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IEEE TRANSACTIONS ON ENERGY CONVERSION 1

Comparative Analysis of Partitioned Stator Flux

Reversal PM Machines Having Fractional-Slot
Nonoverlapping and Integer-Slot
Overlapping Windings
Z. Z. Wu, Student Member, IEEE, Z. Q. Zhu, Fellow, IEEE, and H. L. Zhan

Abstract—This paper proposes a new partitioned stator flux

reversal permanent magnet (PM) (PS-FRPM) machine having
integer-slot overlapping windings, i.e., the slot number per pole
per phase q is an integer, based on the magnetic gearing effect
in stator-PM machines. Compared with the existing PS-FRPM
machine with fractional-slot nonoverlapping windings, a more si-
nusoidal armature reaction magnetomotive force can be achieved
in the proposed PS-FRPM machine with integer-slot overlapping
windings, resulting in lower iron loss and PM loss. Electromag-
netic performance of the PS-FRPM machine, which has q = 1
overlapping windings is analyzed and compared with PS-FRPM
machine, which has q = 0.5 nonoverlapping windings by finite
element (FE) analysis. FE results show that the proposed 24/10/12-
outer-stator/rotor/inner-stator-pole PS-FRPM machine with q = 1
overlapping winding exhibits higher fundamental phase back-
electromotive force, higher average electromagnetic torque and
lower torque ripple, lower loss and higher efficiency, higher self-
inductance but lower mutual inductance, higher d-axis induc-
tance, and potential infinite flux-weakening capability compared
with the 12/10/12-outer-stator/rotor/inner-stator-pole PS-FRPM
machine with q = 0.5 nonoverlapping windings. Both prototype
machines with q = 1 overlapping winding and q = 0.5 nonover-
lapping windings are built and tested to verify the FE analyzes.
Index Terms—Flux reversal (FR), fractional-slot, integer-slot,
magnetic gearing effect, nonoverlapping winding, overlapping
windings, partitioned stator (PS), permanent magnet.
Fig. 1. Cross-sections of proposed 24/10/12-pole overlapping windings and
existing 12/10/12-pole non-overlapping windings PS-FRPM machines. (a) Pro-
I. INTRODUCTION posed overlapping winding with q = 1 (b) Existing non-overlapping winding
with q = 0.5.
ERMANENT magnet (PM) machines equipped with high
P energy-product PM material such as NdFeB can produce
large torque density and high efficiency due to the exemption surface-mounted on the stator teeth. However, conventional
of excitation copper loss [1]–[5]. Compared with rotor-PM ma- stator-PM machines with single stator also suffer from some
chines, the rotor in stator-PM machines, e.g., doubly-salient drawbacks, such as the geometric space confliction between
PM (DSPM) machine [6]–[9], switched flux PM (SFPM) ma- PMs and armature windings, which restrict their total areas and
chine [10]–[18], and flux reversal PM (FRPM) machine [19]– hence the torque density. In [23], a novel partitioned stator (PS)
[21], is very simple and robust without coils or PMs. In DSPM FRPM (PS-FRPM) machine having separate PMs and armature
and SFPM machines, stator lamination is segmented and not windings in two different stators is proposed and analyzed, as
integral which may face manufacturing challenge [22]. How- shown in Fig. 1(b). The results show that the PS-FRPM machine
ever, it is a single piece in FRPM machines, in which PMs are can produce more than 50% higher torque density than the con-
ventional FRPM machine with single stator in which both PMs
and armature windings are placed. The PSs in PS-FRPM ma-
Manuscript received September 15, 2015; revised November 16, 2015; ac- chine are not simple duplication of each other, but produce open-
cepted January 31, 2016. Paper no. TEC.2016.2525826.
The authors are with the Electrical Machines and Drives Group, Univer- circuit and armature reaction fields respectively. In contrast,
sity of Sheffield, Sheffield S10 2TN, U.K. (e-mail: wu.zhongze@gmail.com; in conventional double stator PM machines, including both
z.q.zhu@sheffield.ac.uk; hzhan2@sheffield.ac.uk). rotor-PM [24]–[26] and stator-PM [27] machines, they are iden-
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org. tical. Compared with the magnetically geared machine analyzed
Digital Object Identifier 10.1109/TEC.2016.2525826 in [28], PS-FRPM machines proposed in [23] having smaller PM
0885-8969 © 2016 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications standards/publications/rights/index.html for more information.
 This article has been accepted for inclusion in a future issue of this journal. Content is final as presented, with the exception of pagination.

