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Rotor-Shape Optimization of Interior-Permanent-Magnet Motors To Reduce Harmonic Iron Losses
Rotor-Shape Optimization of Interior-Permanent-Magnet Motors To Reduce Harmonic Iron Losses
1, JANUARY 2010 61
Rotor-Shape Optimization of
Interior-Permanent-Magnet Motors
to Reduce Harmonic Iron Losses
Katsumi Yamazaki, Member, IEEE, and Hiroki Ishigami
N OMENCLATURE
Ia Amplitude of armature current.
β Phase of armature current.
We and Wh Eddy-current and hysteresis losses in core,
respectively.
Wmag Eddy current loss in magnet.
ke and kh Coefficients of eddy-current and hysteresis Fig. 1. Three-dimensional finite-element mesh (49 368 tetrahedral elements).
losses, respectively.
σ Conductivity.
I. I NTRODUCTION
D Density of electrical steel sheet.
f Frequency.
n
k
Order of time harmonics.
Order of space harmonics.
I NTERIOR-permanent-magnet motors are widely used in
industrial applications. One of the main advantages of the
motor is the wide speed range facilitated by field-weakening
Br,n and Bθ,n Amplitudes of radial and peripheral compo- control [1], [2].
nents of nth time harmonics in flux density. On the other hand, the flux density in motors includes many
Bk Amplitude of kth space harmonics in gap flux harmonics, which cause harmonic iron losses. In particular,
density. at high rotational speeds under field-weakening control, the
Jn Amplitude of nth time harmonics in eddy harmonic magnetomotive forces of the permanent magnet often
currents. cause large harmonic iron losses at the stator [3], [4]. The
F Function for estimation of harmonic iron reduction of these harmonics must be indispensable for decreas-
losses. ing the iron loss under high-speed conditions. Reference [5]
τ Instantaneous torque. proposed the control algorithm, which is able to reduce the iron
loss. Reference [6] reported the loss reduction by improving
the shape of the stator teeth. Reference [7] investigated the
variation in iron loss with the rotor-barrier shape by using an
Manuscript received January 5, 2009; revised June 3, 2009. First published analytical model. It can be considered that the harmonic mag-
June 16, 2009; current version published December 11, 2009. netomotive forces of the permanent magnet must be reduced by
The authors are with the Department of Electrical, Electronics and Com- optimizing the shapes of the magnets and rotor core. However,
puter Engineering, Chiba Institute of Technology, Narashino 275-0016, Japan
(e-mail: yamazaki.katsumi@it-chiba.ac.jp; sssasu1007@yahoo.co.jp). few papers reported the optimization of the detailed shapes for
Digital Object Identifier 10.1109/TIE.2009.2025285 the iron-loss reduction.
0278-0046/$26.00 © 2010 IEEE
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62 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 57, NO. 1, JANUARY 2010
Fig. 2. Calculated harmonic iron losses, including the magnet eddy-current loss (Ia = 200 A, β = 50◦ , and 8000 min−1 ).
Fig. 3. Separated iron losses with different origins (Ia = 200 A, β = 50◦ , and 8000 min−1 ).
From these viewpoints, the authors have developed the auto- subdivided into 28 pieces along the axial length to prevent
matic optimization method based on the finite-element method eddy currents. The stator has 48 slots with distributed windings.
[8], [9] and introduced the experimental design method [10], Both the stator and rotor cores are laminated. The inverter is
[11] in order to determine the detailed rotor shapes. First, the an insulated-gate-bipolar-transistor-type PWM inverter whose
main iron-loss components of the motor are investigated by carrier frequency is 10 kHz.
the 3-D finite-element method that considers the carrier of In the case of high speeds, the motor is controlled by the
the pulsewidth-modulation (PWM) inverter. Second, an opti- field-weakening method for the purpose of keeping the line
mization method, combined with an adaptive finite-element voltage under the permitted limit, which is determined by the
method, is introduced to automatically determine the detailed dc voltage of the inverter. In this case, β increases with the
shapes of the magnets and rotor core. The optimized motor is rotational speed in order to decrease the d-axis flux.
manufactured to confirm the validity of the numerical calcu-
lation. Third, the contribution of each part of the rotor to the B. Loss Investigation of Conventional Motor
iron-loss reduction is analyzed by an orthogonal array in the
experimental design method. Finally, several novel designs of First, the 3-D finite-element analysis that considers the car-
the rotors are proposed from the viewpoints of manufacturing rier harmonics of the PWM inverter [8] is carried out in order
cost and performance. to understand the main loss factors of the conventional motor.
