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Permanent Magnet Synchronous Motor (PMSM) Design
Permanent Magnet Synchronous Motor (PMSM) Design
Characterized by permanent
magnets on rotor
Known for its simplicity and
low maintenance
No copper loss on rotor
High efficiency
Exploded View of a PM Motor
stepped magnet
Magnetization Profile
parallel magnetization radial magnetization
most popular
FEA
Halbach Array (3)
Airgap Flux Density
Rotor is outside
Stator Volume and Size
D 2l Pout
T
T V
0 m
Typically
V0 8 ~ 9 in3 / (ft lb) for 10hp or less (air cooled)
Destimated 1
3
(TV0 )
We can pick up D close to Destimated.
Stator Core Design
core gap, per half pole pitch
/P
leff Bg (a )ris da
D
0
l
cos( )d
2 /2
B
ef g, ae ae
2 P
D
f
0
pk
l ef Bg ,
P f
pk
DBg , pk leff
B (1)
core
core ,
pk dckili Pdc kili
tooth
l eff B g ( ae ) ri d Bg , pk s leff
ae
0
tooth s Bg , pk leff
B (2)
toot
h
t s k i li t i li
dc
D
1.6P
Effect of Pole Number on Yoke Flux Density
Finite Element Analysis
bs 0 (0.1 ~ 0.5)b
s
d s 0 (0.1 ~ 0.5)b
s
ds1
(0.1 ~ 0.5)bs
Stator Conductor Size
Js,copper Ia,rated / C
S
a
Air - cooled
400A/cm Js,copper A/cm 2
: 2
800
Ia,rated / C
Sa
J s,copper
Permanent Magnets
Copper loss
Typical
PC I 2 R
u
Stray losses
Electrical phenomenon such as skin and proximity
effect
Motor Losses (2)
Mechanical loss
Windage loss
Friction loss
Finite Element Analysis
Fundamental harmonic
dm
Da
g
D
Poles
2Hg g 2H m d m 0 0Hmdm 0 Bm Bg Ag
gBg Am
dm Bm Am
g H A
0 m g
Working Point for Permanent Magnetics (1)
Bm
R
0Hc 0Hm 0
R
H
B ( H H c) ( H H c) H
Br
Br
BH
H
c (BH) ( BH
To get )
Br Hc
Hc ,H
0 B
max m m
H 2 2
Working Point for Permanent Magnetics (2)
Br
rm
0 H
c
1 1.2
rm
d m Ag
Load Line: B H P is called permeance coefficient
m 0 c
g Am
dm
Pc 0 H m P Ag Ag / g Rm Pg
c
g A A /d R P
m m m g m
Define: B B H (1 )H
P
Bm
m
m m r m m c
c
H 1 rm
0 m m
Typically pick up: m 0.5 0.
9
Airgap Magnetic Field from PM Rotor
PM electrical angle
Bg , rotor PM embrace:
Bm
PM
PM
2
PM PM PM PM
2 2 de
Bm 2 2 P
2
2
B
g , rotor
B
Rh
de
2
d
h 1,3,5...
P
B B cos(h ) B cos(h )
Rh rh de rh d
2
B )d
2 PM /2
cos(h )d )cos(h
PM /2
rh B
/2 mae B (
ae /2 m ae ae
2 PM PM
PM
4 sin h pitch
th factor for the
2
h harmonic
B
kph sin PM
m
h
2
h
Phasor Diagram
V Bnet
jXS I A BS
E A BR
Typically, design cos 1 at full-load for PMSM.
sin 1/3 =19.47 ) so that (1 / 3)T
( T
cos Br , 0.94 Br , pk
pk
Ba , PM
sin Br , 0.33Br , B
4
sin B
pk
pk
pk r, pk m
2
Air Gap Size and PM Thickness
From: ˆ
Ba , pk 4 0 N a 1.5 2IA,rated
gˆ total P
gˆ dm
kg' g' g d / P (A A )
From: total c total total m rm
g
c g m
m
P
Carter’s coefficient c
1
m rm
g (1 m )g
'total
dm m g 'total rm
Effective Air Gap
gˆ total kc g 'total
where the Carter’s coefficient
kc s
2b b
b g'
2
s s 0
ln 1 s 0
s0
atan total
2 g 'total bs 0 2 g 'total
approximately
k s
c
bs20 d ds1
s 5 g ' b ts
bs0 s0
ds
total s0
s
gtotal
Rotor Sizing
Rotor is assembled by
heating and cooling.
Rotor is welded and
well balanced after
assembly.
Air Gap Size
For a 2-pole PM rotor 2 geff H H m Dr 0
g
2 g eff Bm ( A Am )
Dr 0 H mD r 0
S N g g
eff
D r/ 2 B
m
Pc
g eff 0H
Carter’s coefficient
m
Dr Dr Dr D
g k (g ) g
eff
c
2 2 2
2 rm rm
1 1 Dr D
( ) k (1 1 Dr
)
k
P 2 c
2 c
2
c rm rm
D
kc DD
D
r
1 1k g r
kc c
2
Pc rm
Define: B B H (1 )H Bm m
P
m m r m m c
1 rm
c H
0 m m
Typically pick up: m 0.5 0.
8
Effective Air Gap
gˆ k g gˆ g
Dr
, g g
Dr
' ' 2
total c total total eff total
2 rm rm
where the Carter’s coefficient
kc s
2b b
b g'
2
s s 0
ln 1 s 0
s0
atan total
2 g 'total bs 0 2 g 'total
approximately
kc s
2
ts d ds1 ds
b
s 5s g0 ' b bs0 s0
total s0
s
gtotal
Example - Specifications