2 IEEE TRANSACTIONS ON ENERGY CONVERSION

pole-pair number and iron piece number exhibit higher power

factor due to smaller flux-leakage [29]. More importantly, the
PS-FRPM machine is essentially a stator-PM machine as the
rotating part is the iron pieces whilst PMs are fixed. However,
the magnetically-geared machine in [28] has PMs in the rotor.
As well known, fractional-slot non-overlapping windings are
commonly used in the stator-PM machines, including both
single stator-PM [1]–[22] and PS-PM machines [23], since
machines with fractional-slot non-overlapping windings have
shorter end-winding length than those with integer-slot overlap-
ping windings [30]–[32]. However, machines with fractional- Fig. 2. Armature reaction MMF in 12/10/12-pole PS-FRPM machine with
slot non-overlapping windings have less sinusoidal armature non-overlapping windings.
reaction magnetomotive force (MMF) distribution, resulting in
higher loss and other parasitic effects such as torque ripple, noise a PS-FRPM machine. The cross-section of 12/10/12-pole PS-
and vibration due to the additional spatial harmonics [33]. In this FRPM machine having non-overlapping windings is shown in
paper, the PS-FRPM machine equipped with fractional-slot non- Fig. 1(b). The equivalent pole-pair number of armature reaction
overlapping windings in [23] is extended to integer-slot overlap- of 12/10/12-pole PS-FRPM machine is 4 which is defined as
ping armature winding having slot number per pole per phase the highest forward rotating MMF harmonic order. This can be
q = 1, based on the magnetic gearing theory [32], [34]–[39]. derived as follows.
The electromagnetic performance of the proposed PS-FRPM The three-phase symmetric sinusoidal currents iA , iB , and iC
machine having q = 1 integer-slot overlapping windings will be can be expressed as,
investigated and compared with the existing PS-FRPM machine ⎧ √
with q = 0.5 fractional-slot non-overlapping windings. ⎪
⎪ iA = 2Irm s sin (ωe t)
⎪
⎪  
This paper is organized as follows. In Section II, the operation ⎪
⎪ √
⎨ 2π
principle of PS-FRPM machine is analyzed based on magnetic iB = 2Irm s sin ωe t −
3 (3)
gearing theory and the overlapping winding layout is proposed ⎪
⎪  
⎪
⎪ √
and employed. In Section III, electromagnetic performance of ⎪
⎪ 2π
⎩ iC = 2Irm s sin ωe t +
the 24/10/12-pole PS-FRPM machine with q = 1 overlapping 3
windings and the 12/10/12-pole PS-FRPM machine with q = 0.5
where Irm s is the phase root mean square (RMS) current, ωe is
non-overlapping windings are comparatively analyzed by fi-
the electric angular speed which is given by,
nite element (FE) analysis. In Section IV, both prototype ma-
chines with q = 1 overlapping windings and q = 0.5 non- ωe = Nr Ωr (4)
overlapping windings are built and tested to validate the FE
predicted electromagnetic performance, followed by conclu- where Nr and Ωr are rotor iron piece number and the rotor
sions in Section V. rotating speed in rad/s, respectively.
In 12/10/12-pole non-overlapping winding PS-FRPM ma-
II. PS-FRPM MACHINE WITH NON-OVERLAPPING chine, the armature reaction MMF can be illustrated in Fig. 2,
AND OVERLAPPING WINDINGS in which Nc is the number of coil turns and θ1 is half of the coil
pitch θcp . With non-overlapping winding, θcp is equal to outer
A. Fractional-Slot Non-Overlapping Winding With q = 0.5
stator slot pitch θsp ,
In a magnetic gear, the two rotating parts transmitting torque
can be any two of inner PMs, middle iron pieces and outer PMs, θcp θosp π
θ1 = = = (5)
exhibiting variable gearing ratios as analyzed in [40], [41]. If 2 2 Nos
the two rotating parts are iron pieces and outer PMs, the gearing
ratio Gr can be expressed as, The Fourier series expansion of armature reaction MMF in
nip Fig. 2 can be expressed as,
Gr = (1) ⎧ ∞
po
⎪
⎪ 3SABC 
⎪
⎪ FABC (θ, t) = [MABCq sin (ξ)]
where nip and po are the iron piece number and outer PM pole- ⎪
⎪ 2 q =1
⎪
⎪ √
pair number, respectively. The relationship between nip , po and ⎪
⎪
⎪
⎪ SABC = 2 2Nc Irm s
inner PM pole-pair number pi can be govern by, ⎪
⎪
⎨ π
1 (6)
nip = po + pi (2) M = sin (4qθ1 )
⎪
⎪
ABCq
q
⎪
⎪ ⎧
For a magnetic gear with po = 4, nip = 10 and pi = 6, if ⎪
⎪
the outer rotating PMs are substituted by three-phase armature
⎪
⎪
⎪
⎪ ⎨ −4qθ + Nr Ωr t, q = 3r − 2
⎪
⎪
⎪ ξ = 4qθ + Nr Ωr t, q = 3r − 1
windings made of twelve non-overlapping coils injected by sym- ⎪
⎪ ⎪
⎩ ⎩
metric sinusoidal currents, the magnetic gear can be extended to 0, q = 3r
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WU et al.: COMPARATIVE ANALYSIS OF PS-FRPM MACHINES HAVING FRACTIONAL-SLOT NONOVERLAPPING 3

