Permanent Magnet Brushless DC Motor Design For Solar Fed Surface Type Water Pumping

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2020 International Conference on Power, Instrumentation, Control and Computing (PICC)

Permanent Magnet Brushless DC Motor Design


for Solar Fed Surface Type Water Pumping
2020 International Conference on Power, Instrumentation, Control and Computing (PICC) | 978-1-7281-7590-4/20/$31.00 ©2020 IEEE | DOI: 10.1109/PICC51425.2020.9362417

Aryadip Sen,Member IEEE Bhim Singh,Fellow IEEE Mr. Chaitanya Pansere Mr. Darshan Dudharejiya
Electrical Engineering Electrical Engineering Electronics & Control Electronics & Control
Department Department Department Department
Indian Institute of Indian Institute of Shakti Pumps ( India) Shakti Pumps ( India)
Technology Technology Ltd Ltd
New Delhi, India New Delhi, India Indore, India Indore, India
aryadipsen@gmail.com bsingh@ee.iitd.ac.in chaitanya.pansare@shaktipumps. darshan.dudharejiya@shaktipum
com ps.com

Dr. Chinmay Jain Mr. Manoj Modi


Electronics & Control Electronics & Control
Department Department
Shakti Pumps ( India) Shakti Pumps ( India)
Ltd Ltd
Indore, India Indore, India
chinmay.jain@shaktipumps.com manoj.modi@shaktipumps.com
Abstract— An IE4 compatible improved designed permanent that the little literature has addressed the issue of design of
magnet brushless DC (PMBLDC) motor is presented here for PMBLDC motor for agricultural water pumping. The design of
solar powered surface mounted water pumping. With the growing PMBLDC motor for a bore-well electrical submersible pump
attention on green energy, focus on solar powered irrigation and
domestic water pumping are rapidly increasing. High efficiency, (ESP) is presented in [3]. Some design concept along with few
compact size and robustness make the PMBLDC motor highly simulated results are presented. A clear comparison between
compatible with the solar powered water pumping applications. rare earth type surface PM machine and IPM machine, is given
Focusing this, a detailed design of PMBLDC motor with cost and here. A method to achieve the desired magnetic anisotropy
efficiency optimization, is presented. This work aims a low cost,
using ferrite type of magnet and inter flux barrier, is discussed
high efficient commercial development of permanent magnet
brushless DC (PMBLDC) motor keeping the irrigation pumping here. No physical construction for validation is reported. A
in prime focus. Considering the maximum usage of the renewable PMBLDC motor design is reported in [4]. Here, a magnetic
energy and to keep the running cost of the water pumping as low analysis is presented with skewed magnetic fixture. However,
as possible, another aim of this work is to make the developed for detailed machine optimization with machine efficiency,
PMBLDC motor solar power compatible. Initially a mathematical magnetic pole arc is not presented. The design of a low speed
approach for different parameter analysis of designed PMBLDC
and high torque PMBLDC machine is presented in [5]. Only
motor is followed by an analysis validation using RMxprt
designing tool. Detailed performance analysis and modelling are design specification and computer aided design constraints are
done using software made by Ansoft Corp. for finite element presented. A multi-physics design approach of permanent
analysis. Magnetic material and efficiency of the system are magnet tubular linear motor is presented in [6]. FEA for
optimized using parametric analysis and FEA tool. For analysis magnetic field distribution is done and results are used for 3-D
and performance validation of developed motor, an industrial thermal simulation to view the detail thermal distribution of the
product prototype is fabricated and tested at industrial testing
motor. A single phase brushless DC motor design for water
facility.
cooling pump system, is reported in [7]. The genetic algorithm
Keywords— Finite Element Analysis (FEA), Ansys-RMxprt, (GA) optimization is used here for optimum solution on the
Parametric Analysis, Permanent Magnet Brushless DC (PMBLDC) constructed meta-model, which consists of two objective
motor functions. A, comparison between the generalized gradient
reduced gradient (GRG) algorithm based optimization and
I. INTRODUCTION
genetic algorithm (GA) is also shown. In [8], the design of a
With the drastic advancement of power electronics and PMBLDC motor for engine cooling of automotive engine
magnetic materials in last few decades, permanent magnet application is reported. A bifilar winding is incorporated with
brushless DC (PMBLDC) motors are now widely used in conventional four phase half-wave PMBLDC motor fan to get
modern industrial and domestic applications due to their the efficiency of the full wave motor along with voltage spikes
inherent advantages such as high power density, high and torque ripple reduction. A FEA based design synthesis of a
reliability, high torque density along with hassle free PMBLDC motor is presented in [2]. Details of using of design
maintenance [1, 2]. After extensive literature survey, it is found variables, setting of FE model based design synthesis, final

