ ⎝ pr ⎠
In (1) and (2), pg, ps and pr are the grid winding, secondary
winding and rotor pole numbers respectively; ωg, ωs are the
grid winding and secondary winding electrical angular
supply frequencies and ωm, is the rotor mechanical speed in
radians / sec. Analysis of the second case, where the rotor
pole number is given by the difference between the stator
winding pole numbers has been shown to not provide the
desired coupling for some pole combinations [20] and may Fig. 3 Linearized ideal rotor geometry.
result in designs that are not practical for manufacture. This Considering the geometry in Fig. 3, if the steel is
paper concentrates on designs that meet the criteria described infinitely permeable, the flux entering the rotor at a given
in (1).
point in the air gap, θ1 must be equal to the flux exiting the
To understand the operation of a BDFRM it may help to rotor at θ2, where the angles are related by
consider an example case. Consider a machine with the pole
numbers pg=2, ps=6 and pr=4. If the secondary (control) θ 2 = θ1 + λr − 2α . (3)
winding is excited with DC current whilst the grid winding is
connected to a 60Hz supply, the rotor speed given by (1) is In (3), λr is the rotor segment angular period defined as
equal to 900rpm. Under this condition, the machine with a 4- 2π
pole rotor acts similarly to an 8-pole synchronous machine. λr = (4)
The secondary winding acts analogously to a field winding, pr
with the magnitude of the current controlling the flux
density, and hence torque and induced back-emf in the grid and α is the angular distance between θ1 and the start of the
winding. If the secondary winding supply is adjusted to a relevant rotor segment, calculated using

2309
 α = mod (θ1 − θ 0 , λr ) (5) The normalized air-gap flux den nsity waveforms produced
by each of the grid and stator wind dings at an instant in time
where θ 0 is the initial mechanical positionn of the rotor d- are plotted in Fig. 4 for three designn cases. In each case, the
axis. initial rotor mechanical position hass been arbitrarily set to 15
degrees.
If we now consider the flux density in thhe ideal case with
infinitely permeable steel, it is possible to calculate the air- The three cases in in Fig. 4 are (a) pg = 6, pr =4 , ps = 2;
gap flux density using Ampere’s Law and tthe summation of (b) pg = 8, pr = 6, ps = 4; (c) pg = 6,
6 pr = 5, ps = 4. It can be
two mmf functions at the angles definned by (3). To observed in all three cases that:
understand the impact of the rotor aand stator pole
combinations, the resulting flux density caan be normalized • the flux density in each segmennt is symmetric about the
relative to a 1.0 per unit flux density that w
would be obtained center of the segment, where the air-gap mmf is zero;
with a round rotor and identical air-gap length. • the flux density from one segment
s to the next is
discontinuous (each segm ment is magnetically
independent of the other segmen
nts).
Inspection of the plots in Fig. 4 also indicates that the flux
density is a function of the periodicc nature of the two stator
windings. In Fig. 4 (a) the 6-pole grid
g and 2-pole secondary
stator windings exhibit negative periodicity over 180°
mechanically. As a result the air-g gap flux density is anti-
periodic over any pair of points 180 0° apart. In Fig. 4 (b) the
8-pole grid and 4-pole secondary stator windings exhibit
positive periodicity over 180° mech hanically. As a result the
air-gap flux density is periodic over any pair of points 180°
apart. In both cases, the radial comp
ponent of reluctance force
(a) is balanced around the circumferencce of the machine. In Fig.
4 (c) a 5-segment rotor is used. Neither
N the 6-pole excited
grid flux density nor the 4-pole excited secondary flux
density exhibit symmetry around the t circumference of the
rotor. In this case, the radial forces are not balanced and
unbalance magnetic pull (UMP) sho ould be expected.
The exact shape of the ideal flu
ux density waveform is a
function of the angle between statoor currents and the rotor
position, however the above statem ments are valid for any
angle. This information can be useed when considering the
spacing and positioning of flux guid
des and flux barriers in a
realistic rotor design.
ms plotted in Fig. 4 gives
Fourier analysis of the waveform
(b) information about the ability of anny given rotor and stator
pole combination design to provid de coupling between the
grid and secondary windings. The magnitude
m of the Fourier
harmonics can be used as a couplingg factor that describes the
magnitude of a flux density harmonic relative to that
produced by a similar winding with a round rotor and no
saliency [20]:
μ
Bˆij = Cij 0 Mˆ gap j . (6)
g
In (6), Bˆ ij is the peak flux density of
o space order i resulting
from Mˆ gap j a winding air-gap mmf of
o space order j. Cij is the
coupling factor obtained from Fourier analysis of a
(c) waveform like the examples given in Fig. 4; g is the air-gap
Fig. 4 Idealized air-gap Flux Density ffunctions: length. Analysis using the coupling g factors has shown [20]
(a) p g = 6 , pr = 4 , ps = 2 ; (b) p g = 8 , pr = 6 , ps = 4 ; (c) that: (i) to maximize available grid electric loading, the grid
winding should have more poles than the secondary
p g = 6 , pr = 5 , ps = 4 .
winding; (ii) to maximize the secon ndary power factor for a

