Design of

Rotating Electrical Machines

Juha Pyrhönen, Tapani Jokinen, Valéria Hrabovcová

Three-phase permanent magnet motor with rotor surface magnets, a two-layer

integral slot winding and open-circuit cooling

This calculation sheet is designed for analytical evaluation of a three-phase permanent

magnet motor with rotor surface magnets, a two-layer integral slot winding and
open-circuit cooling.

While every effort has been made to ensure the accuracy of the information and technical
data in this calculation sheet, the authors cannot accept any liability for damage, injury,
breakdown, or poor performance arising from the application of this machine design or
data contained in it. The reader is responsible to check the calculations and the technical
data and conduct such tests as may be necessary to ensure that the machine design
suggested by this publication is suitable for the use to which it is put.

The design process follows the outline presented in Chapter 7. The table and equation
numbers refer to the numbering in the textbook.

1. Initial data of the motor

Shaft power, W P := 160000

3
n := 41.667 n⋅ 60 = 2.5000 × 10
Speed, 1/s (min-1) P
T := T = 611.1501
2π n
Torque T = P/(2πn), Nm
U := 690
Line-to-line voltage, V star connected

Number of phases m := 3

Number of pole pairs p := 4

Frequency, Hz f := n⋅ p f = 166.6680

Angular frequency, 1/s ω := 2 ⋅ π ⋅ f

Desired efficiency η := 0.95

cosφ := 0.91
Power factor

Coercivity of the permanent magnets, A/m Hc := 800000

Remanence flux density of the permanent magnets, T Br := 1.05

Permeability of vacuum, Vs/(Am) μ 0 := 4 ⋅ π ⋅ 10

−7

Permeability of the permanet magnet Br

μ rec := μ rec = 1.0445
material μ 0⋅ Hc

Temperature rise in the machine windings, K Θ := 80

6
Conductivity of copper at 20 degrees C, S/m σ Cu20C := 57⋅ 10

−3
Temperature coefficient of resistivity for copper, 1/K α Cu := 3.81⋅ 10

Space factor of the stator core k Fe := 0.97

Density of iron, kg/m3 ρ Fe := 7600

Density of the permanent magnet material, kg/m3 ρ PM := 7500

ρ Cu := 8960
Density of copper, kg/m3

We introduce the BH curve of the M800-50A lamination material. The specific loss
of this material at 1.5 T and 50 Hz is
P15 := 6.6 W /kg
⎛ 0.0 ⎞ ⎛⎜ 0 ⎞⎟
⎜ ⎟
⎜ 0.1 ⎟ ⎜ 84.5 ⎟
⎜ 0.2 ⎟ ⎜ 107 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 0.3 ⎟ ⎜ 121 ⎟
⎜ 0.4 ⎟ ⎜ 133 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 0.5 ⎟ ⎜ 145 ⎟
⎜ 0.6 ⎟ ⎜ 156 ⎟
⎜ 0.7 ⎟ ⎜ 168 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 0.8 ⎟ ⎜ 180 ⎟
⎜ 0.9 ⎟ ⎜ 194 ⎟
⎜ ⎟ ⎜ ⎟
1.0 ⎟ 209 ⎟
B := ⎜ H := ⎜
⎜ 1.1 ⎟ ⎜ 228 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 1.2 ⎟ ⎜ 254 ⎟
⎜ 1.3 ⎟ ⎜ 304 ⎟
⎜ 1.4 ⎟ ⎜ 402 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 1.5 ⎟ ⎜ 660 ⎟
⎜ 1.6 ⎟ ⎜ 1480 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 1.7 ⎟ ⎜ 3710 ⎟
⎜ 1.8 ⎟ ⎜ 7300 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 1.9 ⎟ ⎜ 15000 ⎟ T 2
⎜ 2.0 ⎟ ⎜ 30000 ⎟
⎜ ⎟ ⎜ ⎟
⎝ 2.1 ⎠ ⎝ 100000 ⎠

B 1
BH curve of M800-50

0
4 5
0 5 .10 1 .10
A/m
H

We also introduce the graph for the yoke magnetic voltage calculation
 ⎛0 ⎞ ⎛ 0.72 ⎞
⎜ ⎟ ⎜ ⎟
⎜ 0.1 ⎟ ⎜ 0.72 ⎟
⎜ 0.2 ⎟ ⎜ 0.72 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 0.3 ⎟ ⎜ 0.72 ⎟
⎜ 0.4 ⎟ ⎜ 0.72 ⎟
⎜ 0.5 ⎟ ⎜ 0.72 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 0.6 ⎟ ⎜ 0.71 ⎟
⎜ 0.7 ⎟ ⎜ 0.70 ⎟ Influence of the maximum flux density of the stator or rotor
⎜ ⎟ ⎜ ⎟ yoke on the definition of the coefficient c, applied in the
⎜ 0.8 ⎟ ⎜ 0.67 ⎟ determination of magnetic voltage (see Fig. 3.17)
⎜ 0.9 ⎟ ⎜ 0.63 ⎟
By := ⎜ ⎟ c := ⎜ ⎟
1.0
⎜ ⎟ ⎜ 0.57 ⎟ 1
⎜ 1.1 ⎟ ⎜ 0.48 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 1.2 ⎟ ⎜ 0.40 ⎟
⎜ 1.3 ⎟ ⎜ 0.33 ⎟ c 0.5
⎜ 1.4 ⎟ ⎜ 0.26 ⎟
⎜ ⎟ ⎜ ⎟
⎜ 1.5 ⎟ ⎜ 0.20 ⎟
⎜ 1.6 ⎟ ⎜ 0.17 ⎟
⎜ ⎟ ⎜ ⎟ 0
0 0.5 1 1.5 2
⎜ 1.7 ⎟ ⎜ 0.16 ⎟
By
⎜ 1.8 ⎟ ⎜ 0.15 ⎟
⎜ ⎟ ⎜ ⎟
⎝ 1.9 ⎠ ⎝ 0.14 ⎠

2. Tangential stress

The determination of the main dimensions starts with choosing the appropriate
tangential stress for open-circuit cooling according to the machine type (Table 6.3).

