IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 28, NO.
5, SEPTEMBER / OCTOBER 1992
On the Evolution of ac Machines for
Spindle Drive Applications
Antonino Fratta, Alfredo Vagati, Member, ZEEE, and Franco Villata, Member, IEEE
Abstract-In the field of ac spindle drives, the induction motor
is widely adopted. Synchronous solutions (reluctance, interior
permanent magnets) are often suggested to overcome some
drawbacks of the induction motor.
The paper compares the different options by considering the
machine torque-density and the inverter power size needed for a
given constant-power speed range. It is shown that an axially
laminated reluctance motor gives more torque density than the
induction motor but nearly requires the same inverter size.
By adding a proper quantity of permanent magnets, the
inverter size can be greatly reduced. A comprehensive discussion
is made on this subject, aiming to point out a design solution
that is “optimal” for the whole drive.
I. INTRODUCTION
T” E AC DRIVES for spindle applications require, as
known, high torque density and wide constant-power
speed range that is typically greater than 1:3. A totally
enclosed motor construction is preferred, and a forced
cooling is normally considered, acting on the stator of the
machine. Moreover, high dynamic performances are re-
quested, particularly with respect to load disturbances. An
overload factor is often needed that is typically 1.5. At
last, for certain applications, the feasibility of an axis-like
position control is appreciated. Anyway, a positioning
feature is nearly always requested for tool replacement.
At present, the commonly adopted ac machine is the
induction motor. The field-oriented control strategy is
coming into general use because of its high-dynamic pre-
rogatives.
The adoption of the induction motor (IM) certainly
constitutes a positive step with respect to dc solutions but
still exhibits some disadvantages, mainly regarding the
torque density and the inverter oversizing needed to ob-
tain wide constant-power speed ranges.
The aim of this paper is to analyze the suitability of the
synchronous choice, as compared with the induction one,
by pointing out a possible trend in optimizing the perfor-
mances of the whole drive.
The authors faced this subject in previous works, show-
ing the possible higher torque density obtainable from an
Paper IPCSD 91-134, approved by the Industrial Drives Committee of
the IEEE Industry Applications Society for presentation of the 1989
Industry Applications Society Annual Meeting, San Diego, CA, October
1-5. Manuscript released for publication September 6, i991.
The authors are with the Department of Electrical Engineering,
Polytecnico di Torino, Torino, Italy.
IEEE Log Number 9201857.
0093-9994/92$03.00 0 1992 IEEE
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1081
axially laminated reluctance motor (ALRM) [l]and calcu-
lating the needed inverter oversizing, which is nearly valid
for both ALRM’s and IM’s, once the constant-power
speed range is given [21.
On the other hand, the interior permanent magnet
(IPM) synchronous machines have been intensively stud-
ied in recent years [3]-[6]. Of particular interest at the
present time is the analysis made in [3]. It is shown there
that a tradeoff exists between the power capability at high
speed and the amount of PM flux once the anisotropy
characteristics are given, that is, the IPM machine can be
suitable for field weakening if it is properly designed.
It will be shown in this paper that these approaches
converge to point out an “optimal” solution for spindle-
drive applications.
11. RELUCTANCE
VERSUS
INDUCTION
A. The Torque Density
As far as the comparison is concerned, let us think
about both machines having the same two-pole sinu-
soidally would stator and only differing in the rotor struc-
ture.
Referring to a d , q frame, rotating at a speed w , it will
be synchronousyith the rotor for the reluctance motor
(RM), with the A, rotor linked-flux vector for the induc-
tion motor. Because 5, E, and are the stator voltage,
current, and linked flux vectors, respectively, (1) can be
written for both machines. The torque is expressed by (2).
Neglecting the magnetic nonlinearity and considering,
for the IM, that the rotor linked-flux module A, is con-
stant, the vector diagram in Fig. 1 is valid for both
machines.
Nearly equal stray inductances L , are supposed, for
both machines, because of the same stator structure: this
gives evidence to the “principal” flux vector 4. Equation