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given grid power factor, the grid and seccondary winding TABLE I. EXPERIMENTAL MOTOR DE
ETAILS (DIMENSIONS IN MM).

pole numbers should be as close together ass possible. Pole Combination pg = 6, ps = 2, pr = 4

Length 173.5
IV. EXPERIMENTAL VALIDATION OF IDEEALIZED THEORY Rotor diameter 63.1
This paper aims to use the foundation of the idealized Airgap length 0.425
Stator Slots 36
theory to develop manufacturable designss and investigate 2-pole turns per phase 60
how well those designs approach the iidealized theory. 6-pole turns per phase 180
However, as a first step, it is beneficial to vaalidate the theory 2-pole resistance 1.7
using an existing BDFRM. Previous rresearch on the 6-pole resistance 3.2
BDFRM [12][13][17], has led to the manufacture of Interpole dimensions (Fig. 5) x = 34, y = 15, z = 12
prototype machines with axially laminatted rotors. That
research has also shown that these machines can suffer from
excessive iron loss due to eddy currents. In this paper, a
previously manufactured machine is usedd to validate the
idealized rotor theory.
In general, the rms back-emf E inducedd in a winding of
an electrical machine due to flux density B̂ is given by
⎛ 2ω ⎞ ⎛ Bˆ ⎞
E = 2lr ( kw1 N ph ) ⎜ ⎟⎜ ⎟. (7)
⎝ p ⎠⎝ 2 ⎠
Extending this to the specific case with two sets of windings,
substitution of (6) into (7), together witth the analytical
expression for the air-gap mmf when ssaturation is not
significant, results in
Fig. 5 ng brass interpole and segment
Experimental axial rotor, showin
⎛ 2ω ⎞ ⎛ μ ⎞ ⎛ 6 ⎞
Eij = 2lr ( k w1 N ph ) ⎜ i ⎟ Cij ⎜ 0 ⎟ ⎜ ⎟⎟ ( k w1 N ph ) j I j . (8) spacing.
⎜
⎝ pi ⎠ ⎝ g ⎠ ⎝ π p j ⎠
i

Applying (8), it is possible to predict the opeen circuit voltage

induced in a grid winding, if the rms current flowing in the
secondary winding is known.
Experimental tests have been carried outt using the motor
shown in Fig. 5 and Fig. 6. Details of the design are provided
in Table I Unfortunately, full design details from the time of
manufacture were not available; details on w winding turns and
short pitching are based on counting turrns in the actual
machine and knowledge of the design proocess followed at
the time. As has been mentioned, it is know wn that an axially
laminated machine can suffer from high iron losses. To
reduce the impact of iron losses on testing,, tests are carried
out at reduced frequency with the rotor stationary. One set of
windings is excited at a time and the oppen circuit phase
Fig. 6 Stator of the experimental macchine, with 4-layer winding.
voltages in the other winding recorded. Froom (1) it is clear
that the windings will see the same fr frequencies, with
opposite phase sequencing. The experim mental facility is
shown in Fig. 7. A DC machine is uused to drive a
synchronous machine at low speed in orderr to generate low
frequency sinusoidal voltages. The test macchine is visible to
the right of the image, with a blue frame, annd is connected to
a dividing head to allow the rotor to be loocked and rotated
from point to point. Measurements were rrecorded using a
digital 3-phase power meter and analoggue oscilloscope.
Under locked rotor conditions, the phase voltages may be
unbalanced due to the position of the rotorr relative to each
phase. For this reason, tests were carried out at 5 degree
steps, for a total of 72 tests. An example off test results at 0°
is provided in Fig. 8.
Fig. 7 Experimental Test Facility