Fig. 4. Armature reaction MMF in 24/10/12-pole PS-FRPM machine with

Fig. 3. Armature reaction MMF spectrum in the existing 12/10/12-pole non- overlapping windings.
overlapping windings and the proposed 24/10/12-pole overlapping windings
PS-FRPM machines (N c = 18, Irm s = 10 A).
the integer-slot PS-FRPM machine with overlapping windings
having q = k (k = 1, 2, 3, . . . ), nos is 24k based on (8). In
where SABC and MABCq are the Fourier series coefficients, and
24/10/12-pole PS-FRPM machine, q can be calculated by,
r is a positive integer.
According to (6), the armature reaction MMF spectrum can be nos 24
q= = = 1. (9)
shown in Fig. 3. In Fig. 3, the largest forward rotating harmonic 2pea m 2∗4∗3
is the fourth MMF harmonic. Actually, the winding layout of
The cross-section of the 24/10/12-pole overlapping winding
the 12/10/12-pole PS-FRPM machine is exactly the same as
PS-FRPM machine with q = 1 is given in Fig. 1(a). The winding
that in the 12-slot/4-pole-pair fractional-slot surface-mounted
layout in the proposed 24/10/12-pole overlapping winding PS-
PM (SPM) machine [42], [43]. Consequently, the equivalent
FRPM machine is the same as that of the conventional 24-slot/4-
pole-pair numbers in these two machines are the same, i.e., 4.
pole-pair integer-slot SPM machine with q = 1 overlapping
Therefore, the equivalent pole-pair number of armature reaction
winding [4]. It can be observed from Fig. 1(a) and (b) that
pea can be defined as 4 in the 12/10/12-pole PS-FRPM machine.
both the machines have the same rotor pole number Nr = 10
The PM pole-pair number and rotor iron piece number are 6 and
and the same PM pole-pair number pPM = 6. The proposed
10, respectively. Due to the modulation of the ten-pole rotor iron
overlapping winding machine has 24-pole outer stator, which
pieces to the sixth static PM field, the fourth rotating field will
is twice of the non-overlapping winding one. However, due to
be generated in the outer air-gap, synchronizing with armature
different winding layouts with overlapping and non-overlapping
reaction MMF and the interaction of them will produce aver-
windings respectively, the same pea can be obtained, i.e., 4. The
age electromagnetic torque. Similarly, due to the modulation of
non-overlapping winding machine with pea = 4 is analyzed as
the 10-pole rotor iron pieces to the fourth rotating armature re-
aforementioned. Here, the overlapping winding one is analyzed
action field with the same electric rotating speed, the sixth static
as follows.
field will be generated in the inner air-gap, synchronizing with
Fig. 4 shows the armature reaction MMF in the 24/10/12-
PM MMF and the interaction of them will also produce aver-
pole PS-FRPM machine with q = 1. Compared with that of the
age electromagnetic torque. Therefore, the relationship between
12/10/12-pole PS-FRPM machine with q = 0.5 non-overlapping
pea , Nr and the PM pole-pair number pPM is given by [36],
windings, three-phase MMFs are overlapped in the 24/10/12-
Nr = pPM + pea (7) pole PS-FRPM machine with q = 1 overlapping windings. In
Fig. 4, θ1 is also the half of the coil pitch θcp , which is three
Therefore, the slot number per pole per phase q in fractional- times of outer stator slot pitch θsp in the 24/10/12-pole PS-
slot SPM machine can also be employed in the PS-FRPM FRPM machine with q = 1 overlapping windings,
machine. In 12/10/12-pole PS-FRPM machine, it can be
calculated as, θcp 3θosp 3π
θ1 = = = (10)
2 2 Nos
nos 12
q= = = 0.5 (8) The Fourier series expansion of the armature reaction MMF
2pea m 2∗4∗3
in the 24/10/12-pole PS-FRPM machine can be expressed as,
where nos is the outer stator pole number, m is the phase number. ⎧ ∞
⎪
⎪ 3SABC 
⎪
⎪ F ABC (θ, t) = [MABCq sin (ξ)]
B. Integer-Slot Overlapping Winding With q = 1 ⎪
⎪ 2 q =1
⎪
⎪ √
⎪
⎪
As shown in (8), due to q = 0.5, the 12/10/12-pole non- ⎪
⎪ 2 2Nc Irm s
⎪
⎨ SABC =
overlapping winding PS-FRPM machine is a fractional-slot π
1 (11)
machine. In this section, its integer-slot counterpart with ⎪
⎪ MABCq = sin (4qθ1 )
⎪
⎪ q
overlapping windings having the same pea , Nr and pPM is in- ⎪
⎪ ⎧
⎪
⎪
troduced. ⎪
⎪ ⎨ −4qθ + Nr Ωr t, q = 3 r − 2
⎪
⎪ 4qθ + Nr Ωr t, q = 3 r − 1
In integer-slot machines, the slot number per pole per phase q ⎪
⎩ ξ =
is an integer. With the same pea = 4, Nr = 10 and pPM = 6, in ⎩
0, q = 3 r
 This article has been accepted for inclusion in a future issue of this journal. Content is final as presented, with the exception of pagination.
4 IEEE TRANSACTIONS ON ENERGY CONVERSION
Fig. 5. Normalized MMF distributions in 24/10/12-pole PS-FRPM machine
with overlapping windings.
Fig. 6. FE predicted rated on-load iron loss versus rotor speed for 24/10/12-
pole and 12/10/12-pole PS-FRPM machines (p c u = 20 W, id = 0).
The armature reaction MMF spectrum of 24/10/12-pole
PS-FRPM machine is illustrated in Fig. 3 based on (11). The
largest forward rotating harmonic is still the fourth MMF
harmonic and hence pea = 4 in the 24/10/12-pole PS-FRPM
machine. Similar to the 12/10/12-pole PS-FRPM machine
having non-overlapping winding with q = 0.5, the 24/10/12-
pole overlapping winding PS-FRPM machine with q = 1 also
operates based on the magnetic gearing theory. The modulation
of rotor iron pieces to the PM static and armature reaction
rotating MMFs make them synchronize with each other in both
outer and inner air-gaps, resulting in average electromagnetic
torque production [36].
More importantly, compared with that of the 12/10/12-
pole PS-FRPM machine with non-overlapping windings, a
more sinusoidal armature reaction MMF can be achieved in
the 24/10/12-pole PS-FRPM machine with overlapping wind-
ings, Fig. 5. The total harmonic distortions of the normalized
MMFs of the 12/10/12- and 24/10/12-pole PS-FRPM machines
are 43.85% and 8.60%, respectively. As shown in Fig. 3, the
magnitude of the fourth MMF harmonic can be enhanced, whilst
other harmonics can be significantly reduced to 0 despite 20th
and 28th harmonic will be slightly increased. This indicates that
the proposed 24/10/12-pole PS-FRPM machine with integer-
slot overlapping armature winding has lower loss than the exist-
ing 12/10/12-pole PS-FRPM machine with fractional-slot non-
overlapping armature winding, as evidenced by Figs. 6 and 7
for FE predicted iron loss and PM eddy current loss, respec-
tively. The iron loss piron is calculated by three parts including
hysteresis loss phiron , eddy current loss pciron , and excess loss
Fig. 7. FE predicted rated on-load PM eddy current loss versus rotor speed for
24/10/12-pole and 12/10/12-pole PS-FRPM machines (p c u = 20 W, id = 0).
peiron ,
2
piron = phiron + pciron + peiron = khiron f Bm ax
+ kciron f 2 Bm
2
ax + keiron f
1.5 1.5
Bm ax (12)
where khiron = 261.64 W/m3 , kciron = 0.10037 W/m3 and
keiron = 3.296 W/m3 are the hysteresis, eddy current and ex-
cess loss coefficients, respectively. Bm ax is the maximum flux
density.
III. ELECTROMAGNETIC PERFORMANCE
In the previous section, based on the magnetic gearing anal-
ysis of the existing PS-FRPM machine with non-overlapping
windings, the PS-FRPM machine with overlapping windings
having more sinusoidal armature reaction MMF and lower
losses is introduced. In this section, the electromagnetic perfor-
mance of these two types of PS-FRPM machines, i.e., 24/10/12-
pole one with q = 1 one and 12/10/12-pole one with q = 0.5,
are comparatively analyzed as follows.
The design parameters of the proposed 24/10/12-pole PS-
FRPM machine are listed in Table I, together with those of the
existing 12/10/12-pole one [23]. The design parameters Rosy to
θri shown in Table I are globally optimized with other parameters
fixed, under brushless AC (BLAC) operation, copper loss pcu =
20 W, and zero d-axis current control, id = 0, for the largest
average electromagnetic torque. For a fair comparison, the PM
volume in the proposed 24/10/12-pole PS-FRPM machine is
fixed to be the same as that in the existing 12/10/12-pole one,
i.e., 13414.6 mm3 , during the optimization [23].
A. Flux-Linkage, Back-EMF and Cogging Torque
The open-circuit flux distributions of the two optimized ma-
chines at d-axis position are given in Fig. 8. As shown in Fig. 8,
some flux paths in the rotor iron piece “R1” are shorter in the
24/10/12-pole PS-FRPM machine due to the doubled outer sta-
tor poles, resulting in smaller magnetic reluctance and hence
higher phase peak flux-linkage and fundamental phase back-
EMF as shown in Figs. 9 and 10(b), respectively. The 24/10/12-
pole PS-FRPM machine has 5.56% higher fundamental phase
back-EMF than the 12/10/12-pole one, i.e., 3.72 and 3.52 V,
respectively. It is worth noting that the third phase back-EMF
harmonic in the 24/10/12-pole PS-FRPM machine is caused by
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WU et al.: COMPARATIVE ANALYSIS OF PS-FRPM MACHINES HAVING FRACTIONAL-SLOT NONOVERLAPPING 5