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2020 International Conference on Power, Instrumentation, Control and Computing (PICC)

design choice are elaborated here by designing an axial torus efficiency is 87%.
PMBLDC motor. • The parameter optimization is done to reduce the volume and
No physical prototype manufacturing and testing are reported size of permanent magnet, which optimizes the production
here. A dual notched PMBLDC motor of radial flux motor cost of the motor.
design is presented in [10]. The rare earth permanent magnet is • The efficiency improvement is achieved unchanging the
used for the design. An optimization is used for cogging torque existing housing for a 3HP motor, which is used for regular
reduction and magnetic material reduction. A well tradeoff is production of commercialized motor. This makes stator’s
reported between cogging torque reduction and permanent outer sizing remain unchanged.
magnet volume reduction. Multi-objective optimization and The designed and fabricated motor is used for solar PV array
modelling analysis of permanent magnet machine are discussed powered single stage voltage source inverter (VSI) fed water
in [11]. Three different optimization techniques are applied to pumping application. Fabrication details of designed motor
compare the optimized parameters. A weighted cost function is along with test results are presented here.
also adopted. The objective of the design is reported as weight
minimization along with efficiency maximization. No II. PARAMETER CONSIDERATION OF THE DESIGNED PMBLDC
prototype validation is reported. A particle swarm optimization MOTOR
based design optimization is reported for electrical machine Based on the application requirement, the parameter selection
design in [12]. Five different test functions are used for the is done for any kind of PMBLDC motor design. Selection of
validation of the proposed algorithm. By optimizing different permanent magnetic material is very important for the
performance constraints, total harmonic distortion (THD) of the PMBLDC motor design. For performance and cost
back EMF is reduced. A prototype is built and experimental optimization of the PMBLDC motor, the selection of proper
results are reported for analysis validation. FEA validation is magnetic grade is very important. Selection of number of poles
one of the most potential tool for machine analysis and design stator slots and phases, depend on the application requirement.
parameter validation without making the original machine The determination of proper air-gap length and magnetic
prototype. A FE model based design of permanent magnet loading effects are required for improved performance of a
PMBLDC motor adversely. Precise selection of stator
Vernier machine is reported in [13]. The air gap permeance and
lamination dimension is important for optimizing the stator core
magnetic equivalent circuit model are taken into consideration
loss and to select outer housing of the designed motor.
here for FEA. As the model simulation time is too high for FEA
Depending on all the above mentioned basic parameters, rest of
based analysis, it is ideally used for final validation of analytical the parameters are calculated and nearest value is selected
approach. A semi-modular dual stack ferrite type PMBLDC according to the possibility of the implementation. Considering
motor design is presented in [14]. Different design parameter the mentioned parameter selection, details, designing of the
variation and effect on motor performance are presented here. aforementioned PMBLDC motor designing is done. A
A prototype is developed for mentioned design and few parameters and specifications of the designed motor and the
experimental results are presented. A magnetic planetary available motor are mentioned in Table-I.
geared based permanent magnet brushless DC (PMBLDC)
motor design is presented in [15]. A multi objective III. PARAMETER SELECTION FOR PMBLDC MOTOR DESIGN
optimization concept is presented for optimization of machine High demand of energy savings and renewable energy fed
efficiency, total loss, cogging torque. An optimization and irrigation pumping force to develop energy efficient and cost
detailed FEA results are presented. A proper design of winding effective motor solution for water pumping.
is one of critical part of PMBLDC motor. The proper design of
A. Primary Parameter Selection
machine rated torque, voltage rating and current rating, depend
Depending upon application requirement, parameter
on compact design of machine windings [16-17]. Compactness
selection of a permanent magnet brushless DC (PMBLDC)
and weight of the machine are also effected by the improper motor design is varied.
design of machine windings. For water pumping application, medium speed high torque
With the development of the high efficiency permanent magnet PMBLDC motor is required. For this application, an interior
based motor integration with renewable and green energy, rotor type PMBLDC motor design is appropriate [1]. According
makes the whole system highly energy efficient and compact. to that, an interior rotor type motor is designed for surface type
Easy availability of solar energy along with very less water pumping application.
maintenance, zero sound operation, and robust system, make The proper phase selection is very important for the design of a
solar photovoltaic (PV) array fed PMBLDC motor fed system PMBLDC motor. The torque ripple content of the designed
worthy to replace the conventional water pumping. PMBLDC motor depends on the phase numbers [1]. As the
number of phase is reduced, the torque ripple content in the
The main merits of presented work are as follows.
motor increases in higher quantity. A detailed relation between
• An IE4 standard PMBLDC motor is designed. The designed number of phases and torque ripple content is provided in Table-
motor’s commercial product prototype is tested at industrial II.
testing facility. The efficiency of the designed motor is 91.5%
where the same class 4 pole, 3 Ph., 50 Hz, 3 HP motor