(2) can also be written as (3):
dA
RE+ - + j w h
dt
T=$xE. (3)
The reluctance motor rotor behaviour can be defined
through its d and q axis magnetizing inductances L,,
and L,, .Analogously, the induction motor behavior refers
to the parameters L , and k,L,, where L , is the magne-
 1082 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 28, NO. 5, SEPTEMBER / OCTOBER 1992
id Wd d
Fig. 1. Vector diagram of both machines.
tizing inductance, L , the stray rotor inductance, and k,
the rotor coupling coefficient.
ThereforeJ4) to (7) can be written for the RM. For the
IM, analogously, (8) to (11) are valid. The stator resis-
tance R is posed to be equal for both machines, as has
been seen. The IM rotor resistance has been indicated as
R,. The quantity P, represents the Joule losses amount.
The following represent the reluctance motor:
P, = R( i i +ii)
and the following represent the induction motor:
(
T = L , 1--Y r ) i , i ,
P, = R(i2 + i i ) + R,(k,i,)*.
By inspection of (6) and (101, the torque capability may
differ in three factors: the magnetizing inductance L,, or
L,, the reaction coefficient between brackets, and the
current capability at a given loss amount.
For the reluctance machine, the first two factors can be
made equivalent to the IM ones if an axially laminated
rotor structure is considered, as schematically depicted in
Fig. 2. The pole-flux can be nearly the same at a given
maximum induction value and a given airgap.
The quadrature magnetizing inductance L,, , more-
over, can be made “equivalent” to k,L,. The L,, value,
in fact, strongly depends on the ratio between the thick-
ness of both nonmagnetic and magnetic materials. This
ratio can, in general, be dependent on the rotor angular
coordinate 6 (Fig. 2). A complete analysis is made in [7].
At the present time, it is easier to consider this ratio as a
constant, for example, unity.
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ql
Fig. 2. Schematic of an axially laminated two-pole rotor.
Therefore, at low speed values, where the iron losses
are neglegible with respect to the Joule losses, it can be
concluded that the ALRM gives more torque density than
the IM because of the second term in (111, which is
comparable with the first one.
However, in a spindle drive, iron losses also can play an
important role in defining the torque capability at high
speed. Therefore, it is necessary to prove that the ALRM
does not exhibit more iron losses than the IM, in princi-
(4) ple. Unfortunately, this is not true if the rotor is not
suitably designed. This is due to the effect of the stator
slots on the rotor laminations.
Let us refer to Fig. 3, in which a slotted stator is
schematically depicted (two slots per pole per phase),
together with a laminated two-pole rotor, in a certain
reciprocal position. Of course, the first harmonic mmf
(7) distribution will be synchronous with the rotor.
The slots rotate with respect to the rotor, producing a
periodical variation of the airgap reluctance “seen” by
each rotor segment. During this rotation, two kinds of
segments are to be pointed out: those for which their
airgap ends “see” the stator slots in-phase (continuous
lines) and those for which their airgap ends “see” the
stator slots in opposition (dashed lines). Let us focus, for
the moment, on a nonskewed machine. The flux conduc-
tion in these two kinds of segments is very different.
The first kind of segment shows the highest total airgap
reluctance ripple (Fig. 4), but it does not produce ripple
on the flux between adjacent segments. Therefore, iron
losses are mainly related to the large segment flux ripple
in a rotor having only this kind of segment.
The second kind of segment (dashed lines in Fig. 3)
shows reduced total airgap reluctance ripple (Fig. 51,
thanks to the phase opposition between the reluctance
distributions of their airgap ends. On the other hand, high
ripple on the adjacency flux is expected. Therefore, care
must be taken on the choice of materials to be interposed
between segments of this kind. Anyway, in a rotor having
only this kind of segment, with electrically nonconductive
material interposed, the rotor losses are low and mainly
located close to the airgap ends. This is due to the ripple
of the adjacency flux. It lowers the flux ripple inside the
segment, which is at maximum close to the airgap ends.
In a real case, the segment thickness is a finite quantity,
comparable with the stator tooth. Two strategies can be
followed to lower the rotor iron losses.
 ___

