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0278 0046 c 2015 IEEE Personal use is permitted but republication redistribution requires IEEE permission See http www ieee org publications standards publications rights index html for more information This article has been accepted for publication in a future issue of this journal but has not been fully edited Content may change prior to final publication Citation information DOI 10 1109 TIE 2015 2494006 IEEE Transactions on Industrial Electronics IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS 1 Abstract Permanent magnetic actuators PMAs are usually used for vacuum circuit breakers VCBs due to their fast linear motion and large holding force As the holding force becomes larger so does the current capacity of the circuit breaker Producing a large holding force with the same PMA size is therefore important in PMA design This paper presents a design method of a PMA for vacuum circuit breakers To attain the desired holding force under the restriction of the PMA size most of the influential PMA yoke design parameters were obtained by Taguchi method PMA dynamic characteristics were simulated considering the electromagnetic characteristics the PMA driving circuit and the mechanical components connected to the PMA output shaft Experiments were performed to validate the proposed design method and the experimental results were compared with the simulation results Index Terms Permanent magnetic actuator PMA design circuit breaker Taguchi method holding force transient simulation I INTRODUCTION HE purpose of a circuit breaker CB is to prevent accidents when unexpected problems occur in the electric power transmission line The kind of CB can be classified according to its interrupter type vacuum air oil or gas Among these the vacuum interrupter has the advantage of minimal arcing and the disadvantage of restricted application for medium voltages below 75 kV 1 4 The maximum stroke of the vacuum interrupter should be limited to a certain value In this case a permanent magnetic actuator PMA can be a suitable actuator for driving the vacuum interrupters because it can be effectively operated in a limited stroke has a large holding force and has high reliability and low maintenance Manuscript received September 15 2014 revised May 29 2015 and August 6 2015 accepted September 26 2015 Copyright c 2015 IEEE Personal use of this material is permitted However permission to use this material for any other purposes must be obtained from the IEEE by sending a request to pubs permissions ieee org C H Lee is with the Department of Transdisciplinary Studies Seoul National University Suwon Korea e mail lch snu ac kr B H Shin is with the Department of Mechanical Engineering Hanbat National University Daejeon Korea e mail jedidiah hanbat ac kr Y B Bang corresponding author is with the Advanced Institutes of convergence Technology Seoul National University Suwon Korea e mail ybbang snu ac kr The main application of a PMA is the above mentioned vacuum circuit breaker VCB and therefore the research on PMAs is often performed in relation to VCBs This research can be categorized into two groups research on PMA characteristic analysis and research on PMA design First research on PMA characteristic analysis was performed in consideration of the electromagnetic behavior driving circuit and mechanical system connected to the output shaft The electromagnetic field of a PMA was analyzed based on the finite elements method FEM 5 6 The parametric mesh generation technique and the node moving technique were also used to analyze the electromagnetic field at different displacements of the armature 7 8 This electromagnetic field is generated by the coils as well as the permanent magnets of the PMA therefore research was conducted to analyze the electromagnetic field of the PMA in consideration of the driving circuit 6 9 The mechanical system connected to the PMA output shaft also affects its dynamic characteristic with this in mind some research was performed to predict the dynamic behavior of PMAs 10 13 Second there has been research on PMA design to improve the performance of PMAs To overcome the short stroke which is a common characteristic of a PMA a newly designed PMA in which additional coils or magnets were arranged along the stroke was proposed 14 15 By laminating the armature as well as the outer yoke the output thrust could be increased due to the reduced eddy current effect 9 Optimal design methods were applied to the PMA to increase the output thrust in a limited volume 7 16 To make a magnitude difference in the making closing and breaking opening force which is useful in effectively using the space for coils auxiliary permanent magnets were installed 17 For this paper PMA characteristic analysis such as dynamic simulation was also performed in consideration of the electromagnetic characteristics driving circuit and connected mechanical system including the friction factor However this paper is more related to PMA design using the Taguchi method The cross sectional yoke shape of mass produced industrial servomotors is nearly optimally designed not to generate a ripple torque Several types of servomotors with different output powers are manufactured by just changing the axial yoke length which occurs by changing the number of yoke laminates while keeping the cross sectional shape However in the case Designing a Permanent Magnetic Actuator for Vacuum Circuit Breakers Using the Taguchi Method and Dynamic Characteristic Analysis Chang Hyuk Lee Bu Hyun Shin and Young bong Bang Member IEEE T 0278 0046 c 2015 IEEE Personal use is permitted but republication redistribution requires IEEE permission See http www ieee org publications standards publications rights index html for more information This article has been accepted for publication in a future issue of this journal but has not been fully edited Content may change prior to final publication Citation information DOI 10 1109 TIE 2015 2494006 IEEE