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2020 International Conference on Power, Instrumentation, Control and Computing (PICC)

TABLE-I TABLE III


SPECIFICATION OF AVAILABLE AND DESIGNED MOTOR ELECTRICAL STEEL SPECIFICATION
Core loss at Magnetic
Parameter Available Motor Designed Motor Lamination
Grade 1.5T at Polarization(T)
Thickness
50Hz(W/Kg) at 2500(A/m)
Power(kW) 2.2 2.2
M310-50 A5 0.5 3.10 1.49
Voltage(V) 380 380
M350-50 A5 0.5 3.50 1.50
Pole 4 4
M400-65 A5 0.65 4 1.52
Torque(N-m) 7 7
M470-65 A5 0.65 4.70 1.53
Speed(rpm) 3000 3000
M530-65 A5 0.65 5.30 1.54
Efficiency (%) 87 91.5
M700-65 A5 0.65 7.00 1.57

TABLE II
RELATIONSHIP BETWEEN PHASE AND TORQUE RIPPLE important factor behind magnetic flux and motor performance.
No. of Phases
Approximate Maximum Considering the motor performance efficiency and cost factor,
Torque Ripple(%)a selection of proper magnetic material and the grade of the
1 100 permanent magnet is one of the most important factor.
According to the availability of different type permanent magnet
2 30
material, ferrite magnet offers the minimum cost and
3 15 Neodymium Boron (NdFeB) type magnets are the costliest. But
comparing to the motor efficiency, NdFeB type magnet offers
4 10 better efficiency rather than Samarium cobalt (SmCo) and ferrite
type magnet.
6 7
Considering the efficiency and cost trade off, NdFeB type
magnet is used for the presented design.
B. Design and Selection of Lamination for Stator and Rotor Using a detailed cost analysis, the tradeoff between the magnet
The selection of electro-steel grade with proper thickness plays cost and the efficiency of the motor hence the energy savings are
justified in the cost analysis section.
a crucial role in the design of stator stack. A high performance
motor (normally specified with high efficiency and high speed) IV. PARAMETER OPTIMIZATION OF DESIGNED PMBLDC MOTOR
requires thin lamination thickness (0.35 m.m to 1 m.m). The
Parametric analysis and design optimization are prior important
electro steels used in any kind of rotating electrical machine,
factors on the way to complete the design analysis of electrical
transformers are conformed to IEC 60404-8-4(part 8 section4)
machine before the fabrication of the prototype.
and EN10106 (Cold rolled non oriented steel sheet according to
The optimization of machine design is an interrelated process.
the British standard ). The lamination thickness of the electro-
All performance parameters to be optimized, are
steel is directly related to the core losses of the machine.
interdependent. So proper tradeoff between the desired
The lamination thickness and quality of the steel on the basis of
parameters under optimization and other inter linked
permeability and resistivity directly affect the machine
parameters are the crucial part of the optimization.
efficiency in inverse proportion. Different graded electro-steels
For permanent magnet type machine, it is utter most important
with different thickness and respective core losses are presented
due to the use of permanent magnet. As the cost of the
in Table-III.
PMBLDC machine mainly depends upon the volume of the
A trade-off between the motor efficiency and the cost of the
used permanent magnet, so volume optimization of the
motor is also important. The increase percentage of motor
permanent magnet in the machine like PMBLDC motor is one
efficiency with the use of higher grade efficiency with the use
of the most important factor.
of higher grade electro steel, is needed to be optimized with the
For optimization of the permanent magnet volume, a
increases cost of the machine. For the discussed design of the
PMBLDC motor, a selection is done between 0.5 m.m 0.65 magnetic equivalent circuit of one pole is shown in Fig.1, is
m.m steel on the basis of efficiency, loss component and derived from the principle of flux conservation.
machine cost using finite element analysis (FEA) PMBLDC In Fig.1 ϕr =Remnant Flux, ϕ M =Magnetic Flux, ϕ L =Leakage
simulation model. Flux, Fa=Armature MMF, Rg=Air gap Resistance, PL=Leakage
C. Permanent Magnet Selection Permeance. PM0=Magnetic Internal Permeance.
The B-H curve’s second quadrant of the PM is given in Fig.2.
The proper selection of permanent magnet on the rotor is prime The derived magnetic point of operation is as,
factor for the PMBLDC motor design as it is the main source of
the motor flux. Permanent magnet material is the most.