FRA’ITA et al.: ON THE EVOLUTION OF ac MACHINES FOR SPINDLE DRIVE APPLICATIONS 1083

(a) (b)
Fig. 6. “Real” rotor segments.

Let us report, at this point, some results obtained from

Fig. 3. Influence of the stator slots. measurements made on prototype machines. The iron
losses of three different four-pole machines have been
measured, by a no-load test condition, at a fundamental
Total reluctance
frequency of 50 Hz and at the same maximum induction
value at the airgap (0.5 T). Machines 1 and 2 have a rated
torque of about 30 Nm, and machine 3 has a torque of
about 150 Nm. Machine 1 is not skewed, whereas machine
2 has a stator skewed by one tooth pitch; machine 3 was
skewed, as was machine 2. Machines 1 and 2 have a rotor
built with a larger number of laminations, approaching
the situation in Fig. 2 (except for a four-pole situation, of
course). The third one, on the contrary, has been built
~
following the rule shown in Fig. 6(a).
Because of the different dimensions, we will refer to
Fig. 4. In-phase segments (airgap ends reluctance distributions).
per-volume losses only. The following iron losses have
been found:
Total reluctance machine l ( 4 9 kW/m3)
machine 2 (45 kW/m3)
machine 3 (16 kW/m3).
The comparison between the skewed and nonskewed
machines (1 and 2) shows that the previous considerations
are nearly applicable to a skewed machine as well. The
great difference in losses between the first two machines
Fig. 5. In-oppositionsegments (airgap ends reluctance distributions). and the third one, on the other hand, can mostly be
referred to the different rotor construction, proving the
validity of the above made considerations.
If a large number of real segments is wanted to produce When considering full load conditions, a test (machine
a near ideal “distributed rotor anisotropy,’’ then the rotor 3) did not show any significant increase of the iron losses.
segment pitch must be one half the stator tooth pitch. As a conclusion, it has been stated that a properly
These segments are to be positioned with their axes like designed ALRM exhibits iron losses as low as the IM
the dashed lines in Fig. 3. does. As a consequence, the torque-density of the ALRM
Conversely, if a lower number of real segments is is superior because of the absence of rotor Joule losses.
wanted, for practical reasons, the ends of each real seg- This increase can be roughly estimated around 20%.
ment must be as wide as the stator tooth pitch or, in
principle, multiple. Therefore, the induction oscillations B. The Inverter Sizing
at the airgap mainly affect the iron close to the rotor The inverter size, which is needed to obtain a constant-
surface, and the flu in the deeper iron is constant. Let us power speed range, is of great influence on the cost of the
observe that, in this case, each segment acts as a magnetic whole drive. If large constant-power ranges are requested,
shunt on the stator teeth, producing some increase in the as in the case, the needed size strongly depends on the
stray inductance. speed range itself.
These two “practical” situations are shown in Fig. 6. As shown, at least in steady-state conditions the RM
The extreme segments near to the q axis are omitted. and the IM behaviors can be described by the same set of
The above considerations have been made on a section equations. In fact, (1)-(3) are valid for both, and there is a
of the machine. Skewing does change the situation, pro- one-to-one correspondence between (4)-(6) and (8)-(10),
ducing axially flowing fluxes. provided that L,, = L, and L,, = k,L,. At present, it

