Mihaly Katona

24448147500

Publications - 8

Robustness of a flux-intensifying permanent magnet-assisted synchronous reluctance machine focusing on shifted surface-inset ferrite magnets

Mihaly Katona Tamas Orosz

Publication Name: Computers and Structures

Publication Date: 2025-09-01

Volume: 316

Issue: Unknown

Page Range: Unknown

Description:

Flux-intensifying permanent magnet-assisted synchronous reluctance machines use relatively small amounts of non-rare earth permanent magnets, making them viable alternatives for remanufacturing older machines, aligning with EU directives and circular economy principles. The asymmetric rotor topology is particularly suited for micromobility applications, which benefit from shifting inset magnets, as reverse motoring is rarely required. However, this design could be more sensitive to manufacturing and positioning errors of the magnets. To investigate the effects of the uncertainties of the shifted surface inset magnets, first, an optimal topology is selected based on average torque, torque ripple, and cogging torque using the NSGA-II optimisation method. The effects of the magnet shifting and its robustness are analysed using the Taguchi and ANOVA methods, validated by Full Factorial calculations. Results indicate a 31.25 % reduction in permanent magnet volume without compromising torque output with magnet shifting. The machine's average and cogging torque remain within a 5 % robustness threshold for a ±0.06 mm discrete manufacturing tolerance. Torque ripple may exceed this limit up to 14.77 %. However, the likelihood of exceeding the threshold is only 12.10 %. The reduced magnet volume and maintained performance make this topology a promising option for remanufactured machines in micromobility applications, supporting circular economy goals.

Open Access: Yes

DOI: 10.1016/j.compstruc.2025.107845

Parameter Sensitivity Analysis and Rotor Topology Optimisation of a Synchronous Reluctance Machine

Mihaly Katona Tamas Orosz

Publication Name: Lecture Notes in Networks and Systems

Publication Date: 2025-01-01

Volume: 1258 LNNS

Issue: Unknown

Page Range: 14-23

Description:

As environmental policies tighten and consumers demand sustainable products, transitioning from a linear to a circular economy is crucial. A promising approach to circular economy is remanufacturing end-of-life electric machines to meet original or new specifications. Designing a rotor for remanufacturing with a different topology to fulfil the new requirements is a complex, non-linear optimisation task. In this paper, a permanent magnet-based synchronous machine is transformed into a synchronous reluctance machine with a new rotor topology. In this research, the Taguchi method is used to estimate parameter sensitivity. For optimisation, the Non-dominated Sorting Genetic Algorithm II was selected. Multi-criteria decision-making methods also helped choosing the optimal designs for maximum torque and minimal torque ripple. The sensitivity analysis revealed that the cut-off barrier shape significantly affects the average torque. In contrast, the height of the inner flux barrier had the most negligible effect. Most parameters showed almost the same magnitudes to torque ripple except for the height of the flux barrier, which again was the least significant. TOPSIS and SPOTIS methods using statisticalvariance and entropy weights showed some disagreements, indicating the complexity of selecting the optimal design.

Open Access: Yes

DOI: 10.1007/978-3-031-81799-1_2

Circular Economy Aspects of Permanent Magnet Synchronous Reluctance Machine Design for Electric Vehicle Applications: A Review

Mihaly Katona Tamas Orosz

Publication Name: Energies

Publication Date: 2024-03-01

Volume: 17

Issue: 6

Page Range: Unknown

Description:

Innovative technological solutions have become increasingly critical in addressing the transportation sector’s environmental impact. Passenger vehicles present an opportunity to introduce novel drivetrain solutions that can quickly penetrate the electric vehicle market due to their shorter development time and lifetime compared to commercial vehicles. As environmental policy pressure increases and customers demand more sustainable products, shifting from a linear business approach to a circular economy model is in prospect. The new generation of economically competitive machines must be designed with a restorative intention, considering future reuse, refurbishment, remanufacture, and recycling possibilities. This review investigates the market penetration possibilities of permanent magnet-assisted synchronous reluctance machines for mini and small-segment electric vehicles, considering the urban environment and sustainability aspects of the circular economy model. When making changes to the materials used in an electric machine, it is crucial to evaluate their potential impact on efficiency while keeping the environmental impact of those materials in mind. The indirect ecological effect of the vehicle’s use phase may outweigh the reduction in manufacturing and recycling at its end-of-life. Therefore, thoroughly analysing the materials used in the design process is necessary to ensure maximum efficiency while minimising the environmental impact.

Open Access: Yes

DOI: 10.3390/en17061408

Remanufacturing a Synchronous Reluctance Machine with Aluminum Winding: An Open Benchmark Problem for FEM Analysis

Miklós Kuczmann Mihaly Katona Tamas Orosz Zoltan Nemeth Dávid Gábor Bányai

Publication Name: Electronics Switzerland

Publication Date: 2024-02-01

Volume: 13

Issue: 4

Page Range: Unknown

Description:

The European Union’s increasing focus on sustainable and eco-friendly product design has resulted in significant pressure on original equipment manufacturers to adopt more environmentally conscious practices. As a result, the remanufacturing of end-of-life electric machines is expected to become a promising industrial segment. Identifying the missing parameters of these types of machines will play an essential role in creating feasible and reliable redesigns and remanufacturing processes. A few case studies related to this problem have been published in the literature; however, some novel, openly accessible benchmark problems can facilitate the research and function as a basis for comparing and validating novel numerical methods. This paper presents the identification process of an experimental synchronous machine. It outlines methodologies for identifying material properties, winding schemes, and other critical parameters for the finite element analysis and modelling of electric machines with incomplete information. The machine in question is intended for remanufacturing, with the plan to replace its faulty winding with an aluminium-based alternative. It also serves as an open benchmark problem for researchers, designers, and practitioners.

