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Prediction of Cogging Torque Using The Flux-MMF Diagram Technique
Prediction of Cogging Torque Using The Flux-MMF Diagram Technique
IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 32, NO. 3, MAYIJUNE 1996 569
NOMENCLATURE
T, Electromagnetic torque. (N.m)
W' CO-energy. (J)
i Instantaneous current. (A) Fig. 1. Flux-MMF diagram for any one phase of a typical 4-pole, rare-earth
8 Rotor position. (" or rad) magnet, sinewave brushless ac motor at RMS currents of 0, 4, 8, 12, 16, 20,
and 24 A. Area enclosed by an ellipse indicates average torque. Incremental
+
cp Magnetic flux.
Magnetic flux-linkage.
M M F Magnetomotive force.
(Wb)
(V-S)
('44
areas enclosed by the magnetization curves at successive rotor positions
indicate instantaneous torque.
1, Length of magnet. (m) where minimizing torque ripple, vibration, and noise is an
A, Area of magnet. (m2> essential requirement. In order to be able to develop alternate
B, Remanent flux density. (T)
and improved techniques of reducing cogging torque, it is
po Permeability of air. (Wm)
important to be able to predict it accurately for any given
pr. Recoil permeability of magnet.
motor geometry and configuration. Most of the recent literature
on cogging makes use of some form of analytical method,
1. INTRODUCTION the Maxwell stress method or the stored energy method,
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570 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 32, NO. 3, MAYIJUNE 1996
100-
r iron permeability and/or zero flux density under the stator slots
[ 3 ] ,[ 5 ] . Cogging torque is then derived from the flux density
distribution either by taking the derivative of the associated
80 - coenergy [3], [4] or by summing the lateral magnetic force
-E along the sides of the stator teeth [5].
z Finite element analysis is by far the most popular approach
m 60-
FF for numerically calculating the cogging torque [ 121, [16]-[25].
L
MMF (Amp-turns)
B. Cogging Torque Minimization Techniques
Fig. 3. The flux-MMF diagram for a permanent magnet
An extensive variety of techniques for minimizing cogging
torque is documented in the literature for both sinusoidal and
explains the methodology of plotting the flux-MMF diagram trapezoidal permanent magnet machines. The majority of this
for a permanent magnet, and predicting cogging torque from work has been carried out during the past decade coincident
it by applying the principle of virtual work. Section V an- with the growing interest in brushless PM machines for high-
alyzes many of the methods employed for cogging torque performance applications. However, many of these techniques
minimization using the flux-MMF diagram technique. Finally, trace their origins to the same fundamental methods developed
Section VI summarizes the main advantages of the flux-MMF years earlier for minimizing ripple torque in conventional ac
diagram technique and discusses the improvements which and dc machines.
could be implemented to make the technique faster and more One of the most effective of these familiar techniques for
comprehensive. cogging torque minimization is stator slot skewing. Several
studies have demonstrated that skewing the stator slots by
one stator tooth pitch can reduce the cogging torque to
11. REVIEW OF COGGING TORQUE
very low levels [3], [SI, [9], [23], [28]. If stator skewing
CALCULATION AND MINIMIZATION TECHNIQUES
poses unacceptable manufacturability problems, the alternative
approach of skewing the rotor magnetic field distribution via
A. Calculation Techniques either skewed rotor magnets (or magnetization) [20], [28] or
Documented techniques for calculating cogging torque fall skewed mounting of discrete magnet segments on the rotor
into two primary categories-analytical and numerical. An- [9] has been demonstrated to yield similar cogging torque
alytical approaches typically begin with calculation of the reductions.
magnetic flux density distribution along the machine’s airgap Since the airgap magnetic permeance variations caused by
[3]-[5], [8], [9], [14], [U], [26]. These calculations invariably stator slots are such an important factor in cogging torque
require a series of simplifying approximations in order to make generation, a variety of additional techniques have been sug-
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DEODHAR et ul.; PREDICTION OF COGGING TORQUE USING THE FLUX-MMF DIAGRAM 571
gested for minimizing these variations or at least favorably closed trajectory over one electrical cycle. The shape of this
modifying their harmonic spectra. One of the more obvious of trajectory is an ellipse for a sinusoidally excited machine and
these approaches is minimization of the stator slot openings a parallelogram for a squarewave excited machine [33]. Fig. 1
[4], [SI, [8], [17], [23] which has the undesirable effect of shows the flux-MMF diagram for any one phase of a typical
complicating the stator construction. Taking this approach a 4-pole, rare-earth magnet sinewave brushless ac motor, at
step further, slotless stator configurations have been adopted in different load currents. Instantaneous as well as average torque
some special applications where total elimination of cogging at any given current can be calculated from the flux-MMF
torque is required [2S], [26]. diagram by applying the principle of virtual work
Other techniques seek to reduce cogging torque produc-
tion by pushing the harmonic components in the spatial
airgap permeance distribution to higher frequencies by either
adding dummy slots [29] or dummy teeth [30] to the sta- The total area enclosed by a flux-MMF diagram is fixed by
tor laminations. Alternatively, this frequency spectrum can its particular shape, and this area indicates the average torque
be beneficially modified to reduce cogging torque either by produced over one electrical cycle for any one phase. The total
shifting the angular positions of individual stator slots [SI area consists of a number of incremental areas bound by the
or by adopting a fractional number of slots per pole design magnetization curves at successive rotor positions and each of
[8], [24], [28]. However, the impact of such techniques on these areas indicates the instantaneous torque at a particular
both the average and ripple torque production when the rotor position for any one phase. This makes it possible to
windings are excited must be carefully considered. calculate torque ripple at any given current.
