An Industrial Switched Reluctance Motor Drive: Design, Implementation, and Acoustic Noise Modeling and Reduction

Abstract

This thesis presents the design, implementation, and acoustic noise modeling and reduction for an industrial switched reluctance motor drive. Although SRMs offer advantages such as simple construction, fault-tolerant operation, and cost-effective manufacturing, their adoption in various applications can be limited due to high torque ripple, acoustic noise, and challenges associated with power converter and control implementation. To overcome these limitations for industrial applications, a high-efficiency, Silicon-Carbide (SiC), 10 kW, bidirectional SRM drive has been developed and experimentally validated. The proposed drive enables compatibility with single- and three-phase AC sources as well as DC power sources, offering a flexible and efficient solution for modern industrial systems. To understand the fundamentals of acoustic noise modeling, a multi-physics simulation workflow is first established accounting for the switching effect introduced by the inverter drive. This workflow involves electromagnetic, modal, and harmonic response analyses, allowing the extraction of radial and tangential forces, vibration modes and their natural frequencies, and the motor’s acoustic signature in the form of Equivalent Radiated Power (ERP) level. The same workflow is then applied to an SRM to evaluate its acoustic noise performance under different current control techniques. The simulation results are correlated with experimental measurements of Sound Power Level (SWL), obtained using the developed drive with an SRM mounted on a dynamometer setup. The outcomes of this work demonstrate that industrial SRM drives are feasible, and that acoustic noise can be effectively modeled and reduced through the application of appropriate current control techniques, offering a clear path forward for industrial electrification using SRMs.