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Design Rotor V-Shape Permanent Magnets-Good
Design Rotor V-Shape Permanent Magnets-Good
Abstract- This paper looks into the mechanical and The aim of this paper is to set rules for designing a rotor
electromagnetic design for rotors with embedded magnets of with V-shape-magnets with low leakage flux within the rotor,
Permanent-Magnet-Synchronous Machines. In a study it has been
investigated in which way a solid bridge between the permanent which is mechanically robust at maximum speed and has a low
magnets improves the mechanical stability of the system and if it torque ripple while fulfilling the torque and power
has an influence on the electromagnetic performance. In the requirements. Therefore it was necessary to carry out
second part a new design process for the rotor is introduced. The mechanical and electromagnetic calculations for different rotor
aim of this design process is to decouple the calculation of the designs, which have been realized in this study by the Finite
reluctance torque from the permanent magnet torque and to
reduce the complexity of the electromagnetic design for the rotor. Elements Method (FEM).
B. Modelling
In the first part it is investigated which effects a solid bridge
between the magnets building a V-shape has on the torque
performance of the electrical machine and on the mechanical
robustness of the rotor. A simple machine design with
V-magnet shape is chosen (see Fig. 1). In Tab. 1 the geometric
data of the model and the chosen materials are summarized. A
FEM model is built to perform the mechanical as well as the
electromagnetic calculations. Forces of electromagnetic origin
and temperature effects were neglected in these simulations
[3]. The yield is indicated by planar von Mises stress. Fig. 2. Stress results at 8640 rpm for design without solid bridge.
TABLE I
GEOMETRIC DATA AND MATERIALS FOR FEM MODEL
Symbol Value Symbol Value
Rad1 108.5 mm p 8
Rad3 145 mm Z 24
Gap 1 mm wmag 13 mm
LM 3,5 mm Lfe 70 mm
a_0 0,5 mm
Material Material property Value
M330-35AP Bending strength 350 N/mm²
E-modulus 190000 N/mm²
NdFeB 210/250h Bending strength 250 N/mm²
E-modulus 150000 N/mm²
Fig. 3. Stress results at 8640 rpm for design with solid bridge.
C. Mechanical Calculations
According to the geometric data in Tab. 1 two different rotor The torque performance is 9% higher when reducing the
geometries are built. One model is built without a bridge area for leakage flux in the rotor by using a solid bridge
between the magnets; the other one has the solid bridge. The between the PMs building the V-shape. But at the same time
spacing between the magnets (a_0) stays equal. Stress the torque ripple and cogging torque increase as well. The
simulations are done with FEM at the overload speed of comparison of the induced voltages shows that the design with
8640 rpm. At this speed the yield stress of the electrical steel solid bridge couples more permanent magnet flux with the
should not exceed 350 N/mm². Calculations are performed for stator due to the lower leakage flux and the higher saturation of
both models. The length of X2 is adjusted until the permitted the leakage flux paths. Consequently, the utilization of the PM
yield stress is kept. flux is better when using a solid bridge between the magnets.
In Fig. 2 and Fig. 3 the von Mises stress at maximum speed
is shown. The resulting length of X2 for the model with a solid TABLE II
RESULTS OF ELECTROMAGNETIC CALCULATIONS
bridge between the magnets is 0.82 mm. This is in contrast to
Design without Design with
the model without the solid bridge where a length of 1.75 mm Quantity Difference
solid bridge solid bridge
is required for X2. With these values the resulting area for the Maximum Torque
214 Nm 233 Nm
19 Nm
leakage flux in each model is calculated. This is carried out by TMAX +9 %
Torque Ripple 14,3 Nm
multiplying X2 with the active length. The model with solid TRP
65,8 Nmpp 80,1 Nmpp
+22 %
bridge has one more path which is the solid bridge between the Cogging Torque 3,5 Nm
8,1 Nmpp 11,6 Nmpp
magnets. However, the model with the solid bridge reaches its TCG +43 %
mechanical robustness with 61 % of the leakage flux area Induced Voltage 40 V
210 Vpeak 250 Vpeak
UPH +19 %
compared to the model without this bridge.
D. Electromagnetic Calculations
In a second step the electromagnetic calculations with the
two models were carried out. For both designs the
electromagnetic torque for different load angles (see Fig. 4),
the induced phase voltage and the cogging torque were
calculated. In Tab. 2 the results are shown.