σ Ftan := 33500 ⋅ cosφ 4

σ Ftan = 3.0485 × 10 Pa
3. Rotor size

The rotor volume Vr can be solved from Eq. (6.2)

Dr2
T = σ F tan π l ' = 2σ F tanVr ,
2

where Dr is the outer rotor diameter and l' the equivalent length of the rotor.
The volume Vr is
 T
Vr :=
2 σ Ftan Vr = 0.0100 m3

The ratio of equivalent core length and air-gap diameter is according to Table 6.5:

l' π
=χ≈ p
Dr 4p

π p
χ := χ = 0.3927
4⋅ p

From the equations above we can solve the rotor diameter (including surface magnets)
and the equivalent iron core length:
3
4⋅ Vr
Dr := Dr = 0.3191 m
π⋅χ

We select a rounded number

Dr := 0.32 m

l´ := χ ⋅ Dr l´ = 0.1257 m

4. Air gap and core length

Air-gap length (from the surface of the permanent magnet to the stator inner
surface) is calculated from Eq. (6.42):
0.4
0.18 + 0.006 ⋅ P −4
δ := δ = 9.0410 × 10 m
1000

Surface magnets need a supporting band, the thickness of which is about 1 mm,
and thus the physical air-gap length is increased to

δ := 0.0016 m

The inner diameter of the stator is

Ds := Dr + 2 ⋅ δ Ds = 0.3232 m

As there are no cooling channels, we have nv := 0 b v := 0 b ve := 0

The core length in a machine with no cooling channels is

 l := l´ − nv⋅ b ve − 2 ⋅ δ l = 0.1225 m

5. Stator winding

The number of slots per pole and phase q is chosen

q := 2

and the winding pitch W = 5/6τp.

5
W τp :=
6

The number of stator slots:

Q := 2 ⋅ p ⋅ m⋅ q Q = 48.0000

The stator slot pitch:

Ds
τ u := π ⋅ τ u = 0.0212 m
Q

The stator pole pitch:

Ds
τ p := π ⋅ τ p = 0.1269 m
2⋅ p

6. Air-gap flux density and linear current density

Since the tangential stress has already been selected, the amplitude of the
fundamental of the air-gap flux density has to correlate with the selected stress
value, which was the average value. According to Table 6.1, the peak value of
the fundamental air-gap flux density varies normally from 0.8 T to 1.05 T. Let
us choose for the fundamental air-gap flux peak density

B1peak := 0.95 T

As the magnets are rectangular, also the waveform of the flux density is
approximately rectangular. About 5-8 % of the flux that the rotor surface
permanent magnets create is lost as leakage flux, so the real magnets have to be
5-8 % wider than they are in our calculations. Let us choose for the effective
relative magnet width

α PM := 0.80
The amplitude of the first term of the air gap flux density Fourier series is:

⎛ π⎞
4 sin ⎜ α PM ⎟
⎝ 2⎠
B1peak = Bmax
π

where Bmax is the maximum value of the rectangular flux density. From this
equation we obtain

π ⋅ B1peak
Bmax :=
⎛ α PM ⋅ π ⎞ Bmax = 0.7845 T
4 sin⎜ ⎟
⎝ 2 ⎠

According to Table 6.2, the linear current density RMS value for an air-cooled
nonsalient pole PMSM is 35-80kA/m

Tangential loading assuming sinusoidal flux density waveform to estimate the

mechanical torque is

Aˆ Bˆ δ cos ϕ ABˆ δ cos ϕ

σ F tan = =
2 2
We may solve for the RMS linear current density

σ Ftan
A := 4
0.5⋅ B1peak ⋅ cosφ⋅ 2 A = 4.9870 × 10 A/m

This value corresponds well to the values given in Table 6.3.

7. Number of coil turns in a phase winding

The number of coil turns in series in a phase winding can be calculated according
to Eq. (7.7)

2 EPM 2 EPM
N= =
ωkw1Φ m ωk w1α PM Bˆδτ pl '
ˆ

where EPM is the permanent-magnet-induced voltage. The value of EPM has a

significant influence on the machine performance. Depending on the desired machine
performance, EPM may vary from slightly under the supply voltage to slightly over the
supply voltage. If the motor performance after the design is not desired the designer
may consider changing EPM. Now EPM is assumed to be
 U
EPM := EPM = 398.3717 V
3

ν := 1

⎛ π ⎞ ⎛ ν ⋅π ⎞
2 ⋅ sin⎜ ν ⋅ ⋅ W τp⎟ ⋅ sin⎜ ⎟
⎝ 2 ⎠ ⎝ m⋅ 2 ⎠
k w( ν ) :=
Q ⎛
⋅ sin⎜ ν ⋅ π ⋅
p⎞
⎟
m⋅ p ⎝ Q⎠