The tight interrelationship between cogging torque produc- Fig. 2 shows the electromagnetic torque ripple curves ob-
tion (without current excitation) and ripple torque production tained from the flux-MMF diagram shown in Fig. 1. Note
(during excitation) is particularly apparent in trapezoidal PM that these curves are valid only at low speed where friction,
machines where conflicts often arise during attempts to reduce windage, and iron losses can be neglected. At zero current, the
both components simultaneously. Since trapezoidal machines predicted torque ripple is zero. The reason is straightforward:
favor concentrated stator windings in order to minimize ripple at any nonzero current, the flux-MMF diagram is an ellipse
torque, skewing of the stator slots to reduce the cogging torque enclosing an area which is proportional to current; but, at
has the undesired effect of increasing the ripple torque [3]. zero current, the diagram is just a vertical line which does
As a result of this trade-off, alternative approaches for not enclose any area and hence does not predict any torque.
reducing the cogging torque in trapezoidal machines have This confirms the fact that cogging torque ripple, by itself, is
been investigated with unskewed stators. For example, optimal independent of any current excitation.
ratios of magnet arc width to pole pitch have been identified As seen from Figs. 1 and 2, with the conventional way of
for minimizing cogging torque, combined with a strategy of plotting the flux-MMF diagram for any one phase, it is not
shifting alternate magnet arcs by one-half stator slot pitch possible to predict cogging torque in a permanent magnet
in multi-pole-pair designs [9], [12], [22]. However, the ef- motor, as the phenomenon of cogging depends only on the
fectiveness of these techniques is dependent on maintaining interaction of permanent magnets with stator slotting, and
accurate mechanical tolerances on the physical dimensions it is independent of the nature of any current excitation
and magnetization of the rotor magnets. Other rotor-based and distribution of conductors in any one phase. In order
techniques which have been proposed for reducing cogging to circumvent this problem, it is proposed that rather than
torque include shaping of the rotor magnet segments [23] and plotting the flux-MMF diagram for any one phase, the flux-
addition of a thin magnetic retaining ring [16]. MMF diagram could be plotted for a permanent magnet
All of the cogging torque minimization techniques reviewed corresponding to any one pole so that the cogging torque can
in this section involve modifications of the machine design. If be predicted by applying the principle of virtual work. The
circumstances make it impractical to reduce cogging and/or next section describes the methodology in detail.
ripple torque sufficiently in the basic machine design, a
separate set of control-based techniques have been developed IV. FLUX-MMFDIAGRAM
FOR A PERMANENT
MAGNET
to compensate these parasitic torque components by modifying Fig. 3 shows a typical flux-MMF diagram for permanent
the current excitation waveforms [6]. magnet which is constructed using a combination of flux-MMF
data obtained from the finite element analysis and the demag-
netization characteristic. Just as in the case of conventional
111. THE FLUX-MMFDIAGRAM
flux-MMF diagram, finite element solutions are generated at
The flux-MMF diagram and its application to various motor incremental rotor positions over one cogging torque cycle.
types have been described in detail in [31]-[35]. It is a Using these solutions, values of total flux emanating from the
generalized version of the flux-linkage versus current (II,- z) permanent magnet for any one pole are obtained at each rotor
diagram used commonly for analyzing switched reluctance position. The corresponding MMF values are obtained using
motors, relays, etc. [36]-[41]. It plots the variation of in- the demagnetization curve as in
stantaneous effective flux linking a particular phase against
the instantaneous MMF in that phase. Both the quantities are
functions of rotor position and the flux-MMF diagram is a
MMF = 1,
PoPr
(2 - Br). (2)
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572 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 32, NO. 3, MAYIJUNE 1996
PREDICTED (TOTAL) x x
Fig. 4. Flux plot for a 6-slot, 4-pole ferrite magnet brushless dc motor.