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 V. DESIGN CHOICES
Previous work, together with the validation in this paper,
indicates that there are some good and bad choices that may
be made in the early stages of the design of a BDFRM. In the
view of the authors, a good design should:
• Use radial laminations with flux barriers, similar to that
used in the design of synchronous reluctance machines.
This type of rotor design is known to have higher
saliency than traditional salient poles [28] and to avoid
the iron losses of axially laminated designs [16].
• Use an even number of rotor segments. An odd number
of rotor segments may lead to high levels of UMP [23].
A process to develop an initial full design has previously
been published [20]. However, that work assumes that one is
Fig. 8 Test result, 2-pole field excited at 2.948A, 10.375Hz, induced capable of designing and building a rotor to act as closely as
voltge waveforms in 6-pole winding. possible to the ideal case. In this paper, the initial design is
Averaging the results for all 72 cases, the average rms used as a starting point for the investigation of additional
rotor design factors. The starting design is summarized in
voltage induced in the 6-pole winding is 12.3 V rms. The
Tables III to V.
terminal voltage of the 2-pole winding is measured to be
11.84 V. Accounting for resistive voltage drop in the TABLE III. DESIGN SPECIFICATION.
winding, this corresponds to a back-emf of approximately Grid Winding Power 16 kW
6.8 V rms. Grid Winding Voltage 400 V
To validate the idealized theory, the measured current Grid Winding Frequency 50 Hz
and frequency of 2.95 A rms at 10.375 Hz, may be Grid Winding Power Factor 0.8 lagging
Synchronous Speed 500 r/min
substituted into (8). The coupling factor term required in (8)
RMS Specific Electric Loading 32000 A/m
is obtained by Fourier analysis of the waveforms in Fig. 4
(b); C22 = 0.1817 and C62 = 0.3183. Using this information, TABLE IV. VARIABLES CHOSEN BY DESIGNER.
the idealized theory predicts a back-emf in the 6-pole pg 8
winding of 12.1 V rms and a 2-pole winding back-emf 6.84 ps 4
V rms and terminal voltage of 11.85 V rms. This data is Saturation Factor 0.5
summarized in Table II Air gap radius 136.3 mm
Air gap length 0.65 mm
The agreement between the theoretical approach and the Secondary rated RMS current 16.7 A
test data is remarkably good. It is important therefore to Number of stator slots 48
stress the fact that the tests have been carried out at reduced TABLE V. CALCULATED DESIGN VARIABLES.
voltage and frequency. As a result, saturation and iron loss
effects are not significant, i.e., the tests more closely Stack length 251 mm
represent ideal conditions than typical running conditions. Stator Outside Diameter 420 mm
Notwithstanding this point, these results do indicate that the Peak grid-winding flux density 0.76 T
Peak secondary-winding flux density 0.53 T
idealized analysis is suitable for use for first principles Grid Winding Specific Electric Loading 16220 A/m
design and the theory developed in previous works is valid. Secondary Winding Specific Electric Loading 15780 A/m
The challenge in moving forwards, addressed in the Number of Gid and Secondary Turns/Phase 144 each
remainder of this paper, is to build a rotor design that is as Torque Density (negelecting end over hang) 8.6 x10-3 N⋅m/m3
close as possible to the ideal case, without the negative side Air gap volume torque density 20.9 x10-3 N⋅m/m3
effect that are found with use of axial laminations, UMP or Grid Self Inductance 46.0 mH
unwanted additional coupling between phases caused by, for Grid – Secondary Mutual Inductance 62.4 mH
example, 3rd harmonics due to saturation. Secondary Self Inductance 87.8 mH
Grid phase resistance 0.183 Ω
TABLE II. COMPARISON OF EXPERIMENTAL AND THEORETICAL Secondary phase resistance 0.367 Ω
VOLTAGES.
A radially-laminated BDFRM rotor with flux barriers is
V2 (V) E22 (V) E62 (V) similar to a synchronous reluctance rotor. An example of one
Experimental 11.84 6.83 12.3 segment of a 6-pole rotor design is shown in Fig. 9. The air
Idealized 11.85 6.84 12.1 flux barriers weaken the rotor structure which may lead to
deformation due to centrifugal forces during operation or
increase manufacturing difficulty as the lamination may be
less rigid than a traditional lamination. Structural FEA (using

2312
the JMAG commercial package) has been carried out on a
number of variations of the design in Fig. 9. All structural
analysis in the paper has been carried out assuming a
Young’s modulus of 152 GPa and Poisson’ss ratio of 0.3. Fig.
10 plots the structural deformation for three similar designs
with different numbers of structural bridgees across the flux
barriers. In each case, the actual deformatioon is scaled by a
factor of 1000, and the color map increasess from purple (no
deformation) to red (maximum deformattion). The initial
design, Fig. 10 (a), with many bridges, resullts in a maximum
predicted displacement of 3.1 μm. If the bridges are
removed, Fig. 10 (b), the ability of the rotorr to guide flux in
(a) (b) (c)
the desired path is improved, but the maximmum displacement
increases to 13.5 μm. In the final case, F Fig. 10 (c) three Fig. 10 Structural deformation due to centrifugal force at 500 rpm
bridges are re-introduced and the maximum m displacement is (scaled by 1000) with different numbers of bridges
b across flux barriers (a)
8 bridges; 3.1 μm peak deformation (b)) no bridges, 13.5 μm peak
4.8 μm. In all cases, the maximum displacement occurs near deformation, (c) 3 bridges, 4.8 μm
m peak deformation
the center of the segment. However, analyssis of the air-gap
flux density with an idealized rotor in Fig. 4 indicates that
the flux density in the center of each segment is low.
Therefore, it is possible to remove some oof the steel at the
center of the segment without significcant impact on
performance.