The winding factor for the fundamental

−3
k w( 1 ) = 933.0127 × 10

2 ⋅ EPM
N := N = 57.6031
ω⋅ k w( 1 ) ⋅ α PM ⋅ Bmax⋅ τ p⋅ l´

8. Number of conductors in a slot

The number of parallel branches is selected as

a := 1

The number of conductors in a slot is

N
zQ := 2 ⋅ a ⋅ m⋅ zQ = 7.2004
Q

zQ has to be an even number in a two-layer winding. (In a one-layer winding, zQ

has to be an even or odd number, i.e. an integer number.) The rounding to an even
number may make a large difference to zQ calculated above. Changing the number
of parallel paths may help.

a := 2

N
zQ := 2 ⋅ a ⋅ m⋅ zQ = 14.4008
Q

we select zQ := 14

and the number of coil turns in the phase winding becomes

Q⋅ zQ
N := N = 56.0000
2⋅ a⋅ m
9. New Bmax

The rounding of zQ influences the peak value of the flux-density-induced voltage

EPM and the power factor. To keep the induced voltage EPM unchanged, we
will use a new air-gap flux density in the following calculations

Bmax = 0.7845 T

(Note that you have to insert appropriate values in the following equation.)
⎛ z Q non − rounded ⎞
Bmax new = ⎜ ⎟ Bmax old
⎜ z Q selected ⎟
⎝ ⎠

⎛ 14.4 ⎞ ⋅ 0.7845
Bmax := ⎜ 14 ⎟ Bmax = 0.8069 T
⎝ ⎠

10. Width of the stator slot

According to Table 6.1, the flux density of a stator tooth for nonsalient-pole
synchronous machines varies normally from 1.5 T to 2.0 T. Let us choose for
the apparent density

Bdapp := 1.6 T
l 'τ u
According to the textbook, the apparent flux density is Bˆd' = Bˆδ
kFe ( l − nvbv ) bd
The tooth width is solved as
l´⋅ τ u Bmax
b d := ⋅ b d = 0.0113 m
( )
k Fe⋅ l − nv⋅ b v Bdapp

11. Stator slot dimensions

To determine the stator slot dimensions, we have first to estimate the stator
current, Eq. (7.9a):
P
Is =
mηU s,ph cos ϕ

The stator phase voltage Usph

U
Usph :=
3

The initial guess for the stator current is

 P
Is :=
m⋅ η ⋅ Usph ⋅ cosφ Is = 154.8621 A

The area of one conductor in a stator slot is

Is
Scs =
aJ s

Selecting the value Js = 4.5 A/mm2 for the stator current density (Table 6.2), we obtain

6
J s := 4.5⋅ 10 A /m2

Is
−5
Scs := Scs = 1.7207 × 10 m2 Scs⋅ 1000000 = 17.2069 mm2
a⋅ Js

The wound area SCus of the stator slot is obtained by

z Q S cs
S Cus =
k Cus

where kCu,s is the space factor of the slot. The space factor inside the slot
insulation is about

k Cus := 0.63

With this value of the space factor, the wound area of the slot

zQ⋅ Scs
−4
SCus := SCus = 3.8238 × 10 m2 SCus⋅ 1000000 = 382.3757 mm2
k Cus

The slot form and the slot dimensions are

presented in the figure below.

We can choose the following dimensions

 b 1 := 0.003 m b1
h1
h1 := 0.001 m h2 h3

h2 := 0.002 m

h3 := 0.0050 m h' h5 h
4

h6 := 0.0005
m

h´ := 0.0005
m
b4c h6
b4
Other dimensions are determined as follows b5c
b5
π ⋅ ⎡⎣Ds + 2 ⋅ ( h1 + h2)⎤⎦
b 4 := − bd b 4 = 0.0103 m
Q

2 ⋅ π ⋅ h3
−3
b 4c := b 4 + − 2 ⋅ h6 b 4c = 9.9152 × 10m
Q

The height h5 is determined so that the tooth width bd is constant and the wound
area of the slot SCus has the value calculated above. The following two equations
are used to solve h5

2πh5
b5c = b4 c +
Q
b4c + b5c π
Scus = h5 + b52c
2 8

The slot separator h' is assumed zero. Its influence has been taken into
account in the space factor kCus. The user must give an iteration value for h5
to match SCus
h5 := 0.027 m SCus⋅ 1000000 = 382.3757 mm2
2 π h5
b 5c := b 4c + b 5c = 0.0134 m
Q

⎛ b 4c + b 5c ⎞ π
SCus := ⎜ ⎟ ⋅ h5 + b5c2 1000000 ⋅ SCus = 386.4566 mm2
⎝ 2 ⎠ 8

The value h5 given above satisfies the equations with sufficient accuracy. b5 gets
the value
b 5 := b 5c + 2h6 b 5 = 0.0144 m
b 5c
h4 := h5 + h4 = 0.0337 m
2

The total area of the slot is needed later in the calculations

⎛ b4 b1 ⎞ ⎛ π ⋅ h3 ⎞ ⎛ b 4 + b 5 ⎞ π
Sslot := b 1⋅ h1 + h2⋅ ⎜ + ⎟ + h3⋅ ⎜ b4 + ⎟+⎜ ⎟ ⋅ h5 + b 52
⎝2 2 ⎠ ⎝ Q ⎠ ⎝ 2 ⎠ 8