-1 50
5 10 15 20 25 30
Variation of flux is then plotted against the variation of ANGLE [MECH DEG ]
MMF over one cogging torque cycle. This represents the flux-
Fig 5 Companson between the predicted and the measured cogging torque
MMF diagram for a permanent magnet corresponding to any for the motor shown in Fig. 4.
one pole-a triangle in dark solid lines in Fig. 3. The so-
called “load lines” at each incremental rotor position, shown
by dotted lines in Fig. 3, are assumed to be linear. This is
adequate in most cases except when there is high saturation in
stator tooth tips or when the magnet working point is pushed
beyond the “knee point” due to extremely high load currents,
in which case, the load lines may be nonlinear [42].
Note that the flux-MMF diagram for a permanent magnet is
similar to the flux-linkage versus current ($ - i) diagram for a
switched reluctance motor or a relay. While the PM diagram
is plotted in the second quadrant, the SR diagram is usually
plotted in the first quadrant and both can take account of
linear as well as nonlinear magnetization curves. Once the flux-
MMF diagram for any one pole is obtained, predicting cogging
torque becomes an easy matter of calculating instantaneous
torque for every incremental rotor position using the rate of
change of co-energy with displacement as in (1). Even when no
current is flowing, (1) can still be applied by replacing “2” with
“MMF” of the permanent magnet. Finally, total cogging torque
is obtained by simply adding together the cogging torques for Fig. 6. Flux plot for an lg-slot, 6-pole ferrite magnet brushless dc motor.
the individual poles.
The technique is validated by performing finite element curves which are consequently different from each other. This
analysis as well as experimental measurements on a small 6/4 phenomenon is peculiar to motors with fractional number of
(6-slot, 4-pole) ferrite magnet brushless dc motor. Fig. 4 is slots per pole. In motors with integral number of slots per
a flux plot showing the cross section over two poles. Fig. 5 pole (an 18-slot, 6-pole motor shown in Fig. 6, for example),
compares the predicted cogging torque curve against measured each pole is subjected to an identical magnetic circuit and the
points and it shows a close match between the two. The flux-MMF diagram is exactly the same for all poles.
measured points were obtained using an experimental setup
in which the motor under test was driven by a dividing head
through a sensitive torque transducer. The rotor was taken v. ANALYSISOF VARIOUS METHODSOF COGGING TORQUE
through each incremental position over a cogging torque cycle MINIMIZATION USING THE FLUX-MMFDIAGRAMTECHNIQUE
in both directions and the results were averaged to eliminate
the effect of friction.
It is interesting to note that in Fig. 5 total predicted cogging A. Skewing
torque is made up of two slightly different cogging torque This is the most common method applied for reducing cog-
curves corresponding to the set of north and south poles which ging torque in permanent magnet motors. Either the stator or
are mirror images of each other. The reason can be seen clearly the magnets can be skewed but both have essentially the same
from Fig. 4. While one set of poles with same polarity is electromagnetic effect on motor operation and cogging torque.
facing teeth, the other set is facing slots, which means that the The choice is generally dictated by the manufacturability of a
two sets are subjected to different magnetic circuits. When the particular design. The flux-MMF diagram technique is adept
flux-MMF diagrams are plotted for each set, they are slightly at taking account of fractional as well as integral slot pitch
different from each other, giving rise to cogging torque ripple skew [34].
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~
' * * WITHOUTSKEW
0.15-
A x x x WITH SKEW OF HALF SLOT PITCH
02 Fig. 9. Flux plot for an 18-slot, 6-pole rare-earth magnet brushless dc motor
with normal teeth.
180
015
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~
514 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 32, NO. 3, MAY/JUNE 1996
0.6i I 15
* * * WITHOUT BIFURCATED TEETH
x x x RAMALLY MAGNETISED
a-02-
-06-
-0.8l I I
5 10 15 20 5 10ANGLE [MECH.
15 DEG.]20 25 30
ANGLE [MECH. DEG.]
Fig. 11. Cogging torque curves with and without bifurcated teeth for the Fig. 13. Cogging torque curves with radial and parallel magnetization of
motors shown in Figs. 9 and 10, respectively. magnets for the motors shown in Figs. 4 and 12, respectively.
VI. DISCUSSION
AND CONCLUSION
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DEODHAR et al.: PREDICTION OF COGGING TORQUE USING THE FLUX-MMF DIAGRAM 575
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516 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 32, NO. 3, MAYIJUNE 1996
Authorized licensed use limited to: UNIV PUBLICA DE NAVARRA. Downloaded on February 02,2022 at 14:43:41 UTC from IEEE Xplore. Restrictions apply.