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 1084 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 28, NO. 5, SEPTEMBER / OCTOBER 1992
is convenient to introduce, for both machines, the ‘total”
inductances L , = Ld, + L, (or L , + L , ) and L , = L,,
+ +
L, (or k, L, L J . Therefore, disregarding the resis-
tance and in steady-state conditions, both machines can
be described through these two parameters. Let us just
remember that the speed w in (1) is the rotor speed in a
RM, whereas in the IM, the slip speed should also be
taken into account.
Disregarding the slip for simplicity, it is expected that
the inverter sizing is the same for both machines if they
are described by equal d and q inductances. A complete
analysis is made in [2]. Let us now outline some aspects to
justify the quite large inverter sizing that is normally
needed.
For a given machine, once its ratings io and A, are
defined, together with the maximum allowable voltage U,,
the loci of voltage, current, and linked flux are defined,
representing the maximum power versus speed working
points.
In Fig. 7, these loci are plotted for a machine perform-
ing its maximum power factor at io and A, ratings; this in
order to refer to a well-defined working condition. “w,” is
the speed at which the maximum voltage is reached, and
w 1 is the speed beyond which the current must decrease.
In fact, flux angles larger than 7~/4would lead to decreas-
ing torque with increasing current; consequently, the flux
angle is kept constant for w > w l , and the current de-
creases with the speed. This is the main reason for the
quite larger inverter oversizing.
In Fig. 8, the per-unit voltage, current, and power are
reported as function of the speed. Considering a constant
power speed range considerably higher than w l / w o , a
situation occurs that is close to that defined in the figure
by the segment AB; the represented situation is relative
to a 1 5 range.
As it can be seen, the ratio between the inverter kVA
and the rated kW is quite large, and it becomes increas-
ingly worse as the requested speed range increases.
Let us observe that the maximum voltage is reached at
a flux angle 6, which mainly depends on the ratio (12).
The lower this ratio is, the wider the constant-power
speed range results for a given utilization factor of the
inverter.
The ratio (12) can also be expressed through the A,
permeance, the @, pole-flux, and the F, total stator mmf.
Therefore, it can be directly related to the machine de-
sign. It follows that it is preferable to increase the torque
by increasing the pole-flux instead of the magnetomotive
force. Qualitatively, this leads to use more iron and less
copper, which in turn lowers the stray fluxes.
On the other hand, if we consider an already designed
machine, it follows that its strong exploitation through
forced cooling equally leads to a further increase in the
inverter oversizing.
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=a
w =wo
I
d
Fig. 7. Vector loci for maximum power.
-
__
voio
I
w, 0 1 w
Fig. 8. Voltage, current, and power versus speed.
Some little differences may occur between the IM and
the ALRM in obtaining low L , values; but the conclusion
is that a different solution must be found if the inverter
oversizing has to be greatly reduced.
111. RELUCTANCE AND IPM MACHINES
IPM machines have been intensively studied in recent
years [3]-[6]. The interest in this kind of machine lies in
the capability of featuring both anisotropy and PM torque
and in the feasibility of field-weakening operation.
At present, the analysis made in [3] is of particular
interest. If power capability at high speed is wanted, as in
the case, it is shown there that a particular relationship
must be true between the open-circuit pu voltage and the
pu reactance in the direction of lowest permeability.
Let us observe that in the IPM modeling, the d axis is
normally chosen in the PM direction, but it is possible to
consider the IPM machine as a RM to which a proper PM
quantity is added. That is because we will chose the q axis
in the direction of lowest permeability as is usual for a
RM. Therefore, the ( d , q ) frame is the same as we have
defined in the previous chapters.
Let us start from the diagram in Fig. 7. In the case of a
completely ideal RM (Ld + w; L , = 0), the flux and
current vectors would always be in quadrature and no
problem should arise.
In the equally ideal case of Ld + 03, L , # 0, however,
a A, PM flux vector in the ( -4) direction would perfectly
compensate for the q-axis reactance, as it is shown in Fig.
9. We have indicated h, as the reluctance flux and the
total one as h,.The flux-weakening range would be infi-
nite at unity power factor. The needed amount of PM flux
 FRATTA et al.: ON THE EVOLUTION OF ac MACHINES FOR SPINDLE DRIVE APPLICATIONS 1085

P
-
qt voio f

Fig. 9. Ideal behavior ( L , m).

m

Fig. 10. Vector diagram of two differently compensated machines.