TABLE I
DESIGN PARAMETERS OF PROPOSED 24/10/12-POLE AND EXISTING
12/10/12-POLE PS-FRPM MACHINES

Globally
Parameters Unit optimized Prototypes

24/10/12 12/10/12 24/10/12 12/10/12

Outer stator pole number, N o s - 24 12 24 12

Rotor pole number, N r - 10
Inner stator pole number, N i s - 12
Stack length, L s mm 25
Outer stator outer radius, R o s o mm 45
Inner stator inner radius, R i s i mm 10.4
Outer air-gap width, g o mm 0.5
Inner air-gap width, g i mm 0.5
Outer stator tip top length, l o t t mm 0.5 1 1
Outer stator tip bottom length, l o t b mm 2 2 3
Total PM volume, V P M mm3 13414.6 14922.6
PM arc, θ P M ° 30
PM remanence, B r T 1.2
PM relative permeability, μ r - 1.05
PM bulk conductivity S/m 625000
Number of coil turns, N c - 18
Outer stator yoke radius, R o s y mm 42.5 43 42 42
Outer stator inner radius, R o s i mm 30 31 31.75
Rotor inner edge radius, R r i mm 25.5 26.5 26.25
Outer stator tooth arc, θ o s t ° 4.5 7 5 8.12
Outer stator tip arc, θ o t ° 3 3 2 4.94
Rotor piece outer edge arc, θ r o ° 20 23 18 Fig. 10. Phase back-EMFs of 24/10/12-pole and 12/10/12-pole PS-FRPM
Rotor piece inner edge arc, θ r i ° 28 24 24 machines, N c = 18 @400 r/min. (a) Waveforms (b) Spectra.
Inner stator yoke radius, R i s y mm 21.31 22.48 21.75

the non-zero corresponding pitch factor, i.e., 0.62 calculated by

FE. However, the third pitch factor kp3 is zero in the 12/10/12-
pole PS-FRPM machine as,
 

Nr
kp3 = cos 3π −1 = 0. (13)
nos
It should be noted that the third phase back-EMF har-
monic makes no contribution to the line one in machines with
Y-connection windings.
For PM machines, another important open-circuit character-
istic is cogging torque besides back-EMF. Cogging torque in
PM machines is resulted from the interaction of PMs and slots.
Fig. 8. Open-circuit field distributions of 24/10/12-pole and 12/10/12-pole
PS-FRPM machines at d-axis position. (a) 24/10/12-pole (b) 12/10/12-pole.
As shown in Fig. 11(a), the cogging torque of the proposed
24/10/12-pole PS-FRPM machine is 23.6% lower than that of
the existing 12/10/12-pole one, i.e., 0.20 and 0.26 Nm respec-
tively. However, the harmonic orders in these two machines
are the same as shown in Fig. 11(b), i.e., 6th, 12th, 18th, etc.