2
Proceedings of the 2008 International Conference on Electrical Machines
250 Proposed geometry for rotor
lamination with V-magnet shape
200
optional: optimization of
100 PM-torque performance
with solid bridge
Optimization of full-torque
without solid bridge
50 performance
0
0 10 20 30 40 50 60 70 80 90 Rotor geometry with V-magnet
load angle [°el] shape
Fig. 4. Torque vs. load angle of both designs. Fig. 5. Proposed electromagnetic design process.
III. ELECTROMAGNETIC DESIGN PROCESS FOR THE ROTOR The resulting rotor design parameters after all 7 iterations
are shown in Tab. 3. This rotor design is used for the further
A. Introduction steps of the design process.
To simplify the design process for rotors with magnet poles
in V-shape, an electromagnetic investigation is carried out. A
120,0 30
design procedure (see Fig. 5) is proposed wherein at first the
machine is designed as a reluctance machine. In other words 100,0 25
the V-shape is investigated without the influence of the PM
ripple and mean value of the produced torque, the magnets are
T [Nm]
60,0 15
added to the FEM model and the whole torque performance is Torque
Torque Ripple
investigated. It is expected that the design process is less Torque Ripple Factor
40,0 10
complex by this method instead of optimizing both torque
components at the same time. If the design process still does 20,0 5
not reveal the expected results, a further step could be added to
the process. This optional step is the investigation of the PM 0,0 0
torque component without the influence of reluctance torque. 1 2 3 4 5 6 7
Design Step
B. Investigation of reluctance torque
As an example, a machine design with 20 poles and 24 slots Fig. 6. Iterative optimization of reluctance torque.
is chosen. For this pole and slot combination very low cogging
torque and torque ripple caused by the PM flux is expected [5]. TABLE III
The parameters wmag and α are designated as degrees of GEOMETRIC DATA OF ROTOR MODEL (STEP 7)
freedom for the investigation of reluctance torque. The size of Symbol Value Symbol Value
the PM slots is kept constant. The two parameters will be Rad1 114 mm p 10
Rad3 145 mm Z 24
adjusted with the aim to maximize the reluctance torque while Gap 1 mm wmag 13.2 mm
obtaining a small torque ripple. At first a known configuration LM 4 mm Lfe 70 mm
is chosen and the torque versus rotor position is calculated. a_0 0,5 mm α 16°
3
Proceedings of the 2008 International Conference on Electrical Machines
C. Investigation of PM and reluctance torque 30
For the calculation of the combined PM and reluctance
torque performance the PMs are added to the FEM model and 25
T RP [Nmpp]
The results show a strong variation of the torque ripple with 15
delta=40
delta=50
performance was calculated. It is shown that the reluctance
150
delta=60 torque is here the main reason for torque ripple. Therefore it is
delta=70
100
delta=80 recommended to optimize the reluctance design once more in
50
delta=90 terms of torque ripple.
The proposed design process was proved to reduce the
0
0 60 120 180 240 300
complexity of finding a suitable rotor design in terms of
-50 maximizing the reluctance torque while achieving a low torque
rotor position [°el] ripple.
IV. CONCLUSION
Fig. 7. Combined PM and reluctance torque versus rotor position.
In this paper the design of rotors for PMSM with embedded
magnets in a V-shape was investigated. In particular, the
Te =
3
[
⋅ p ⋅ (Ld − Lq )⋅ id ⋅ iq + Ψdm ⋅ iq ] (2) mechanical requirements were taken into consideration. The
2 advantages of a solid bridge between the magnets were
analyzed.
One can conclude that torque ripple is mainly caused by A new electromagnetic design process was proposed. The
reluctance torque. This is further proved when comparing the aim to decouple the PM torque from the reluctance torque is to
calculated values with maximum torque ripple at the load angle reduce the complexity for the optimization of the rotor design.
of δ=30°el. The torque ripple calculated for the design without
REFERENCES
PMs is 23.9 Nmpp. At the same load step with PM torque a
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no. 3,pp. 806-812, May/June 2004.
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was shown here that the main reason for the torque ripple is Japan, 2004.
[5] F. Magnussen, et al., “Parasitic Effects in PM Machines With
produced by variation of reluctance torque versus rotor Concentrated Windings”, IEEE Transactions On Industry Applications,
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Permanent Magnet Motor Drives for Field Weakening Applications”,
D. Summary Doctoral Thesis, University of Glasgow, September 1993
[7] J. Salo, et al., “New Low-Speed High-Torque Permanent Magnet
The proposed design process is once performed with a Synchronous Machine with Buried Magnets”, ICEM 2000, Finland,
machine design with 20 rotor poles and 24 stator slots. After August 2000
retrieving a suitable design regarding the reluctance torque