−4
Sslot = 4.8478 × 10 m2 Sslot ⋅ 1000000 = 484.7770 mm2

12. Magnetic voltage over the tooth

The flux density in the tooth is obtained by solving the intersection of the BH curve of the
electric sheet in question and the line given by Eq. (3.46)
Su B
B̂d = B̂d' − μ 0 Ĥ d
Sd B̂d'
Su l 'τ u
where = −1 S
S d k Fe (l − n v bv )bd Bˆ d = Bˆ d' − u μ 0 Hˆ d
Sd
B̂d
see Eq. (3.44)

The apparent flux density in the stator tooth is H

Ĥ d
l´⋅ τ u ⋅ Bmax
Bdapp := Bdapp = 1.6000 T
( )
k Fe⋅ l − nv⋅ b v b d

Using the BH curve of M800-50A, we get for the field strengths in the teeth

vs := lspline( H , B)

Initial guess

Bed := Bdapp (
Hed := interp vs , B , H , Bed ) Hed = 1.4800 × 10
3
A/m

Given

⎛ l´⋅ τ u ⎞
Bdapp − ⎜ k ⋅ l⋅ b − 1⎟ ⋅ μ 0⋅ interp( vs , B , H , Bed ) = Bed
⎝ Fe d ⎠

Bd := Find Bed( ) Bd = 1.5982 T

 (
Hd := interp vs , B , H , Bd ) 3
Hd = 1.4652 × 10 A/m

The solution for the magnetic voltage of the tooth is

∧ hd
U m,d = ∫ H d ⋅ dl We simplify and calculate
0

(
Umds := Hd⋅ h3 + h5 ) Umds = 46.8852 A

The magnetic voltages of the tooth tip and of the rounded part of the tooth are small
and may therefore be omitted.

13. Checking the saturation factor

In the case of a permanent magnet motor, the saturation of the teeth does not influence
the waveform of the air-gap flux density, in other words, αPM remains constant.

14. Height of stator and rotor yokes and permanent magnets. Magnetic voltage
of air gap, stator and rotor yokes, and permanent magnet

The magnetic voltage of the air gap is calculated in the following. According to Eqs.
(3.7b) and (3.8)
⎡ ⎡ 2⎤⎤
2⎢ ⎡ b1 ⎤ 2δ ⎢ ⎛ b 1 ⎞ ⎥⎥
κ := ⋅ ⎢atan⎢ ⎥ − ⋅ ln⎢ 1 + ⎜ ⎟ ⎥⎥
π ⎣ ⎣ 2( δ )⎦ b1 ⎣ ⎝ 2δ ⎠ ⎦⎦ κ = 0.2653

Coefficient γ for the apparent air-gap calculation

τu
k C1 :=
τ u − κ ⋅ b1 k C1 = 1.0391

The equivalent air gap

−3
δ e := k C1⋅ δ δ e = 1.6626 × 10 m

The magnetic voltage of the air gap is according to Eq. (3.35)

Bmax
3
Umδe := ⋅ δe Umδe = 1.0676 × 10 A
μ0

The height of the stator yoke hys and the height of the rotor yoke hyr are solved
from Eqs. (3.48) and (3.49):

Φˆ Φˆ m
Bˆ ys = m =
2 S ys 2k Fe (l − nv b v )hys

Φˆ Φˆ m
Bˆ yr = m =
2 S yr 2k Fe (l − nv bv )hyr

where the air-gap flux is

Φ m := α PM ⋅ Bmax⋅ τ p⋅ l´ Φ m = 0.0103 Vs

The maximum flux densities of the stator and rotor yokes are selected
according to Table 6.1.

Bys := 1.3 T Byr := 1.3 T

Φm
hys := hys = 0.0333 m
( )
2k Fe⋅ l − nv⋅ b v ⋅ Bys

Φm
hyr := hyr = 0.0333 m
( )
2k Fe⋅ l − nv⋅ b v ⋅ Byr

In our example, the rotor carries thin laminations of height hyr. Permanent magnets
are also often placed on solid steel. Such an arrangement may, however, create extra
losses under the permanent magnets.

The magnetic voltages are according to Eqs. (3.51) and (3.52)

Uˆ m,ys = cs Hˆ ysτ ys

Uˆ m,yr = cr Hˆ yrτ yr

The coefficient c can be taken from Fig. (3.17) below

0.8
c
0.6

0.4

0.2

0
0 0.5 1.0 1.5 2.0
Bˆyr, Bˆys /T
From the BH curve of M800-50A, we get for the maximum field strengths in the stator
and rotor yokes
vs := lspline( B , H)

Bys = 1.3000 ( )
Hymaxs := interp vs , B , H , Bys Hymaxs = 304.0000 A /m

Byr = 1.3000 ( )
Hymaxr := interp vs , B , H , Byr Hymaxr = 304.0000 A /m

Using Fig. 3.17, we get the correction factor c:

vs := lspline( By , c)

( )
cs := interp vs , By , c , Bys cs = 0.3300

( )
cr := interp vs , By , c , Byr cr = 0.3300

The average stator yoke diameter (see Figs. 3.1 and 3.2) is

(
Dys := Ds + 2 h1 + h2 + h3 + h4 + h6 + hys ) Dys = 0.4410 m

π ⋅ Dys
τ ys := τ ys = 0.1732 m
2p

The magnetic voltage of the stator yoke is

Umys := cs⋅ Hymaxs⋅ τ ys Umys = 17.3729 A

The height of the permanent magnets is calculated in the following.