Open Access: Yes

DOI: 10.3390/electronics13040727

Accuracy of the robust design analysis for the flux barrier modelling of an interior permanent magnet synchronous motor

Miklós Kuczmann Mihaly Katona Tamas Orosz

Publication Name: Journal of Computational and Applied Mathematics

Publication Date: 2023-09-01

Volume: 429

Issue: Unknown

Page Range: Unknown

Description:

Mass-produced electrical machines are subjected to manufacturing uncertainties in terms of geometry. A robust design is inevitable to ensure the consistent performance of the electric motor. Some parts of the rotor geometry are often simplified, like the flux barrier at the end of the magnets. This paper presents a design optimisation regarding the torque ripple and the average torque. The aim is to assess the effects of the flux barrier on the main properties of a permanent magnet synchronous motor. Also, robust design analysis is presented on the flux barrier. The computational burden of the robust design analysis is immense, even if uniform uncertainties are assumed. In this case, different Design of Experiment (DoE) methods reduce the number of simulations. The efficiency of the DoE methods is compared in terms of simulation number and extreme value approximation. We found that the Central Composite method is the most accurate, while the Plackett–Burman is the most efficient in this particular case.

Open Access: Yes

DOI: 10.1016/j.cam.2023.115228

Cogging Torque Analysis of Toyota Prius 2004 IPMSM Motor with the Digital-Twin-Distiller

Mihaly Katona Péter Kiss Tamas Orosz Krisztián Gadó

Publication Name: Lecture Notes in Mechanical Engineering

Publication Date: 2023-01-01

Volume: Unknown

Issue: Unknown

Page Range: 126-138

Description:

With the recent advancements of the fourth industrial revolution, many sensors are implemented into the products that collect the data and monitor their performance. The measurement data can be stored with the numerical models as a digital twin, and these can serve as a virtual replica of a physical object or process. These digital twins can improve the design and optimization process. The paper uses an open-source tool, the Digital-Twin-Distiller, which can encapsulate the realized finite element analysis of a model into a web application, which can be integrated easily into an optimization chain or any other business process. The paper proposes a numerical model and cogging torque analysis of an interior permanent magnet synchronous machine. The paper examines the effect of two parameters of the magnet groove shape on the cogging torque of the Prius 2004 motor model. It was found that the cogging torque of the motor is highly dependent on the shape of the flux barrier, even with minor changes. On the other hand, the wedge between the two magnets does not affect cogging torque much.

Open Access: Yes

DOI: 10.1007/978-3-031-15211-5_11

Locked-rotor analysis of a Prius 2004 IPMSM motor with Digital-Twin-Distiller

Mihaly Katona Tamas Orosz

Publication Name: 2022 IEEE 20th International Power Electronics and Motion Control Conference Pemc 2022

Publication Date: 2022-01-01

Volume: Unknown

Issue: Unknown

Page Range: 201-208

Description:

In this paper, an open-source tool, the Digital-Twin-Distiller, is used, which can encapsulate the realized FEM model into a web application as a digital twin. Many papers have proposed the cogging torque and the locked-rotor FEM calculations of the Toyota Prius 2004 motor. However, these models have minor differences, mainly in rotor topology. This paper presents a fully defined motor model and the effect of the flux barrier shape on the locked-rotor simulations. The results show that minor structural changes in the flux barrier's shape in the manufacturing tolerance range significantly affect the calculated torque.

Open Access: Yes

DOI: 10.1109/PEMC51159.2022.9962847

Identification for Remanufacturing of a Synchronous Reluctance Machine Considering the Circular Economy Conditions

Miklós Kuczmann Mihaly Katona Tamas Orosz

Publication Name: Chemical Engineering Transactions

Publication Date: 2023-01-01

Volume: 107

Issue: Unknown

Page Range: 469-474

Description:

Due to the growing pressure from governmental entities and customers in the European Union, Original Equipment Manufacturers are being pushed to design and manufacture sustainable and environmentally friendly products. A profitable industrial segment is expected to emerge from recycling end-of-life electric machines. This paper aims to identify an experimental synchronous reluctance machine with faulty copper windings to remanufacture the machine. The rewound design aims to achieve similar or improved characteristics and fit the novel requirements of the circular economy. The recyclability of the machine can be significantly increased by changing the copper windings to aluminum-based hairpin windings. The paper shows the geometrical, material, and winding identification plus finite element method-based analysis of the initial machine. The electric machine’s slot-filling factor can be improved using an appropriate aluminum-based hairpin winding design compared to the original, even in the case of standard slots where the sides of the slots are not parallel.

Open Access: Yes

DOI: 10.3303/CET23107079