Transactions on Industrial Electronics IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS 2 of PMA many parameters should be changed simultaneously to change the output PMAs are usually customized and produced in relatively small quantities compared to industrial servomotors Therefore for a company that does not have its own design knowhow designing a new PMA according to a customer s request is a heavy burden The Taguchi method is one of a number of optimal design methods 18 22 and there are many papers on its application to actual industrial problems 23 26 Furthermore the Taguchi method has been applied to actuator design problems 27 33 Actuators can be optimally designed by selecting the yoke parameters for the control factors design parameters in order to maximize the output torque force 27 28 and minimize the cogging torque force 28 30 For IPM interior permanent magnet motors the output torque can be optimally maximized by redesigning the parameters of the position the volume and the angle between the two segment permanent magnets through the Taguchi method 31 32 Some research has also applied the Taguchi method to solve thermal problems of actuators 27 33 In this paper we apply the Taguchi method for the design of the PMA for VCB In applying the Taguchi method we proposed an effective procedure for its application to PMA design which is different from the usual procedure of repetitively using the orthogonal array to find influential parameters Also we performed a coil design through dynamic simulations which considered the friction of external mechanical components and the operation of the driving circuit Through these we proposed an overall PMA design procedure A PMA prototype was manufactured and experiments were performed to compare the simulation results The contents of this paper are as follows Section II describes the proposed design procedure using the Taguchi method to generate a required holding force Section III presents the PMA s dynamic characteristic analysis Section IV describes the coil design using the dynamic simulation results of Section III Section V compares the experimental results with the simulation results Section VI summarizes this research II YOKE DESIGN The major goals of designing a PMA are to attain the required holding force and to make the PMA operate at the given driving condition capacitor s capacity and charged voltage An increase in the holding force can be attained by increasing the size of the permanent magnets and yoke However the PMA size cannot be arbitrarily increased due to the limitations of its installation space and production cost Fig 1 shows the frame in which the PMA of this research should be installed As known from Fig 1 if the PMA size exceeds the limitations many parts such as shafts links and frames will need to be redesigned To make the PMA operate at the given driving condition enough space for the coils should be secured and a suitable coil diameter should be determined In this section the PMA yoke is designed to attain the required holding force As the yoke becomes larger it is advantageous for increases in both holding force and in coil volume but the design should be performed under the condition of size limitation This research was started at the request of a PMA company that had tried to develop a PMA satisfying some specifications holding force dimensional limits and capacitor s capacity and charged voltage by successive trial and error method but had failed In this paper a PMA will be designed by modifying the original PMA design s parameter values The holding force goal is 600 kgf 5880 N under the volume and stroke constraints as follows Fig 2 a b Fig 1 PMA for VCB driving in its frame a Perspective and partial cross sectional view b Cross sectional view Fig 2 PMA structure TABLE I UNITS FOR MAGNETIC PROPERTIES Part number Part name Material Permanent magnet Nd Fe B Armature Block Steel 1018 Yoke Laminated Steel 1020 Output shaft Stainless steel Spacer Aluminum 6061 Coil Copper 0278 0046 c 2015 IEEE Personal use is permitted but republication redistribution requires IEEE permission See http www ieee org publications standards publications rights index html for more information This article has been accepted for publication in a future issue of this journal but has not been fully edited Content may change prior to final publication Citation information DOI 10 1109 TIE 2015 2494006 IEEE Transactions on Industrial Electronics IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS 3 Width 114 mm Length 203 5 mm Height 180 5 mm and Armature stroke 26 mm 1 Table I presents materials of the PMA parts Ferromagnetic materials were used for the yoke and armature and non ferromagnetic materials were used for the output shafts and spacer A The Taguchi Method PMAs are usually customized and produced in relatively small quantities compared to industrial electric motors Therefore it is imperative to design a new PMA according to the consumer demand but it is inefficient to design a completely new PMA by changing all design parameters to produce the required holding force The orthogonal array of the Taguchi method can be effectively used to solve this problem The orthogonal array of the Taguchi method is a simulation table layout which uses a minimized set of simulations to learn the effects of all control factors on target value To set up the orthogonal array the control factors and their levels should first be selected In this paper some design parameters of the PMA were selected as control factors and holding force was selected as the target value Fig 3 shows the control factors F is the air gap between the permanent magnet and the armature and Table II presents their levels The level two values presented the lengths of the original PMA design parameters which the company determined using the trial and error method and the level one and three values were chosen by subtracting and adding twenty percent to the level two value In Table II there are seven control