The peak value of the total magnetic voltage has to be equal to the current
linkage HchPM
Uˆ Uˆ
Uˆ mtot = Uˆ mδδ + Uˆ mds + Uˆ mPM + mys + myr = H c hPM
2 2
The magnetic voltage over the permanent magnet is

H
Uˆ mPM = c BPM hPM
Br
The permanent magnet flux density BPM is equal to the air-gap flux density

BPM := Bmax

The magnetic voltage over the rotor yoke is according to the textbook
Uˆ myr = cr Hˆ yrτ yr
πDyr π
τ yr =
2p
=
2p
( Dr − 2hPM − hyr )
π π
Uˆ myr = cr Hˆ yr ( Dr − hyr ) − cr Hˆ yr hPM
2p p

The total magnetic voltage

∧
∧ ∧ ∧ H U mys π π
U mtot = H c hPM = U mδe + U mds + c BPM hPM + + cr Hˆ yr ( Dr − hyr ) − cr Hˆ yr hPM
Br 2 4p 2p

from which we can solve the height of the permanent magnets

Umys π ⋅ cr⋅ Hymaxr⋅ ( Dr − hyr)

Umδe + Umds + +
2 4p
hPM :=
Hc π ⋅ cr⋅ Hymaxr
Hc − ⋅ BPM +
Br 2p

−3
hPM = 6.0934 × 10 m 1000⋅ hPM = 6.0934 mm

The magnetic voltage of the permanent magnet

Hc
3
UmPM := ⋅ BPM ⋅ hPM UmPM = 3.7462 × 10 A
Br

The average diameter of the rotor yoke

Dyr := Dr − 2hPM − hyr Dyr = 0.2745 m

π ⋅ Dyr
τ yr := τ yr = 0.1078 m
2p

The magnetic voltage of the rotor yoke

Umyr := cr⋅ Hymaxr⋅ τ yr Umyr = 10.8132 A

15. Outer stator diameter and inner rotor diameter

The outer stator diameter is

Dse := Dys + hys

Dse = 0.4743 m
The inner rotor diameter is

Dri := Dyr − hyr Dri = 0.2411 m

16. Total magnetic voltage of the magnetic circuit

The total magnetic voltage is

Umys Umyr
Umtot := Umδe + Umds + UmPM + +
2 2

3
Umtot = 4.8747 × 10 A
All the dimensions of the motor have now been defined. Next, the resistances,
inductances, losses and other characteristics of the motor are calculated.

17. Stator resistance

The average length lav of a coil turn (Eq. (5.2))

lav := 2l + 2.4W τp⋅ τ p + 0.1 lav = 0.5988 m

The conductivity of copper wire in 100 degrees C (the temperature rise Θ =

80 K) is

σ Cu20C 7
σ Cu := σ Cu = 4.3685 × 10 S/m
1 + Θ ⋅ α Cu

The DC resistance of a phase winding

N⋅ lav
R := R = 0.0223 Ω
σ Cu⋅ a ⋅ Scs

18. Magnetizing inductance

The effective air gap

Umys Umyr
Umδe + Umds + UmPM + +
2 2 −3
δ ef := ⋅δe δ ef = 7.5916 × 10 m
Umδe

The calculation of magnetizing inductance in d-direction of the two-axis

model, Eq. (3.110)
 m 2 1 4 τp
Lmd := ⋅ ⋅ μ 0⋅ l´⋅
2 π
⋅ ⋅
2 ⋅ p π δ ef
(
⋅ kw( 1 ) ⋅ N
2
) Lmd = 1.0954 × 10
−3
H

As the machine is symmetrical in this case,

Lmq := Lmd

otherwise the q-axis effective air gap should first be evaluated.

19. Air-gap leakage inductance and reactance

Leakage factor, Eq. (4.18)

2
⎛k ⎞
ν = +∞
σ δ = ∑ ⎜⎜ wν ⎟⎟
ν = −∞ ⎝ νk w1 ⎠
ν ≠1

Pitch factor, Eq. (2.32) Distribution factor, Eq. (2.24)

⎛ W π⎞ sin(νqα u / 2 )
kpν = sin ⎜ν ⎟ k dν =
⎜ τ 2⎟ qsin(να u / 2 )
⎝ p ⎠

p⋅ 2π
α u := α u = 0.5236 Eq. (2.2)
Q

The air-gap leakage is calculated in two parts for 600 harmonics

2
⎡ ⎡ α u⎤ ⎤
⎢ sin⎢( 1 + 2 ⋅ k ⋅ m) ⋅ q ⋅ ⎥ ⎥
⎢ sin⎡⎢( 1 + 2⋅ k ⋅ m) ⋅ Wτp⋅ π ⎥⎤ ⋅ ⎣ 2⎦
⎥
⎢ ⎣ 2⎦ ⎡ α u⎤ ⎥
300 ⎢ q ⋅ sin⎢( 1 + 2 ⋅ k ⋅ m) ⋅ ⎥ ⎥
⎣ 2⎦
k δ1 :=
∑ ⎢
⎣ ( 1 + 2 ⋅ k ⋅ m ) ⋅ k w ( 1 )
⎥
⎦ k δ1 = 0.0103
k= 1