B. Torque and Efficiency

As pointed out in [23], the reluctance torque in the 12/10/12-
pole PS-FRPM machine is negligible. For the proposed
24/10/12-pole PS-FRPM machine, it is also approximately zero
and hence the maximum torque occurs at current angle of ∼90
elec. deg., as shown in Fig. 12. Therefore, in this paper, PS-
FRPM machines with both non-overlapping and overlapping
windings can operate under id = 0.
Fig. 9. Phase flux-linkage waveforms of 24/10/12-pole and 12/10/12-pole The electromagnetic torque waveforms of the two machines
PS-FRPM machines, N c = 18.
with pcu = 20 W are given in Fig. 13. In Fig. 13, when the cop-
per loss is 20 W, the rated q-axis currents iq are 22.39 and 23.19
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6 IEEE TRANSACTIONS ON ENERGY CONVERSION
Fig. 11. Cogging torque of 24/10/12-pole and 12/10/12-pole PS-FRPM ma-
chines. (a) Waveforms (b) Spectra.
Fig. 12. Torque with current angle for 24/10/12-pole and 12/10/12-pole PS-
FRPM machines (BLAC, P c u = 20 W).
Fig. 13. On-load torque for 24/10/12-pole and 12/10/12-pole PS-FRPM ma-
chines (BLAC, id = 0, p c u = 20 W).
Fig. 14. Torque against q-axis current for 24/10/12-pole and 12/10/12-pole
PS-FRPM machines (BLAC, id = 0).
A for the proposed 24/10/12-pole and the existing 12/10/12-pole
PS-FRPM machines, respectively. The slight difference of iq is
caused by the smaller winding area of the globally optimized
designs of the proposed 24/10/12-pole machine than that of the
existing 12/10/12-pole machine. The RMS current densities in
slot are 3.34 and 3.23A/mm2 , respectively, as the cross-section
slot area for each coil one side are 85.28 and 91.51 mm2 , respec-
tively. The current densities in the winding are doubled in both
machines, due to the slot packing factor is designed as kpf = 0.5.
As shown in Fig. 13, the average electromagnetic torques are
2.87 and 2.83 Nm for the proposed 24/10/12-pole and the ex-
isting 12/10/12-pole PS-FRPM machines, respectively, and the
corresponding torque ripples are 13.71% and 18.95%, respec-
tively. The proposed overlapping winding PS-FRPM machine
exhibits 1.53% higher torque density and 2.77% lower torque
ripple than the existing non-overlapping winding one. Although
the fundamental back-EMF of the 24/10/12-pole PS-FRPM ma-
chine is 5.56% higher, the average electromagnetic torque is
only 1.53% larger than the 12/10–12/-pole PS-FRPM machine.
This is caused by the smaller slot area and hence the lower am-
pere turns with same copper loss pcu = 20 W in the 24/10/12-
pole PS-FRPM machine. Due to the overlapping winding layout,
the back iron is thicker and hence the slot area is reduced in the
24/10/12-pole PS-FRPM machine. The torque ripple Tripple is
defined as,
Tmaximum − Tminimum
Tripple = (14)
Taverage
where Tmaximum , Tminimum and Taverage are the maximum, mini-
mum and average electromagnetic torques.
To comparatively evaluate the overload capabilities of the pro-
posed 24/10/12-pole PS-FRPM machine and its existing 12/10-
/12-pole counterpart, the variation of average electromagnetic
torques against the q-axis current for the two machines is illus-
trated in Fig. 14. As aforementioned, the rated q-axis currents
iq are 22.39 and 23.19 A for the proposed 24/10/12-pole and
the existing 12/10/12-pole PS-FRPM machines, respectively.
The proposed 24/10/12-pole PS-FRPM machine can produce
higher average electromagnetic torque in the whole q-axis cur-
rent range due to larger fundamental phase back-EMF shown in
Fig. 10. It is worth noting that when the q-axis current iq is over-
loaded by more than twice to 50 A under id = 0 control, the slot
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WU et al.: COMPARATIVE ANALYSIS OF PS-FRPM MACHINES HAVING FRACTIONAL-SLOT NONOVERLAPPING 7

Fig. 15. Efficiency versus rotor speed for 24/10/12-pole and 12/10/12-pole
PS-FRPM machines (p c u = 20 W, id = 0). Fig. 16. Flux distributions in 24/10/12-pole and 12/10/12-pole PS-FRPM
machines at d-axis position with only phase A excited (p c u = 20 W, id = 0).
(a) 24/10/12-pole (b) 12/10/12-pole.
TABLE II
SELF AND MUTUAL INDUCTANCES IN 24/10/12-POLE AND 12/10/12-POLE
PS-FRPM MACHINES
TABLE III
SOME CONTROL CHARACTERISTICS IN 24/10/12-POLE AND 12/10/12-POLE
Parameter Unit 24/10/12 12/10/12 PS-FRPM MACHINES