Fig. 1 shows the finite-element mesh. First-order tetrahedral
edge finite elements are employed in the discretization. The
II. C HARACTERISTICS OF C ONVENTIONAL M OTOR analyzed region is reduced to 1/56 of the core length, which
corresponds to half of the thickness of the magnet, by imposing
A. Specification of Conventional Motor
different boundary conditions on each side [8]. The number of
Table I shows the specifications of the conventional motor. time steps per period is set at 1024 for the correct consideration
The motor has one interior magnet per pole. It is a sintered of the carrier harmonics of the PWM inverter. The rotor region
magnet whose remnant flux density is 1.1 T. One magnet is is shifted at each time step due to the rotational speed of the
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YAMAZAKI AND ISHIGAMI: OPTIMIZATION OF PERMANENT-MAGNET MOTORS 63
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F = (kBk )2 . (4)
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YAMAZAKI AND ISHIGAMI: OPTIMIZATION OF PERMANENT-MAGNET MOTORS 65
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TABLE II
L8 O RTHOGONAL A RRAY
Fig. 11. Rotor shapes for the L8 orthogonal array. (a) A = 0, B = 0, and C = 0. (b) A = 0, B = 0, and C = 1. (c) A = 0, B = 1, and C = 0. (d) A = 0,
B = 1, and C = 1. (e) A = 1, B = 0, and C = 0. (f) A = 1, B = 0, and C = 1. (g) A = 1, B = 1, and C = 0. (h) A = 1, B = 1, and C = 1.
TABLE III
E FFECTS AND C ONTRIBUTIONS FOR I RON -L OSS R EDUCTION
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YAMAZAKI AND ISHIGAMI: OPTIMIZATION OF PERMANENT-MAGNET MOTORS 67
Fig. 14. Design variables of additional optimizations. (a) No barrier. (b) Rectangular magnet.
Fig. 15. Conventional- and optimized-rotor structures. (a) Conventional shape. (b) Optimized (first optimization). (c) Optimized (no barrier). (d) Optimized
(rectangular).
Fig. 16. Calculated average torques and iron losses of the conventional and optimized motors (8000 min−1 ). (a) Average torque. (b) Iron loss.
only one of the local optimal solutions because of the nature barrier, respectively. In this case, shape h (A = B = C = 1)
of the process of automatic optimization. More investigations corresponds to the final shape in Fig. 7.
are needed to clarify these issues. From these viewpoints, Table III shows the estimated effect of each factor and their
we introduce an orthogonal array in the experimental design contribution to iron loss. It indicates that the trapezoidal parts of
method [10] to understand the contribution of each part of the magnet A and slit C are very effective in reducing the iron loss,
optimized rotor to the iron-loss reduction. whereas that of barrier B is not. However, there is a large cross
Table II shows the L8 orthogonal array. Fig. 11 shows the effect of A × B. Fig. 12 shows the details of the cross effects
rotor shapes corresponding to the array. Factors A, B, and on iron loss. It indicates that barrier B is effective in the case
C correspond to the trapezoidal part of the magnet, slit, and of the rectangular magnet (A = 0). On the contrary, it causes
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68 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 57, NO. 1, JANUARY 2010
The results of the orthogonal array imply the following. Advanced designs of interior-permanent-magnet motors
were developed in order to reduce harmonic iron losses at
1) In the case of the trapezoidal magnet, barriers are not high rotational speeds under field-weakening control. After the
required from the viewpoint of iron-loss reduction. investigation of the main loss factors in the conventional motor,
2) The rectangular magnet is acceptable when barriers are the automatic optimization method and the experimental design
employed. method were applied to determine the shapes of the magnets
It appears that more improvement in motor performance and rotor core. The validity of the calculation was confirmed by
can be achieved by eliminating the barriers. On the other an experiment. The results of both the calculation and experi-
hand, a cost reduction of the motor can be achieved by using ment indicated that the iron loss of the optimized motor under
mass-produced rectangular magnets. However, these types were field-weakening control was reduced to nearly half of that of the
excluded in the automatic optimization discussed in Section III; conventional motor. It was mainly achieved by the reduction of
this is mainly because the torque became lower than that of the the harmonic magnetomotive forces of the permanent magnet.
conventional motor. Finally, several novel designs of the rotors were proposed
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YAMAZAKI AND ISHIGAMI: OPTIMIZATION OF PERMANENT-MAGNET MOTORS 69
from the viewpoints of manufacturing cost and performance. [9] K. Yamazaki, S. Ohki, A. Nezu, and T. Ikemi, “Development of interior
In order to reduce cost, a rotor employing rectangular magnets permanent magnet motors—Reduction of harmonic iron losses by opti-
mizing rotor structures,” in Proc. IEEE Int. Elect. Mach. Drives Conf.,
and triangle barriers was suitable for utilizing mass-produced Antalya, Turkey, 2007, pp. 489–494.
magnets. On the other hand, to maximize performance, a rotor [10] D. C. Montgomery, Design and Analysis of Experiments. Hoboken, NJ:
employing trapezoidal magnets without barriers was the best. Wiley, 1991.