2
⎡ ⎡ α u⎤ ⎤
⎢ sin⎢( 1 + 2 ⋅ k ⋅ m) ⋅ q ⋅ ⎥ ⎥
⎢ sin⎡⎢( 1 + 2⋅ k ⋅ m) ⋅ Wτp⋅ π ⎥⎤ ⋅ ⎣ 2⎦
⎥
⎢ ⎣ 2⎦ ⎡ α u⎤ ⎥
− 300 ⎢ q ⋅ sin⎢( 1 + 2 ⋅ k ⋅ m) ⋅ ⎥ ⎥
⎣ 2⎦
k δ12 :=
∑ ⎢
⎣ ( 1 + 2 ⋅ k ⋅ m ) ⋅ k w ( 1 )
⎥
⎦ k δ12 = 0.0132
k= −1

Thus, the air-gap leakage factor is

σ δs := k δ1 + k δ12 σ δs = 0.0234
The air-gap leakage inductance

−5
Lδ := σ δs⋅ Lmd Lδ = 2.5685 × 10 H

and the air-gap leakage reactance

Xδ := Lδ ⋅ 2 ⋅ π ⋅ f Xδ = 0.0269 Ω

20. Slot leakage inductance and reactance

ε := 1 − W τp ε = 0.1667 Eq. (4.51)

9
k 1 := 1 − ⋅ε k 1 = 0.9063 Eq. (4.53)
16

3
k 2 := 1 − ⋅ε k 2 = 0.8750
4

h4 − h´ ⎛ h3 h1 h2 ⎛ b4 ⎞ ⎞ h´
λ u := k 1⋅ + k 2⋅ ⎜ + + ⋅ ln⎜ ⎟⎟ + λ u = 2.0048 Eq. (4.49)
3⋅ b4 ⎝ b4 b1 b4 − b1 ⎝ b1 ⎠ ⎠ 4⋅ b4
4m 2 −4
Lu := ⋅ μ 0⋅ l´⋅ N ⋅ λ u Lu = 2.4820 × 10 H Eq. (4.30)
Q

Xu := 2 π f⋅ Lu Xu = 0.2599 Ω

21. Tooth tip leakage inductance and reactance

δ
5⋅
b1
λ d := k 2⋅ λ d = 0.3271 Eq. (4.62)
δ
5 + 4⋅
b1

4m 2 −5
Lσd := ⋅ μ 0⋅ l´⋅ λ d⋅ N Lσd = 4.0497 × 10 H
Q

Xσd := 2 π f⋅ Lσd Xσd = 0.0424 Ω

23. End winding leakage inductance and reactance

The average length lw of the end winding (See Fig. 4.15)

 zQ zQ
q=2

leW

WeW

lav
lew := 0.025 m lw := −l lw = 0.1769 m
2

W ew := lw − 2lew W ew = 0.1269 m

The permeance factors are selected according to Table 4.2. (When we select the
end winding permeance factor, a permanent magnet machine may be regarded as
a salient-pole machine.)
λ lew := 0.518

λ W := 0.138
2 ⋅ lew⋅ λ lew + W ew⋅ λ W
λ w := λ w = 0.2454
lw

The end winding leakage inductance, Eq. (4.64)

4m 2 −5
Lw := ⋅ q ⋅ N ⋅ μ 0⋅ l w ⋅ λ w Lw = 8.5545 × 10 H
Q

Xw := 2 π f⋅ Lw Xw = 0.0896 Ω

23. Synchronous inductance and reactance

The stator leakage inductance, Eq. (4.7)

Lsσ := Lδ + Lu + Lσd + Lw

−4
Lsσ = 3.9993 × 10 H

and the leakage reactance

Xsσ := 2 π f⋅ Lsσ Xsσ = 0.4188 Ω

The direct-axis synchronous inductance, (See Item 18)
−3
Ld := Lmd + Lsσ Ld = 1.4953 × 10 H
and the reactance

Xd := 2 π f⋅ Ld Xd = 1.5659 Ω

Because there is no saliency in the rotor, the quadrature-axis synchronous

inductance is equal to the direct-axis synchronous inductance

Lq := Ld Xq := Xd

24. Losses (except stator losses)

To calculate the core losses, we need the masses of different iron parts.

Bd = 1.5982
Vs/m2

Bys = 1.3000 Vs/m2

f = 166.6680 Hz

The total volume of the stator is

π ⎛ 2
⋅ Dse − Ds ⎞⎠ ⋅ l
2
V´s := V´s = 0.0116 m3
4 ⎝

The volume of the stator yoke

⎡⎛ Dse ⎞ 2 ⎛ Dse ⎞
2⎤
Vys := π ⋅ ⎢⎜ ⎟ −⎜ − hys⎟ ⎥ ⋅ l
⎣⎝ 2 ⎠ ⎝ 2 ⎠⎦
−3
Vys = 5.6557 × 10 m3

The mass of the stator yoke

mys := Vys⋅ k Fe⋅ ρ Fe mys = 41.6939 kg

The total volume of the stator slots

Vslots := Q⋅ Sslot ⋅ l

−3
Vslots = 2.8496 × 10 m3

The volume of the teeth

 Vds := V´s − Vys − Vslots

−3
Vds = 3.0867 × 10 m3
The total mass of the teeth

mds := Vds⋅ k Fe⋅ ρ Fe mds = 22.7555 kg

The mass of the stator teeth (only the height h5 is taken into account) for loss
calculation. The other parts of the teeth have a low flux density and are ignored in
this simplified calculation.