Self-inductance, L A A mH 0.29 0.17

Mutual inductance, L B A mH 0.05 0.08 Parameters Unit 24/10/12 12/10/12
Mutual inductance, L C A mH 0.05 0.08
D-axis inductance, Ld mH 0.39 0.26
Maximum phase current, I m a x A 25
PM flux-linkage, ψ P M mWb 8.84 8.40
2 Flux-weakening coefficient, k f w - 1.10 0.77
RMS current density will be 7.46 and 6.95 A/mm for the pro- Rated rotor speed, Ω r r a t e d rpm 400
posed 24/10/12-pole and the existing 12/10/12-pole PS-FRPM Maximum rotor speed, Ω r m a x rpm Infinite 2801
machines, respectively, resulting in 13.91 and 14.92 A/mm2
winding RMS current densities, respectively, as kpf = 0.5. The
overloaded higher winding RMS current density will increase
the copper loss and the heat. Although the overload operation ductance. The increase of self-inductance can be explained by
is short time, this will make challenge to the cooling system, the field distribution of these two machines with only phase A
which may need to be taken into consideration. excited, Fig. 16. As shown in Fig. 16, due to doubled outer stator
Due to the higher torque density benefitted from shorter mag- poles and q = 1 overlapping windings, the 24/10/12-pole PS-
netic circuit and lower loss due to more sinusoidal armature reac- FRPM machine has higher phase A flux-linkage. Consequently,
tion MMF, the proposed 24/10/12-pole PS-FRPM machine with with both higher self-inductance and lower mutual inductance,
integer-slot overlapping armature winding can exhibit higher ef- the 24/10/12-pole PS-FRPM machine has higher self/mutual
ficiency than the existing 12/10/12-pole PS-FRPM machine with inductance ratio which is beneficial to restrict the short-circuit
fractional-slot non-overlapping armature winding, as evidenced current [44], [45].
by Fig. 15. In Fig. 15, efficiency η is given by,
Pout PEM − piron − pPM D. Flux-Weakening Capability
η= ∗100% = ∗100% (15)
Pin PEM + pcu
In PM machines, flux-weakening capability plays an impor-
where PEM is the average electromagnetic power pPM is PM tant role on the power-constant operation region [46], [47]. The
eddy current loss. flux-weakening capability is evaluated by the flux-weakening
coefficient kfw ,
C. Winding Inductances
In both analyzed PS-FRPM machines, winding inductances Ld (id = −Im ax , iq = 0)Im ax
kfw = (17)
are calculated by, ψPM (iq = 0)
ψXA − ψXPM
LXA = (16) where Ld and ψPM are the d-axis inductance and the PM flux-
IA linkage with consideration of cross-coupling [48]. Im ax is the
where X is A, B or C, ψXA and ψXPM are the average flux- maximum current of the controller. kfw in 24/10/12-pole and
linkages under constant phase A current IA and open-circuit of 12/10/12-pole PS-FRPM machines are 1.10 and 0.77, respec-
phase X respectively. tively, with a controller has maximum current Im ax = 25 A. The
Self and mutual inductances of both machines are listed in Ta- maximum rotor speed in the 24/10/12-pole PS-FRPM machine
ble II. As shown in Table II, the proposed 24/10/12-pole machine is infinite whilst that in the 12/10/12-pole PS-FRPM machine is
has 74.47% higher self-inductance and 28.46% lower mutual in- 2801 r/min as listed in Table III.
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8 IEEE TRANSACTIONS ON ENERGY CONVERSION
TABLE IV
EVALUATION OF END WINDINGS IN 24/10/12-POLE AND 12/10/12-POLE
PS-FRPM MACHINES (BLAC, p c u s = 20 W)
Parameters Unit
Stack length, L s mm
Stack copper loss, p c u s W 20
Half turn coil end length, L e mm
End winding copper loss, p c u e W 14.25
Half turn coil total length, L h a l f mm
Total copper loss, p c u W 34.25
Average torque, T average Nm
Torque/copper loss, T average /p c u Nm/W
Machine volume, V machine dm3
Torque/machine volumn, T average /V machine Nm/dm3
E. Influence of End Winding
In the previous analysis, the end-windings of both machines
are neglected, and the copper loss is the stack active wind-
ing copper loss only. However, as shown in Table IV, the
proposed 24/10/12-pole integral-slot overlapping winding ma-
chine suffers from 34.20% larger end winding length than its
fractional-slot non-overlapping 12/10–12-pole counterpart, due
to the larger coil pitch. In Table IV, half turn coil total length
Lhalf is,
Lhalf = Ls + Le
where Le is the half turn coil end length,
Le = Ks τy
where Ks is the end winding empirical coefficient, which is
related to the pole number. For the 24/10/12-pole and 12/10/12-
pole PS-FRPM machines, it is selected as 1.25 and 1.35, re-
spectively [49]. τy is the coil pitch in terms of circumferential
length,
(Rosy + Rosi + lotb )
τy = θcoil (20)
2
where θcoil is the coil pitch in unit of rad, which is π/4 and π/6
for the 24/10/12-pole and 12/10/12-pole PS-FRPM machines,
respectively.
As shown in Table IV, due to larger Le , the total length of
half turn coil Lhalf in the proposed 24/10/12-pole machine, and
hence the total copper loss, is 11.86% higher than the existing
12/10–12-pole design, when the copper loss per active stack
length is set as 20 W/25 mm. The machine volume Vmachine
in the proposed 24/10/12-pole machine is 17.62% larger than
the existing 12/10–12-pole design. Consequently, the average
torque per total copper loss Taverage /pcu and the average torque
per machine volume Taverage /Vmachine of the proposed 24/10/12-
pole machine are 9.24% and 13.68% lower than the existing
12/10/12-pole machine, although the average electromagnetic
torque is 1.53% higher, as foregoing analyzed.
However, as well known, the influence of end-winding will
be smaller if the stack length is longer, as the end winding
axial thickness is constant when the machine cross-section is
fixed [50], [51]. This is evidenced in Figs. 17 and 18 for
24/10/12 12/10/12
25
17.82 13.28
10.62
42.82 38.28
30.62
2.87 2.83
0.08 0.09
0.39 0.33
Fig. 17. Torque/copper loss versus stack length for 24/10/12-pole and
7.44 8.62
12/10/12-pole PS-FRPM machines.
(18) Fig. 18. Torque/machine volume versus stack length for 24/10/12-pole and
12/10/12-pole PS-FRPM machines.
(19)
both the proposed 24/12/10-pole and the existing 12/10/12-
pole PS-FRP machines. In both machines, Taverage /pcu and
Taverage /Vmachine can be effectively enhanced with longer stack
length Ls , although the increment becomes smaller with
Ls . More importantly, Taverage /pcu and Taverage /Vmachine in the
proposed 24/10/12-pole machine increase faster than the exist-
ing 12/10/12-pole machine, due to the higher average electro-
magnetic torque. When the stack length Ls = 287.5 mm and
Ls = 587.5 mm, the proposed 24/10/12-pole machine even
has similar Taverage /pcu and Taverage /Vmachine as the existing