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2020 International Conference on Power, Instrumentation, Control and Computing (PICC)

Bg Ag
Bm = (1)
Am
Where Bm is the magnetic operating point, Bg is the air gape flux
density, Am and Ag are the permanent magnet area and air gap
area respectively.
An Optimization tool in Maxwell produced by Ansoft Corp.
used here for the presented work, includes random search
algorithm, search based algorithm, quasi Newton algorithm and
gradient algorithm. For loss minimization and efficiency
enhancement in PMBLDC motor design, a genetic algorithm
(GA) is used here as shown in the Fig.2.
Parameters used for PMBLDC motor optimization are material
for stator and rotor stampings, slot of stator shape, magnetic
pole embrace, and stator slot fill factor, air-gap length. In the
optimization process, the design variable can be optimized
independently and some design variable are optimized in
parallel. For final optimized solution, from numbers of iterative
steps, the designer can choose selective steps in compound.
Once the results are in expected lines, the particular variable
can be freezed.

Fig.2 GA based design optimization Flowchart

Fig.1 Magnetic equivalent circuit of one pole obtained cogging torque is very less and ensures vibration and
V. PROTOTYPE MANUFACTURING AND TESTING jerk free running and starting of the designed motor.

For validation of the designed motor using finite element C. Loss Analysis and Comparision
analysis tool, a prototype of designed PMBLDC motor is A detailed loss analysis is done with the designed PMBLDC
fabricated at industrial testing facility. Cold rolled non grain motor and the already available commercial motor. The
oriented SS (stainless steel) quality is used for production of corresponding losses in the different part of the motor are tested
stator and rotor stamping and hence the complete stack of the and analyzed and the total loss comparison is presented in the
designed PMBLDC motor. NdFeB type magnets are used as the Table-IV. The efficiency improvement is seen from 87% to
rotor permanent magnet. The motor prototype is fabricated 91.5%. The loss analysis justifies the result obtained from FEA.
using the industrial product manufacturing facility. The design
D. Distribution of Magnetic Flux Density
validation and testing of the fabricated prototype are done using
the industrial testing facility. Segmented part of the designed Maxwell tensor and finite element analysis (FEA) is used for
PMBLDC machine under fabrication is shown in Fig.3. magnetic flux density distribution, magnetic force and energy
density analysis inside the PMBLDC motor. The magnetic flux
A. Efficiency and Power versus Speed Characteristics lines are plotted at rated speed as shown in Figs.7 a-b. It is seen
It is observed from test results obtained from Ansys model that there is negligible leakage flux in the non-magnetic part of
analysis shown in Fig. 4, the motor attains the designed rated the designed motor. The flux density is seen 1.6 T, which is in
power at the desired 3000 rpm speed. In Fig. 5, it is seen that the desired limit.
the motor attains an efficiency of 91.5 % at the rated speed of
E. Analysis of Cost
3000 rpm.
A detailed comparative cost analysis is shown in Table-V. It is
B. Cogging Torque shown in this table that due to high efficiency, performance
The result obtained from the Ansys model analysis regarding over the existing motor how much energy consumption and
cogging torque of the designed machine, is given in Fig.6.It is energy bill can be saved per annum. It is seen that yearly more
seen that the maximum cogging torque is only 0.15 N-m. The

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2020 International Conference on Power, Instrumentation, Control and Computing (PICC)

TABLE IV 10000
LOSS ANALYSIS
Loss analysis as
Available 8000
per Designed Motor
Motor
IEC 60034-2-

Power (Watt)
1(W) 6000
Friction & 30 30
Windage Loss,
4000

Core Loss 190 88


2000
Stator Copper loss 108 86
0
Total Loss 329 204 0 500 1000 1500 2000 2500 3000 3500
Speed (rpm)
Output 2200 2200 Fig. 4 Power versus speed characteristics
Efficiency (%) 87 91.5 100