factors and their three levels In this case 3 simulations have to be performed to cover all the cases however 18 simulations are enough to comprehend the control factors effects by utilizing the L18 orthogonal array 23 24 The L18 array is a matrix where the rows present the combination of control factor levels for each simulation and the columns present the control factors and the target values as in Table III B First simulation with the L18 orthogonal array In the simulation of this research the holding force was selected as the output as the goal of this simulation was to increase the holding force of the original PMA In Table III is the holding force related to the air gap between the armature and the yoke Fig 3 and it was calculated with FEM using electromagnetic analysis software The air gap was embodied in the simulation due to manufacturing errors For small quantity production each lamination of the PMA yoke is usually produced by laser cutting of 2 4 mm thick steel plate and the laminations are manually assembled to form a yoke For Fig 3 Control factors of the PMA TABLE II CONTROL FACTOR AND LEVELS FOR THE 1ST SIMULATION Control factor Level 1 mm Level 2 mm Level 3 mm A 20 25 30 B 41 25 51 25 61 25 C 40 50 60 D 8 10 12 E 44 55 66 F 0 8 1 0 1 2 G 83 2 104 124 8 TABLE III L18 ORTHOGONAL ARRAY AND THE 1ST SIMULATION RESULT Control factors Target value A B C D E F G N N N N L1 20 41 25 40 8 44 0 8 83 2 3707 3283 3137 3376 L2 20 51 25 50 10 55 1 104 4147 3860 3764 3924 L3 20 61 25 60 12 66 1 2 124 8 4318 3983 3886 4062 L4 25 41 25 40 10 55 1 2 124 8 5764 5206 5024 5331 L5 25 51 25 50 12 66 0 8 83 2 4192 3881 3786 3953 L6 25 61 25 60 8 44 1 104 6388 5985 5866 6079 L7 30 41 25 50 8 66 1 124 8 6995 6367 6133 6498 L8 30 51 25 60 10 44 1 2 83 2 5259 4769 4695 4908 L9 30 61 25 40 12 55 0 8 104 5700 5070 4883 5218 L10 20 41 25 60 12 55 1 83 2 3394 3091 3030 3172 L11 20 51 25 40 8 66 1 2 104 3123 2810 2711 2881 L12 20 61 25 50 10 44 0 8 124 8 6486 5679 5570 5911 L13 25 41 25 50 12 44 1 2 104 6593 5926 5785 6101 L14 25 51 25 60 8 55 0 8 124 8 7784 6952 6796 7178 L15 25 61 25 40 10 66 1 83 2 3192 2982 2877 3017 L16 30 41 25 60 10 66 0 8 104 7334 6610 6433 6792 L17 30 51 25 40 12 44 1 124 8 7310 6496 6264 6690 L18 30 61 25 50 8 55 1 2 83 2 5049 4557 4383 4663 0278 0046 c 2015 IEEE Personal use is permitted but republication redistribution requires IEEE permission See http www ieee org publications standards publications rights index html for more information This article has been accepted for publication in a future issue of this journal but has not been fully edited Content may change prior to final publication Citation information DOI 10 1109 TIE 2015 2494006 IEEE Transactions on Industrial Electronics IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS 4 this reason the laminated surfaces are not smooth and the holding force fluctuates even when the same laminations are reassembled This is why the holding forces and were respectively calculated in relation to their air gaps The air gap levels were set in three levels 0 mm 0 05 mm and 0 1 mm The final output was their average Table III shows the L18 orthogonal array and shows the FEM simulation results of the holding forces Fig 4 shows lines connecting the points which are the averages of N for each control factor For example the point of the holding force for control factor A level 2 A2 was calculated by averaging the holding force of L4 L5 L6 L13 L14 and L15 which included factor A2 The points of the holding forces for control factor A level 1 and A level 3 A1 and A3 were calculated in the same method A line was then drawn to connect the three points As shown in Fig 4 A and G were relatively more influential control factors on the holding force because their data lines had the largest slopes among the control factors A and G are the design parameters that determine the cross section area of the magnetic flux path C and D determine the length and thickness of the permanent magnets The C and D were decided to be level 2 not to increase the PMA production cost by reordering permanent magnets of a different size E which is the armature height did not largely influence the outputs of the simulation it was also not changed from the original design E2 F is the gap between the permanent magnet and the armature Even though it did not largely influence the output of the simulation it can influence the output by minimally changing the overall PMA size Therefore we included F in the second simulation parameters as well as A and G B has little influence on the holding force and was not selected as a second simulation parameter However we maximized it within the PMA height constraint to increase the space for coils Therefore B was determined by 2 while Height was determined to be the largest value 180 5 mm under the condition of 1 2 2 C Second simulation with all combinations of selected control factor The purpose of the second simulation is to determine actual values of A F and G which were selected because they were relatively more influential or easily changeable control factors The second simulation control factor G2 simple notation 2nd G2 was set to have a maximum length of 114 mm with a hardware constraint of 1 and the 2nd G1 was set to be 104 mm which was the original design value Next A plays a role with G to determine the cross sectional area of the magnetic path which is a crucial factor for the holding force design The 2nd A1 and A2 were set to be 24 mm and 25 mm while 25 mm was the original design value A was set to be slightly smaller than the original design value A1 or the same as the original design value A2 because the 2nd G was set to be the same as the original value G1 or the limited maximum value G2 Therefore if A as well as G increased the holding force would increase beyond necessity In addition if A increased the spaces for coils would decrease It is advantageous to have large coil volume when the power source is limited The influence of the control factors on