12/10/12-pole machine, respectively. It is worth noting that the
longer end winding in the proposed 24/10/12-pole PS-FRPM
machine with overlapping winding also brings higher induc-
tance, and hence further enhancing the fault-tolerant capability.
This will be verified by experiments.
IV. EXPERIMENTAL VALIDATION
In the previous analysis, the electromagnetic performance of
the 24/10/12-pole PS-FRPM machine with q = 1 overlapping
windings is analyzed and compared to the 12/10/12-pole PS-
FRPM machine with q = 0.5 non-overlapping windings, which
is built and measured in [23] in terms of phase back-EMF and
static torque. In this section, the 24/10/12-pole PS-FRPM proto-
type machine with q = 1 overlapping windings is manufactured
and measured to validate both the phase back-EMF and static
torque, which will be compared with the 12/10/12-pole PS-
FRPM prototype. Moreover, the dynamic performances of the
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WU et al.: COMPARATIVE ANALYSIS OF PS-FRPM MACHINES HAVING FRACTIONAL-SLOT NONOVERLAPPING
Fig. 19. Photos of 24/10/12-pole and 12/10/12-pole PS-FRPM prototype
machines. (a) 24-pole overlapping outer stator (b) 12-pole non-overlapping
outer stator (c) 10-pole cup Rotor (d) Rotor lamination (e) 12-pole inner stator
(f) Assembled inner stator.
both prototype machines are tested and given in this section to
validate the FE analysis.
The pictures of the 24/10/12-pole and 12/10/12/-pole PS-
FRPM prototype machines are shown in Fig. 18. The dimensions
of the 24/10/12-pole prototype machine are listed in Table I,
whilst those of the 12/10/12-pole prototype machine are given in
[23]. For simplifying manufacturing, only the outer stator of the
proposed 24/10/12-pole PS-FRPM machine is built, Fig. 19(a),
and the two prototypes share the same rotor, Fig. 19(c), and
the inner stator, Fig. 19(e). Consequently, it should be noted
that the dimensional parameters of the 24/10/12-pole prototype
machine listed in Table I are slightly different from those by
globally optimization. To ease the manufacture of the cup ro-
tor, Tbri = 0.5 mm thick iron bridge close to the inner air-gap
are introduced to link the adjacent rotor iron pieces, as can be
seen from Fig. 19(d). Due to the different dimensional parame-
ters from the globally optimized designs as aforementioned, the
electromagnetic performance of the 24/10/12-pole PS-FRPM
9
Fig. 20. Measured three-phase back-EMF waveforms @400 r/min.
(a) 24/10/12-pole (b) 12/10/12-pole.
prototype machine with q = 1 integer-slot overlapping winding
will be compromised. However, the tested electromagnetic per-
formance of both prototypes agree well with the FE predicted
results, as given as follows.
A. Static Performance
The 2-D FE predicted phase back-EMFs at 400 r/min of
the 24/10/12-pole and 12/10/12-pole PS-FRPM machines are
shown in Fig. 20(a) and (b), respectively. Due to manufacturing
tolerance, the back-EMF waveforms are slightly asymmetric.
The comparison of 2D FE predicted and measured phase back-
EMFs is given in Figs. 21 and 22. In both machines, the 2-D FE
predicted values agree well with the measured ones, although
the measured back-EMFs are slightly lower due to end-effect.
As shown in Figs. 21 and 22, the phase fundamental back-EMF
of the proposed machine is even slightly smaller than that of
the existing machine, since the dimensional parameters of the
former one are compromised, as aforementioned.
The 2-D FE predicted static torque waveforms of the
24/10/12-pole and 12/10/12-pole PS-FRPM machines are
shown in Fig. 23(a) and (b), respectively. The static torque is
defined as the electromagnetic torque with constant phase A
current IA , phase B current IB and phase C current IC when
the relationship between them are set as IA = −2IB = −2IC .
Although the peak static torque in the 24/10/12-pole PS-FRPM
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10
Fig. 21. Comparison of 2-D FE predicted and measured phase back-EMFs in
the 24/10/12-pole PS-FRPM prototype machine. (a) Waveforms (b) Spectra.
Fig. 22. Comparison of 2-D FE predicted and measured phase back-EMFs in
the 12/10/12-pole PS-FRPM prototype machine. (a) Waveforms (b) Spectra.
machine is slightly smaller than its 12/10/12-pole counterpart
due to manufacturing compromise, there is a good agreement
between the 2-D FE predicted static torques and the measured
values, as shown in Figs. 23 and 24. Again, the measured ones
are slightly smaller due to end-effect.
IEEE TRANSACTIONS ON ENERGY CONVERSION
Fig. 23. Comparison of 2-D FE predicted and measured static torque wave-
forms (IA = −2IB = −2IC ). (a) 24/10/12-pole (b) 12/10/12-pole.
Fig. 24. Comparison of 2-D FE predicted and measured peak static torques
waveforms (IA = −2IB = −2IC ).
B. Dynamic Performance
Fig. 25(a) and (b) compare the measured and 2-D FE pre-
dicted self- and mutual inductances of the 24/10/12-pole and
12/10/12-pole PS-FRPM prototypes. The self-inductance is
measured directly by LCR meter, whilst the mutual inductance is
calculated by,
LA +B − LAA − LBB
MBA = (21)
2
where MBA is the calculated mutual inductance between phase
A and phase B. LA +B is the measured self-inductance of the
serially connected windings of phase A and phase B. LAA and
LBB are the measured self-inductance of phase A and phase B,
respectively.
 This article has been accepted for inclusion in a future issue of this journal. Content is final as presented, with the exception of pagination.
WU et al.: COMPARATIVE ANALYSIS OF PS-FRPM MACHINES HAVING FRACTIONAL-SLOT NONOVERLAPPING
Fig. 25. Comparison of 2-D FE predicted and measured self- and mutual
inductances. (a) 24/10/12-pole (b) 12/10/12-pole.
Fig. 26. Test rig configuration (U d c = 18 V, Id c = 7.5 A).
As shown in Fig. 25, since the 2-D FE analysis cannot ac-
counting for the end winding inductance, the measured self
inductances are slightly higher than the 2-D FE predicted ones
in both machines. It should be noted that, as the 24/10/12-pole
machine with overlapping winding has longer end winding than
the 12/10/12-pole machine with non-overlapping winding, the
gap between the measured and 2-D FE predicted self-inductance
in the 24/10/12-pole machine is larger than that in the 12/10/12-
pole machine. However, this influence can be eliminated in the
calculated mutual inductance based on (21), resulting in good
agreement between the measured and 2-D FE predicted mutual
inductances in both machines, as shown in Fig. 25. More im-
portantly, it can be observed from Fig. 25 that the 24/10/12-pole