80

Effciency (%)
60
TABLE V
COMPARATIVE COST ANALYSIS
40
Available Designed PMBLDC
Parameter Unit
Motor Motor 20
Rated Power kW 2.2 2.2
0
Efficiency % 87 91.5 0 500 1000 1500 2000 2500 3000 3500
Speed (rpm)
Fig. 5 Efficiency versus speed characteristics
Motor Loading % 100 100

Energy Tariff INR/kW 8 8 0.20

h 0.15

Motor yearly hours 6570 6570


Cogging Torque (N-m)

0.10

operation 0.05

0.00
Yearly Energy kWh 16614 15797
Consumption -0.05

-0.10
Annual Energy INR 132912 126376
Bill -0.15

-0.20
Annual Savings INR 6536 0 50 100 150 200 250 300 350 400

Motor Position (Electrical degree)

Fig. 6 Cogging Torque of the designed PMBLDC motor


than INR 6500 can be saved on energy bill with the
performance efficiency improvement.

(a) (b)
Fig.7 FE Analysis: (a) Distribution of magnetic field of stator and rotor (b) Plot
of magnetic flux lines of designed PMBLDC motor

VI. CONCLUSION
A solar power fed PMBLDC motor design is carried out
considering the world energy scenario of fossil fuel. To reduce
Fig.3 PMBLDCM prototype before assembly : (a) stator stamping (b) rotor the carbon emission and to maximize the renewable energy
stamping (c) stator stack from stamping (d)stainless steel enclosed rotor with usage, solar is considered as the primary source of power
stack(d)stator winding(e)stator with frame supply for the developed motor. The genetic algorithm (GA)
optimization based design of PMBLDC motor has carried out
considering main two objective functions viz. efficiency and
cost. An improved efficiency over available PMBLDC motor

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2020 International Conference on Power, Instrumentation, Control and Computing (PICC)

from 87% to 91.5% design is achieved. As irrigation is [12] W. Zhao, K. Du and L. Xu, “Design Considerations of Fault-tolerant
Permanent Magnet Vernier Machine,” IEEE Trans. Industrial
considered as one of the prime application, so improvement of
Electronics, Early Access.
motor efficiency reduces the input power requirement which [13] S. Sashidhar and B. G. Fernandes, “A Novel Ferrite SMDS Spoke-Type
directly reduces the number of solar panel requirement. BLDC Motor for PV Bore-Well Submersible Water Pumps,” in IEEE
Reduction of input power reduces the total cost of the pumping Trans. Industrial Electronics, vol. 64, no. 1, pp. 104-114, Jan. 2017.
[14] X. Zhu, B. Yan, L. Chen, R. Zhang, L. Quan and L. Mo, “Multi-
system. A prototype fabrication is done for the validation and
Objective Optimization Design of a Magnetic Planetary Geared
commercialization of the designed motor using industrial Permanent Magnet Brushless Machine by Combined Design of
development facility. Testing of the designed motor using the Experiments and Response Surface Methods,” IEEE Transactions on
industrial testing set up is also done to verify the performance Magnetics, vol. 50, no. 11, pp. 1-4, Nov. 2014.
[15] H. Seol, D. Kang, H. Jun, J. Lim and J. Lee, “Design of Winding
of the designed motor. Experimental results and efficiency
Changeable BLDC Motor Considering Demagnetization in Winding
analysis have proven the design optimization and finite element Change Section,” IEEE Transactions on Magnetics, vol. 53, no. 11, pp.
analysis as a strong tool. Use of solar power along with the 1-5, Nov. 2017.
efficiency improvement mitigate the running cost and the [16] P. R. Upadhyay, K. R. Rajagopal and B. P. Singh, “Design of a compact
winding for an axial-flux permanent-magnet brushless DC motor used in
overall cost of the water pumping system broadly. Cost
an electric two-wheeler,” IEEE Transactions on Magnetics, vol. 40, no.
reduction, compactness and reliability make the designed 4, pp. 2026-2028, July 2004.
PMBLDC motor one of the best suite for the agricultural and
domestic water pumping.
ACKNOWLEDGMENT
The authors are highly grateful to the Ministry of Human
Resource and Development (MHRD), Govt. of India and Shakti
Pumps India Pvt. Ltd for supporting this project under funding
grant no. RP03222. The authors are also thankful to DST for
J.C Bose fellowship (RP03128).

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