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    Design and Production of Belt Drive Elevator Traction Machine: Modelling of Double Side Belt System
    (2024) Soyaslan, Mucahit; Avşar, Yusuf; Fenercioğlu, Ahmet; Sarıhan, Feyyaz
    Elevator traction motors are critical components of elevator systems. After the structural analysis of the traction motor, it is necessary to proceed to the production processes for the comfortable and safe use of elevator systems. In this study, the static load values for bearing lifetime calculation, belt selection, and finite element analyses (FEA) were determined. According to calculated loads; materials, bearings, belt, pulley, brake, and encoder were selected. In order to obtain a design in accordance with elevator standards, motor parts were examined for structural analysis. Finite element analyses were carried out according to the determined maximum static load values, and a new belt elevator traction motor design that provides the safety coefficients has emerged. When the FEA analysis results of bending moments are examined; the maximum Von Mises stress acting on the motor frame and shaft was obtained 17.1 MPa and 27.62 MPa respectively. The maximum Von Mises stress was obtained under the torsional moment as 71.4 MPa and the shaft is 6.1 times safe against a torsional moment. This value is the minimum safety factor of the designed system and safety factors of bending moments are higher than this value. The designed elevator machine has got 12.9 kW rated power, 1.6 m/s cabin speed, and 1175 kg carrying capacity. The advantage of the proposed design is to eliminate the casting process with modular structure via double side belt system. The prototype of the designed motor was produced and it was observed that the motor provided the desired constraints as a result of the loading experiments.
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    Design Optimization of PM Synchronous Motor: Rail Mounted Belt Drive Elevator Systems
    (Ieee-Inst Electrical Electronics Engineers Inc, 2024) Avsar, Yusuf; Fenercioglu, Ahmet; Soyaslan, Mucahit
    In this article, the design and optimization of 4.5 kW inner rotor permanent magnet synchronous motor (PMSM) with 400 rpm nominal speed was carried out for belt drive elevator systems. Unlike traditional methods, the integration of the motor into the elevator carrier system is provided directly on the rails. Thus, high cost and complex machine chassis constructions are eliminated. The elevator loads accumulated on the machine were properly transmitted to the building and the ground. The electrical and magnetic modeling of the PMSM was carried out considering the volume constraints that emerge according to the mechanical design. The two most important criteria to be considered in elevator traction motors are providing high efficiency and passenger comfort. In line with these objectives, a design with efficiency above 91% and torque ripple below 1% is presented. Based on the acquired limit values and using the finite element method (FEM), the optimization of parameters such as the slot opening, magnet thickness, embrace, stator tooth thickness, and air gap was conducted via genetic algorithm. In addition, step skewing of magnets was applied to the optimized model to reduce torque ripple. According to the results, 18 slot-20 pole PMSM with 0.61% torque ripple and 90.97% efficiency has been obtained. The designed PMSM was produced and tested using an electrical motor test setup. Based on the test results, the efficiency and cogging torque were obtained as 89.98% and 0.78 Nm (pk2pk), respectively. Thus, the FEM analysis solutions are verified by the test results.
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    Efficiency Optimization of PMSM-Type Elevator Machine: An Industrial Comparison
    (Mdpi, 2025) Soyaslan, Mucahit; Eldogan, Osman; Fenercioglu, Ahmet; Avsar, Yusuf; Ceylan, Nurdogan; Sarikaya, Muhammed Salih
    This study presents the design, modeling, and prototyping of an external rotor permanent magnet synchronous motor (ER-PMSM) specifically for elevator traction systems. The external rotor design aims to surpass the efficiency of conventional inner rotor gearless elevator traction motors. A commercially available 4 kW inner rotor permanent magnet synchronous motor (IR-PMSM) was selected for comparative analysis. Critical parameters, including stator tooth tip thickness, slot tip radius, slot height, stator yoke height, stator tooth thickness, and the number of turns per phase, were optimized to enhance efficiency. The artificial bee colony (ABC) algorithm was utilized for the first time to determine the optimal configuration of an external rotor PMSM. The prototype was fabricated and subjected to rigorous testing using a dedicated electrical motor test setup. Comparative results demonstrated a significant improvement in efficiency for the ER-PMSM over the IR-PMSM, with the efficiency increasing from 72.5% to 84.67% at nominal operating conditions.
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    External rotor gearless elevator machine: a new design with flanged shaft
    (Springer Science and Business Media B.V., 2024) Soyaslan, Mucahit; Eldogan, Osman; Fenercioglu, Ahmet; Avsar, Yusuf
    The design of an external rotor gearless elevator machine (ERGEM) with a flanged shaft for elevator traction systems is presented in this paper. The machine is designed with two distinct shafts. The fixed shaft with stator is one, and the flanged shaft turns with the rotor is the other. The ERGEM's rotational movement has been reduced to a flanged shaft, and a novel motor design has been obtained that fits the market's traction pulleys and brake mechanisms. The flanged shaft provides traction by rotating with the pulley. Instead of making grooves on the rotor surface, an external pulley is used. The loads on the pulley have a negligible effect on the rotor because it is located between two fixing plates. With the plates on the right and left sides of the pulley, a symmetrical load distribution has been achieved. Finite element analyses (FEA) were performed using the maximum static load values. After the final design was approved, the prototype was built and experimental tests were conducted. © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2023.
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    PMSM Design for Elevators: Determination of the Basic Topology Affecting Performance
    (ISRES Publishing, 2024) Avsar, Yusuf; Soyaslan, Mucahit; Fenercioglu, Ahmet
    In recent years, with the increase in high-rise building construction, there has been a rise in demand for elevators. This demand has spurred mutual growth between the vertical transportation sector and high-rise building construction. Both sectors are improving technology, security, and comfort standards. Traditional elevator traction machines typically employ asynchronous motors coupled with geared reducers, despite their low energy efficiency and requirement for large machine rooms. However, with the proliferation of rare-earth magnet materials and advancements in driver technologies, the use of Permanent Magnet Synchronous Motors (PMSMs) in elevator traction machines has increased. PMSMs operate with direct drive, eliminating the need for reducers. High efficiency and passenger comfort are crucial parameters for elevator traction machines. This study focuses on identifying the fundamental topology that could influence the performance of PMSMs for gearless elevator machines. Factors such as stator materials, rotor structures, permanent magnets, winding configurations, slot/pole combinations, cogging torque and torque ripple have been examined to select suitable design topologies for elevator motors. Important topics such as the magnetic properties of grain-oriented silicon steel sheets used in stator construction, B-H curves, lamination forming and stacking factors have been addressed. Two different rotor topologies and magnet arrangements, namely internal and external, have been investigated in PMSM designs. Additionally, the use of four different magnet materials, namely AlNiCo, Ferrite, NdFeB, and SmCo have been compared for PMSM traction motors in elevators. Single-layer and double-layer winding configurations, distributed and concentrated winding configurations have been compared. Fractional slot/pole combinations, which directly affect the performance and comfort of PMSMs, have also been examined based on information obtained from the literature. Particularly, structures with high winding factors, such as 12/10, 12/14, 18/16, 18/20, 24/22, and 24/26 have been identified. Finally, studies on skewing to reduce cogging torque and torque ripple have been addressed. © 2024 Published by ISRES.