machine has higher self-inductance but lower mutual inductance
than the 12/10/12-pole machine with or without consideration
of end winding, which is beneficial to restrict the short-circuit
current, as analyzed in Section III-C.
Based on the test rig shown in Fig. 26, the dynamic per-
formance of the two prototypes are tested. The dc bus voltage
11
Fig. 27. Transient response with speed reference stepping 0–400 r/min-0
with load torque T L = 0.28 Nm (id = 0). (a) Rotor speed (b) D-axis current
(c) Q-axis current.
and current are Udc = 18 and Idc = 7.5 A, respectively. Fig. 27
shows the transient response with speed reference stepping 0–
400 r/min-0 with load torque TL = 0.28 Nm. The 24/10/12-pole
machine has slightly higher q-axis current iq than the 12/10/12-
pole machine, i.e., 2.91 and 2.64 A, respectively, as shown in
Fig. 27(c). The 2-D FE predicted corresponding average elec-
tromagnetic torques are 0.36 and 0.33 Nm, respectively. The
difference between 2-D FE predicted corresponding average
electromagnetic torques and measured 0.28 Nm is caused by
end effect and friction. In both machines, d-axis current id = 0,
which means there is no flux-weakening due to the lower load
torque.
As for the flux-weakening performance, torque-speed curves
of the two prototypes are measured and compared with those
predicted by FE, as shown in Fig. 28. In the constant-torque re-
gion, 2-D FE predicted torque-speed lines have slightly higher
torque in both machines, due to end effect. Also, 2-D FE pre-
dicted characteristic speed is higher than that measured in both
 This article has been accepted for inclusion in a future issue of this journal. Content is final as presented, with the exception of pagination.
12
Fig. 28. Torque-speed curves (U d c = 18 V, Id c = 7.5 A).
machines, since that the end winding inductance cannot be ac-
counted for in the 2-D FE analysis, as aforementioned.
Good agreement can be achieved between the 3-D FE pre-
dicted and measured torque-speed curves in Fig. 28. The gap
between the between the 3-D FE predicted and measured torques
becomes larger with the rotor speed, as the friction goes higher.
More importantly, the 24/10/12-pole machine has smaller char-
acteristic rotor speed than the 12/10/12-pole machine, as the
former one has a higher winding inductance, Fig. 25, but a
similar phase back-EMF, Figs. 20–22.
V. CONCLUSION
In this paper, based on the analysis of PS-FRPM machine
from the perspective of the magnetic gearing theory, a PS-FRPM
machine with overlapping winding having more sinusoidal
armature reaction MMF is proposed. Based on the globally op-
timized designs for the highest average electromagnetic torque,
compared with the existing 12/10/12-pole PS-FRPM machine,
1) The proposed 24/10/12-pole PS-FRPM machine has
smaller iron loss and PM eddy current loss, due to more
sinusoidal armature reaction MMF.
2) The proposed 24/10/12-pole PS-FRPM machine has
5.56% larger open-circuit fundamental phase flux-linkage
and back-EMF, since some flux paths in the rotor iron
piece are shorter in the proposed 24/10/12-pole PS-FRPM
machine as the outer stator pole number is doubled, re-
sulting in smaller magnetic reluctance.
3) The proposed 24/10/12-pole PS-FRPM machine has
1.53% higher torque density, due to the higher phase
fundamental back-EMF, but 2.77% smaller torque rip-
ple due to 23.6% lower cogging torque, despite of higher
5th and 7th phase back-EMF harmonics. Due to higher
torque density and lower loss, the proposed 24/10/12-pole
PS-FRPM machine with integer-slot overlapping arma-
ture winding can exhibit higher efficiency than the exist-
ing 12/10/12-pole PS-FRPM machine with fractional-slot
non-overlapping armature winding.
4) The proposed 24/10/12-pole PS-FRPM machine has
74.47% higher self-inductance and 28.46% lower mutual
inductance, and hence a higher self/mutual-inductance ra-
tio and better capability to restrict the short-circuit current.
5) The proposed 24/10/12-pole PS-FRPM machine has
50.97% larger d-axis inductance but only 5.17% higher
IEEE TRANSACTIONS ON ENERGY CONVERSION
PM flux-linkage, resulting in much higher flux-weakening
capability.
6) The proposed 24/10/12-pole PS-FRPM machine suffers
from 34.20% larger end winding thickness, hence 11.86%
larger total copper loss and 17.62% larger machine vol-
ume, 9.24% lower torque/copper loss and 13.68% lower
torque/machine volume, although the average electromag-
netic torque is 1.53% higher in the designed machine with
25 mm stack length. However, when the stack length is
longer, the influence of the end-winding will be smaller.
The proposed 24/10/12-pole machine will have similar
torque/copper loss and torque/machine volume when the
stack length is 287.5 and 587.5 mm, respectively.
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Z. Z. Wu (S’15) was born in Yancheng, China, in
1988. He received the B.Eng. and M.Sc. degrees in
electrical engineering from Chien-Shiung Wu Col-
lege and the School of Electrical Engineering, South-
east University, Nanjing, China, in 2010 and 2013,
respectively. He has been working toward the Ph.D.
degree with the Department of Electronic and Elec-
trical Engineering, University of Sheffield, Sheffield,
U.K., since April 2013.
His major research interests include the analysis
and design of synchronous machines, and magnetic
gear for electrical vehicle and wind power generation applications.
Z. Q. Zhu (M’90–SM’00–F’09) received the B.Eng.
and M.Sc. degrees in electrical and electronic engi-
neering from Zhejiang University, Hangzhou, China,
in 1982 and 1984, respectively, and the Ph.D. degree
in electrical and electronic engineering from the Uni-
versity of Sheffield, Sheffield, U.K., in 1991.
Since 1988, he has been with the University of
Sheffield, where he is currently a Professor with the
Department of Electronic and Electrical Engineering,
and the Head of the Electrical Machines and Drives
Research Group. His current major research interests
include the design and control of permanent-magnet brushless machines and
drives for applications ranging from automotive to renewable energy.
H. L. Zhan received the B.Eng. and M.Sc. de-
grees in electrical engineering from the Harbin
Institute of Technology, Harbin, China, in 2012
and 2014, respectively. He is currently working
toward Ph.D. degree with the Department of Elec-
tronics and Electrical Engineering, University of
Sheffield, Sheffield, U.K.
His current research interests include permanent
magnet synchronous motor drives and parameter
identification.