[11] K. Yamazaki and H. Ishigami, “Reduction of harmonic iron losses in
interior permanent magnet motors by optimization of rotor structures,” in
Proc. Int. Conf. Elect. Mach. Syst., Wuhan, China, 2008, pp. 2870–2875.
ACKNOWLEDGMENT [12] D. M. Himmelblau, Applied Nonlinear Programming. New York:
McGraw-Hill, 1972.
The authors would like to thank S. Ohki, A. Nezu, [13] K. Yamazaki, H. Ishigami, and A. Abe, “An adaptive finite element
and T. Ikemi of Nissan Motor Company, Ltd., for their support method for minor shape modification in optimization algorithms,” IEEE
in manufacturing the motors. Trans. Magn., vol. 44, no. 6, pp. 1202–1205, Jun. 2008.
R EFERENCES
Katsumi Yamazaki (M’96) was born in Tokyo,
[1] B. Sneyers, D. W. Novotny, and T. A. Lipo, “Field weakening in buried
Japan, in 1964. He received the B.E., M.E., and
permanent magnet ac motor drives,” IEEE Trans. Ind. Appl., vol. IA-21,
Dr. Eng. degrees from Waseda University, Tokyo, in
no. 2, pp. 398–407, Mar. 1985.
1987, 1989, and 1996, respectively.
[2] T. M. Jahns, “Flux-weakening regime operation of an interior permanent-
He jointed Toshiba Corporation, Tokyo, in 1989.
magnet synchronous motor drive,” IEEE Trans. Ind. Appl., vol. IA-23,
Since 2007, he has been a Professor with Chiba
no. 4, pp. 681–689, Jul. 1987.
Institute of Technology, Narashino, Japan. His main
[3] R. Schiferl and T. A. Lipo, “Core loss in buried magnet permanent mag-
fields of interest include the analysis and design
net motors,” IEEE Trans. Energy Convers., vol. 4, no. 2, pp. 279–284,
optimization of motors.
Jun. 1989.
Dr. Yamazaki is the Secretariat of the Rotating
[4] K. Yamazaki and Y. Seto, “Iron loss analysis of interior permanent mag-
Machine Committee of the Institute of Electrical
net synchronous motors—Variation of main loss factors due to driving
Engineers of Japan. He received the Best Poster Paper Awards in the 2004 IEEE
condition,” IEEE Trans. Ind. Appl., vol. 42, no. 4, pp. 1045–1052,
CEFC and 2006 ICEM, respectively.
Jul./Aug. 2006.
[5] C. Cavallaro, A. O. D. Tommaso, and R. Miceli, “Efficiency enhancement
of permanent-magnet synchronous motor drives by online loss minimiza-
tion approaches,” IEEE Trans. Ind. Electron., vol. 52, no. 4, pp. 1153–
1160, Aug. 2005. Hiroki Ishigami was born in Chiba, Japan, in 1983.
[6] V. Zivotic-Kukolji, W. L. Soong, and N. Ertugrul, “Iron loss reduction in He received the B.E. and M.E. degrees from Chiba
an interior PM automotive alternator,” IEEE Trans. Ind. Appl., vol. 42, Institute of Technology, Narashino, Japan, in 2005
no. 6, pp. 1478–1486, Nov./Dec. 2006. and 2007, respectively.
[7] N. Bianchi and M. Barcaro, “Iron losses reduction in synchronous motors Since 2007, he has been with Kanto Auto Works,
with anisotropic rotor,” in Proc. 34th Annu. Conf. IEEE Ind. Electron. Ltd., Yokosuka, Japan. His main fields of interest
Soc., Orlando, FL, 2008, pp. 1258–1263. include the optimization and design of permanent-
[8] K. Yamazaki and A. Abe, “Loss analysis of interior permanent magnet magnet motors.
motors considering magnet eddy currents using 3-D FEM,” in Proc. IEEE
Int. Elect. Mach. Drives Conf., Antalya, Turkey, 2007, pp. 904–909.
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