is Lqio;the compensation effect depends on the current
value, of course. For a current value different from the
-P
rated one io, this compensation is detuned. Another evi- voio+
dent drawback lies in the necessity of a certain q-axis
current, even if zero torque is requested, when a total flux
lower than A, is wanted.
We will return to these drawbacks later. Let us now
analyze the effect of the magnetizing current considering
a realistic machine.
Referring to the Fig. 10 vector diagram, a compensating
amount of magnets equal to L,i,, as in the ideal case,
ww
would lead to a current that is always lagging over an
ideally infinite field-weakening range; this is related to the
Fig. 11. Power versus speed curves of two differently compensated
MO locus. machines.
It may be more convenient, in practice, to add a magnet
quantity that is slightly higher, as indicated in (13), where
a is a number slightly larger than one. the current is, in general, different from io, when a torque
smaller or larger than the rated one is wanted. In both
Al, = aLqio. (13) cases, the compensation is detuned. The MO or PN loci
in Fig. 10 shift vertically; the shift due to the current
In this case, the locus NP is obtained, which leads to a
variation from the rated one is proportional to the L ,
leading current at the highest speed values, and to a finite
value once the considered current value has been defined.
field-weakening range. The related power versus speed
Therefore, low L, values produce low sensitivity to detun-
curves are reported in Fig. 11 for a practical case and for
ing.
resetting the linked flux to its rating. If the requested
As we have outlined above, at.“zero’’ torque and at the
constant-power speed range does not interest the cut-off
highest speed, a q-axis current can be needed to reduce
zone at highest speed, it may be convenient for the NP
the flux value beyond the hl, one. This current is reported
compensation, which exhibits better cos ‘p, values.
as i,(T = 0) in (14):
The strong advantage that has been obtained through
the magnet introduction must be observed. The inverter
size is now only related to the cos cpo value, and any other
oversizing is not necessary, which is different from the
RM case. In other words, we put the magnet in the A0

machine mainly to reduce the inverter size; improving the r a = -.

L*,io
way the machine works occurs too, but as a consequence
of less weight. The L; value shown in (15) is the maximum L, value
The comparison between the ideal situation in Fig. 9 allowing a “zero torque” regulation at the highest speed
and the real one in Fig. 11 points out the effect of the L , not implying any current flow. It depends, of course, on
value. The larger its value is, the better the cos cp, will be the wanted constant-power speed range “r.” If a large “r”
and, consequently, the exploitation of both the inverter is request (at least 1:5), the L: value is quite small. As an
and the machine. As far as the influence of the L , value example, in the prototype machine built following Fig.
is concerned, although a little advantage would be found 6(a) (machine 3), this value should be 3 mH, for r = 5,
in relatively large L, values from the point of view of whereas the measured one was 5 mH. A “demagnetizing”
cos cp, only [3], there are many different reasons for current flow at high speed is consequently necessary.
keeping as small as possible. To obtain low L , values, a structure of the types of Fig.
Equation (13) is a “design” relationship; when the ma- 6 is needed with a reasonably high number of segments.
chine is working, it is no longer valid. First, the PM flux Comparing (12) with (15), it is possible to state that the
can vary, following the temperature variations. Second, ratio (12) must be made as small as possible, independent