md := k Fe⋅ ρ Fe⋅ Q⋅ b d⋅ h5⋅ l md = 13.2043 kg

Correction coefficients for the core loss calculations, Table 3.2

k Fed := 2

k Fey := 1.5

The core loss in the stator yoke is according to Eqs. (3.69 and 3.77)
3
2 2
⎛ Bys ⎞ ⎛ f ⎞ 3
PFeys := k Fey⋅ P15⋅ ⎜ ⎟ ⋅ mys⋅ ⎜ ⎟ PFeys = 1.8868 × 10 W
⎝ 1.5 ⎠ ⎝ 50 ⎠
The core loss of the tooth area is calculated using the mass md defined above
3
⎡⎛ Bd ⎞ ⎤ f 2 2
PFeds := k Fed ⋅ P15⋅ ⎢⎜ ⎟ ⋅ md⎥ ⋅ ⎛⎜ ⎟⎞ PFeds = 1.2042 × 10
3
W
⎣⎝ 1.5 ⎠ ⎦ ⎝ 50 ⎠
The total iron losses are

3
PFe := PFeys + PFeds PFe = 3.0910 × 10 W
Mechanical losses consisting of windage and ventilator losses are calculated from
an experimental equation (Eq. (9.19) and Table 9.2)

Pρ = kρ Dr (l + 0.6 τp)vr2

vr := π ⋅ n⋅ Dr vr = 41.8882 m/s

k ρ := 10 Ws2/m4

( )
Pρ := k ρ ⋅ Dr⋅ l + 0.6⋅ τ p ⋅ vr
2
Pρ = 1.1152 × 10
3
W
The stator slot openings cause permeance harmonic losses in the rotor surface permanent
magnets.
The slot openings b1 cause a frequency fPM on the rotor surface

fPM := n⋅ Q

3
fPM = 2.0000 × 10 Hz

The fictitious air gap for the loss calculation is

hPM
−3
δ PMEC := δ + δ PMEC = 4.5170 × 10 m
2 μ rec

b e := κ ⋅ b 1 −4
b e = 7.9600 × 10 m See Item 14

τu
k CPM :=
τ u − be k CPM = 1.0391

2
⎛ b1 ⎞ ⎛ b1 ⎞
u := ⎜ ⎟+ 1+ ⎜ ⎟ u = 1.3858 Eq. (3.10)
⎝ 2 δ PMEC ⎠ ⎝ 2δ PMEC ⎠
2
1 + u − 2u
β := β = 0.0255
2(1 + u )
2

B0 := β ⋅ Bmax B0 = 0.0206 σ PM := 670000 S /m

σ PM
k ν := fPM ⋅ 2 π ⋅ μ rec⋅ μ 0⋅
2 k ν = 74.3325

fPM ⋅ 2 π
β ν := β ν = 300.0000
π Dr⋅ n

4 2
⎛ 1 ⎞⋅ ⎛ βν ⎞ ⎛ βν ⎞
a Rν := ⎜ ⎟ 4+⎜ ⎟ +⎜ ⎟ a Rν = 4.0435
⎝ 2⎠ ⎝ kν ⎠ ⎝ kν ⎠

⎛ aRν ⎞ ⎛
PPMEC := ⎜
τ u ⎞ ⎛ B0 ⎞ ⎛ k ν ⎞
⎟ ⋅⎜1 + ⎟ ⋅⎜
2
( 2⋅ kν ) 2

⎟ ⋅⎜ ⎟ ⋅ π Dr⋅ α PM ⋅ l
⎝ 2 ⎠⎝ 2l ⎠ ⎝ μ 0⋅ μ rec ⎠ ⎝ σ PM ⎠
βν
2

PPMEC = 723.1000 W
The calculation assumed bulky magnets of one piece each. The losses are large and
therefore the magnets should maybe be made of pieces to minimize the losses.
There are also some additional losses in the machine. Let us assume that they are 0.5
% of the output power

Pex := 0.005 ⋅ P Pex = 800.0000 W

25. Rated load, stator current, stator resistive losses and total losses

The stator current should be known in the loss calculation. The final value of the current
must be iterated.

The old stator current

Is = 154.8621 A
The stator current iteration:

We give a new iteration value for the stator current

Is := 146 A

The stator resistive losses (Item 17)

2 3
PCu := 3 ⋅ Is ⋅ R PCu = 1.4263 × 10 W

The sum of losses in the machine

3
Ploss := PFe + PCu + Pρ + PPMEC + Pex Ploss = 7.1556 × 10 W

Input power
5
Pin := P + Ploss Pin = 1.6716 × 10 W

According to Eq. (7.214)

⎛U E 2 Ld − Lq
⎞
Pin = 3⎜ sph PM sin δ + U sph sin 2δ ⎟
⎜ ωL 2ωs Ld Lq ⎟
⎝ s d ⎠

Initial guess for the new load angle is the previous load angle

δ loadin := 0
 Given

⎛ Usph ⋅ EPM Xd − Xq ⎞
Pin = 3 ⋅ ⎜ ( )
⋅ sin δ loadin + Usph ⋅
2
2 ⋅ X d⋅ X q
( )⎟
⋅ sin 2 ⋅ δ loadin
⎝ Xd ⎠

Thus, the load angle is

180
δ loadinN := Find( δ loadin) δ loadinN = 0.5821 rad deltaN := δ loadinN ⋅
π

The machine runs at a load angle of deltaN = 33.3515 degrees

The direct-axis component of the stator current

( ( ) ( )) − EPM ⋅ Xq
U
⋅ Xq⋅ cos δ loadinN − R⋅ sin δ loadinN
3
Id :=
2 Id = −43.8805 A
Xd⋅ Xq + R

The quadrature-axis component of the stator current

( ( ) ( )) − EPM ⋅ R
U
⋅ R⋅ cos δ loadinN + Xd⋅ sin δ loadinN
3
Iq :=
2 Iq = 139.2407 A
X d⋅ X q + R

The old stator current Is = 146.0000

The new stator current

2 2
Is := Id + Iq

Is = 145.9913 A

If Is differs more than 1 % from the estimated value, give the stator current a new
value and repeat the calculations of Item 25.