(a)

Fig. 9 Example rotor segment from a 6-pole rotor

Two possible modified rotor designs arre shown in Fig.

11. Both designs have identical flux barrierr designs. In Fig.
11 (a) the rotor is made up of 6 independentnt segments, fitted
to a shaft with dovetails. In Fig. 11 (b), tthe segments are
(b)
connected to form a single laminatioon. Independent
segments, as shown in Fig. 11 (a), may redduce leakage flux Fig. 11 Rotor designs: (a) each rotor seggment is independent from the
other segments, dovetail is needed for structtural support; (b) a single rotor
between segments and improve manufactuurability for large lamination with identical flux baarrier design to (a).
machines (similar to the construction of vvery large wound
field synchronous machines with independdent pole pieces).
These designs use a reduced amount of mateerial at the center
of each segment and feature progressive thhicknesses for the
flux paths between the flux barriers. Considering Fig. 4, it
can be seen that highest flux densities are ffound at the outer
edges of each segment, with lower flux dennsity towards the
center of the segments. The width of the flux guides is
adjusted to balance the flux density and saaturation in each
section, with the aim of reducing total relucctance of the flux
path and increasing the saliency. Comparingg the 2 designs in
Fig. 11, the design with individual rotor segments should
offer higher coupling between stator windiings as there is a
better barrier to prevent flux from passing beetween segments. Fig. 12 Structural deformation of new designs due to centrifugal force
at 500 rpm (scaled by 1000), peak deformation 0.75 μm

2313
 Structural FEA of the deformation due to centrifugal VI. CONCLUSIONS
force has been carried out and a deformation plot of a single The paper presents experimental validation of the
segment at 500 rpm is presented in Fig. 12. The peak analytical design process used to identify good initial design
deformation of the new design is only 0.75 μm, 25 % of that starting points when developing a BDFRM. Using the
observed in the design in Fig. 10 (a). analytical design process as a starting point, an initial design
The structural analysis indicates that the revised design is developed and the factors that effect good rotor design are
should be mechanically sound, whether or not constructed investigated. As a starting point, a good rotor design should
from a single lamination or individual segments. Next, have high saliency and be manufacuturable. The analysis
electromagnetic FEA is carried out to investigate torque presented also highlights the fact that there are a number of
production. FEA is carried out at 500 rpm, with both key design choices required to avoid excessive vibrations,
windings operating at rated current. The grid winding is including the choice of rotor pole number, slot number and
excited at 50 Hz, and the secondary winding has DC pole segment number. Structural FEA, together with ideal
excitation. The predicted torque waveforms for both new flux density analysis identifies regions of high deformation
designs are shown in Fig. 13. It should be noted that these that do not contribute to the overall performance of the
waveforms are produced from current-sourced FEA machine and may be removed. Idealized analysis highlights
simulations; a real machine will see current harmonics which the ability to use flux guides with progressive widths to
may reduce the magnitude of the observed torque ripple. It is distribute flux evenly and increase the mechanical strength of
clear that the individual rotor segments are subject to a the rotor. Electromagnetic FEA indicates that the new design
significant torque ripple at a frequency 8 times per supply is an improvement over the original. The laminations
cycle. The frequency of the torque ripple is equal to the slot developed in this paper have been cut and are shown in Fig.
passing frequency of the inter-segment space. This result 14. The motor is currently under assembly.
highlights an additional design constraint of segmented rotor
designs: in addition to avoiding the flux-barrier and slot
combinations highlighted for synchronous reluctance
machines for both stator winding pole numbers [29], a
machine with individual segments should also be designed
such that the slot number is not an integer multiplier of the
number of rotor segments. In the case of a 6-pole rotor, this
requirement implies the need for a distributed fractional slot
per phase per pole winding design, for both windings. The
magnitude of the sudden changes in torque is significantly
reduced if a single lamination with bridges between
segments is used, as shown in Fig. 13. The results indicate
that in a final design, introduction of rotor skew may be
necessary for acceptable torque ripple performance. A
summary comparison of the predicted performance of the
rotor structures in Fig. 9 and Fig. 11, with identical stator
designs and operating conditions is presented in Table VI.
350

300 Fig. 14 Machine laminations for assembly.

Torque (Nm)

250
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