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 1086 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS,VOL. 28, NO. 5, SEPTEMBER / OCTOBER 1992
of the presence of the “compensating” permanent mag-
nets. Therefore, the “optimal” structures for RM and
IPM are the same. Let us observe that this also works in
the sense of reducing the induction ripple at the airgap
due to the quadrature mmf, which is a problem in the
conventional IPM machines. In fact, a fairly large number
of segments in the rotor allows this one to react to the
stator quadrature mmf wave by a staircase wave that
better approaches the sinusoidal excitation. Therefore,
low L , and low losses goals are contemporaneously
reached.
IV. CONCLUSIONS
The field of ac drives that is suitable for spindle appli-
cations has been analyzed.
A comparison between asynchronous and synchronous
solutions has been carried out on the basis of the torque
density of the machine and of the needed inverter size for
a reasonably large constant-power speed range.
The following has been concluded:
0 The induction motor gives less torque density than
the other solutions if they are properly designed.
A reluctance machine with “distributed anisotropy”
(i.e., with a reasonably high number of properly dis-
posed segments) still suffers, as does the IM, for a
quite large inverter sizing.
A proper magnet quantity added to this RM reduces
the inverter size to nearly its “theoretical” value.
Therefore, the “best” solution for spindle drives is to
use a “distributed anisotropy” IPM machines. This one
must exhibit the lowest possible permeance in the mag-
nets direction, whereas the permeance in the other direc-
tion must be as high as possible. Some IPM machines
partially follow this requirement; but the number of rotor
segments should be higher than one. Moreover, the flw
produced by magnets must be directly related to the
lowest permeance; otherwise, large field-weakening ranges
cannot be obtained.
The design of such a type of rotor poses magnetic and
mechanical problems, of course. Once properly solved,
the superiority of this synchronous solution in comparison
with the asynchronous one will no longer be a matter of
discussion.
REFERENCES
[l] A. Fratta and A. Vagati, “A reluctance motor drive for high
dynamic performance applications,” in Conf. Rec. I987 Ann. Mtg.
IEEE Industy Applications Soc., pp. 295-302.
[2] A. Fratta, A. Vagati, and F. Villata, “AC spindle drives: A unified
approach to the field-weakening behavior,” in Proc. Int. Motor-Con
Conf. (Munich, West Germany), June 6-9, 1988, pp. 44-56.
[31 R. Schiferl and T. A. Lipo, “Power capability of salient pole P.M.
synchronous motors in variable speed drive,” in Conf. Rec. I988
Ann. Mtg. IEEE U S ,pp. 23-31.
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[4] B. K. Bose, “A high performance inverter-fed drive system of an
interior P.M. synchronous machine,” in Conf. Rec. 1987Ann. Mtg.
IEEE U S , pp. 269-276.
[5] T. M. Jahns, “Flux-weakening regime operation of an interior
P. M. synchronous motor drive,” in Conf. Rec. 1986 Ann. Mtg.
IEEE US, pp. 814-823.
[6] B. J. Chalmers and S. K.Devgan, “Comparative performance of 7,5
kW P.M. synchronous motors, with Sm CO 5 and Nd. Fe B
magnets,” in h o c . ICEM I988 (Pisa, Italy), pp. 41-43, vol. 111.
[7] A. Fratta and A. Vagati, “Axially laminated reluctance motor: An
analytical approach to the magnetic behavior,” in Proc. ICEM
1988 (Pisa, Italy), pp. 1-6, vol. 111.
Antonino Fratta was bom in Torino, Italy, on
1957. He received the degree in electrical engi-
neering from Politecnico di Torino, Italy, in
1982. He received the National Ph.D. degree in
1987 from Politecnico di Torino, concentrating
on high-performance synchronous reluctance
drives.
He holds three international patents (one
pending) on synchronous machines and power
converter structures. He worked as scientific
consultant in the field of ac drives and as project
head for the innovative designs of synchronous machines and power
converters at the Magnetic R and D Centre. He joined the Department
of Electrical Engineering of Politecnico di Torino in 1990 as Assistant
Professor. His research activities are in ac drives, involving the machine
as well as the power converter design, modeling, and control.
Alfred0 Vagati (M’87) was born in Torino, Italy,
in 1945; he received the doctor degree in electri-
cal engineering, with honors, from Politecnico di
Torino in 1970.
From 1971 to 1974, he was employed as a
researcher at Olivetti S.p.A. He joined Politec-
nico de Torino in 1975 as Assistant Professor.
From 1982 to 1990, he was Associate Professor
of Electrical Drives in the same university. In
1990, he became Professor of Electrical Ma-
chines and Drives at the University of Cagliari,
Italy, and in 1991, he joined Politecnico di Torino in the same capacity.
His research and professional interests concern electrical machines and
power electronics control of industrial drives. Current activities include
high-performance ac drives, with particular attention to synchronous
reluctance drives.
Franco Villata (M’90) was born in Firenze, Italy,
in 1941. He received the degrees in electrical
engineering from Politecnico di Torino, Italy, in
1965.
From 1965 to 1966, he was at Politecnico di
Torino as Assistant Professor. From 1966 to
1967, he was employed at ENEL in the power
plant design department. He rejoined Politec-
nico di Torino in 1967 as Assistant Professor.
From 1983 to 1986, he was Associate Professor
in the same university. Since 1986, he became
Professor of Electrical Machines and Drives at Politecnico di Torino.
His research and professional interests concern electrical machines and
power electronics.