26. Efficiency and power factor

The efficiency of the machine is

P
η := ⋅ 100
Pin η = 95.7192 %
The power factor of the machine may be calculated as

Pin
cosφ :=
3 ⋅ U⋅ Is cosφ = 0.9580

27. Masses of the active materials

The masses of the stator yoke mys and the teeth mds have been
calculated above.

The rotor core outer diameter

Dryi := Dr − 2 ⋅ hPM Dryi = 0.3078 m

The mass of the permanent magnets

Dryi + Dri
mPM :=
2
(
⋅ π ⋅ α PM ⋅ l⋅ hPM ⋅ ρ PM ) mPM = 3.8608 kg

The mass of the copper

( )
mCu := ρ Cu⋅ l + 2 ⋅ lw ⋅ Q⋅ zQ⋅ Scs mCu = 49.3474 kg

The mass of the rotor yoke

2 2
Dryi − Dri
myr := k Fe⋅ π ⋅ ⋅ l⋅ ρ Fe myr = 25.9511 kg
4

The total mass of the active parts is

mtot := myr + mys + mds + mCu + mPM mtot = 143.6087 kg

28. Load angle equation graph

The output torque at the rated point is

P
Tsh := Tsh = 611.1501 Nm
2⋅ π ⋅ n

Neglecting losses, the load angle equation is

i := 0 .. 100
 π
δ load := i⋅
i 100

⎡⎢ EPM ⋅ Usph 2 ⎤
T( δ load ) :=
3⋅ p
⋅⎢ ⋅ sin( δ load ) +
Usph
⎛ 1 − 1 ⎞ ⋅ sin( 2 ⋅ δ )⎥
⋅⎜
Xd ⎟⎠
load ⎥
2⋅ π ⋅ f ⎣ Xd 2 ⎝ Xq ⎦

( (
max T δ load )) = 1.1614 × 103 Nm Maximum torque

( (
max T δ load ))
= 1.9003 Peak torque per rated torque
Tsh

Load characteristic
1500
1375
1250
1125
1000
Torque (Nm)

875
( )
T δ load 750
625
500
375
250
125
0
0 0.31 0.63 0.94 1.26 1.57 1.88 2.2 2.51 2.83 3.14
δ load
Load angle (rad)

29. Summary of the machine design data

Main data:

5
Pin = 1.6716 × 10 W P = 1.6000 × 105 W η = 95.7192 cosφ = 0.9580

U = 690.0000 V EPM = 398.3717 V Usph = 398.3717 V Is = 145.9913

Id = −43.8805 A Iq = 139.2407 A deltaN = 33.3515 degrees

−3
N = 56.0000 k C1 = 1.0391 hPM = 6.0934 × 10 m

Q = 48.0000 q = 2.0000 W τp = 0.8333 Bmax = 0.8069 T

3
l´ = 0.1257 m PCu = 1.4263 × 10 W

Ds = 0.3232 m 3
W
PFe = 3.0910 × 10
Dse = 0.4743 m W
Pex = 800.0000
 3
m Pρ = 1.1152 × 10 W
τ p = 0.1269

m PPMEC = 723.1000 W
τ u = 0.0212 α PM = 0.8000

Magnetic voltages / A Um := 2UmPM + 2Umds + 2Umδe + Umys + Umyr

3 3
UmPM = 3.7462 × 10 Umys = 17.3729 mmf := Um mmf = 9.7494 × 10
3
Umds = 46.8852 Umyr = 10.8132 Θ PM := hPM ⋅ Hc 2 ⋅ Θ PM = 9.7494 × 10

3
Umδe = 1.0676 × 10

Slot dimensions Resistances and reactances in Ω, inductances in H

Usph
−3
b 1 = 3.0000 × 10 m ZN := ZN = 2.7287 Ω
Is
b 4 = 0.0103 m
ZN
−3
LN := LN = 2.6057 × 10 H
b 5 = 0.0144 m ω
R = 0.0223 Ω
−3
h1 = 1.0000 × 10 m
−3
Xd = 1.5659 Ω Ld = 1.4953 × 10 H
−3
h2 = 2.0000 × 10 m
−3
Lmd = 1.0954 × 10
H
−3
h3 = 5.0000 × 10 m
−3
Xq = 1.5659 Ω Lq = 1.4953 × 10 H
h4 = 0.0337 m
−3
Lmq = 1.0954 × 10 H
h5 = 0.0270 m
−4
−4 Xsσ = 0.4188 Ω Lsσ = 3.9993 × 10 H
h6 = 5.0000 × 10 m
R −3
Rpu := Rpu = 8.1738 × 10
ZN
Ld
Ldpu := Ldpu = 0.5739
LN
Lmd
Lmdpu := Lmdpu = 0.4204
LN
Lq
Lqpu := Lqpu = 0.5739
LN
 Lmq
Lmqpu := Lmqpu = 0.4204
LN
Ls σ
Lsσpu := Lsσpu = 0.1535
LN

The figure below shows a FEM*-calculated flux plot of the machine at the
rated operation point.
*FCSMEK software