2016 International Conference and Exposition on Electrical and Power Engineering (EPE 2016), 20-22 October, Iasi, Romania

Multiphysics Design, Analysis and Optimisation

Platform of PMSM for Automotive Applications

Radu Siecoban, Radu Martiş, Claudia Martiş Calin Husar, Lucian Coadălată, Cristi Irimia
Technical University of Cluj-Napoca Siemens Industry Software SRL
Cluj-Napoca, Romania Brasov, Romania
Radu.Siecoban@emd.utcluj.ro

Abstract—The present paper describes a CAD platform that appropriate modeling languages, was developed. The block
combines analytical design, numerical electromagnetic and vibro- diagram can be seen in Fig.1.
acoustic analysis of Permanent Magnet Synchronous Machines
for automotive drives systems with a large range of rated power. At component-level, following the specifications (inputs
For dynamic validation and transient behavior two control and constraints), for the given machine application, fast
strategy were taken in consideration (speed and torque control). analytical design tool, in-house developed, is applied to
compare different options and to arrive to a first design. The
Keywords— multiphysics, multi-domains, electromagnetic preliminary sizing will give the main dimensions of the
analysis, control strategy, PMSM, optimisation machine. The main sizing equation is the usual Dg2ls equation,
named the output power equation, relating the machine
I. INTRODUCTION dimensions to the magnetic and electric loading. The platform
The Surface Mounted Permanent Magnet Synchronous provides tools to perform analytical optimization (based on
Machines (SMPMSMs) are widely used in automotive Hooke-Jeeves method) to minimize geometrical dimensions
applications, due to the well-known advantages, such as high according to different objective functions (output power,
efficiency and high power density. Nowadays, a large amount efficiency, average torque) and to deliver geometrical and
of research work was done to improve the design of PMSM; material data (for electromagnetic analysis) and machine
however there are still challenges in reducing the design and parameters (for control design).
development timeline and to speed-up the time-to-market of
the final product integrating the electrical machine [1].
Therefore, there is a need for developing advanced design and
analysis tools enabling a fast and multiphysics analysis and
validation, by combining different methods, techniques and
tools, either numerical or analytical.
In this paper, a SMPMSM CAD platform is presented. The
platform combines both analytical and numerical design
methods’ advantages, as it fasten the dimensioning and analysis
and offer a precise validation of the different configurations of
SMPMSM electromagnetic design. In-house developed tools,
scripts and models developed using both open source and
licensed software packages are connected via specific in-house
interfaces providing the support for the data flow between
different modules. The platform is able to perform
optimizations at two levels to minimize geometrical
dimensions according to different objective functions (output
power, efficiency, average torque, etc.).

II. PLATFORM PRESENTATION

The design and analysis of PMSM for automotive
applications have to address several challenges due to the
specific application and environmental constraints of (i.e.
small volume and weight, low vibrations and noise level
needed, etc.). To answer these challenges, a CAD platform,
combining multiple simulation and analysis methods with Fig. 1. Platform diagram of the design, modelling and optimization of an
EMD.

978-1-5090-6129-7/16/$31.00 ©2016 European Union

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 After the design is settled, geometrical data are extracted III. RESULTS
for being implemented in the Electromagnetic design module. Further, an example of a 36 stator slots and 6 rotor poles
Thus, in this second stage, a numerical method is used for SMPMSM design and analysis using the multi-domains CAD
refining the magnetic design, supported by a second FEM- platform is presented. Table I shows the main inputs of the
based optimization loop. Both open-source (FEMM) and machine.
licensed software package (JMAG Designer) are available to
be used for electromagnetic analysis, either as a stand-alone
modules or as part of a co-simulation tool, for further analysis A. Material and Sizing
at drive level. Soft magnetic material steel sheets were chosen (saturation
flux density at 2.2T) for the stator as well as the rotor cores and
The optimization procedure works on the principle of NdFeB Permanent Magnet with a 1,2T remanence and 810000
maximizing a certain output (in this case, the electromagnetic A/m coercivity at 100°C.
torque). Following the electro-magnetic analysis, the torque
average, torque peak, or the percentage of torque ripples can be The analytical sizing procedure [1],[3],[4], implemented in
selected to be minimized or maximized, depending on the type Matlab, delivers to the next modules the geometrical and
of optimization required for the specific motor model. material data (for electromagnetic design) and circuit
Parameters such as geometrical dimensions, number of turns, parameters (for control design). All the information can be
input current can be modified for this procedure, in order to plotted on the screen and/or is accessible via a text file.
obtain a more desirable result for the output objective function
created. TABLE I. THE REQUIREMENTS AND MAIN DIMENSIONS OF THE
MACHINE
For the study of the control strategy impact on the
performances of the electrical drive, MATLAB-Simulink Parameter Value Unit
simulation was implemented. Therefore, the electromagnetic Rated voltage 400 V
design module will be coupled via an electrical circuit model to Rated power 700 W
the control design module to analyze the transient behavior of Rated speed 1500 rpm
Stator slots 36 -
the drive.
Number of phases 3 -
Further, based on the results of the electromagnetic design, Number of pole pairs 3 -
the structural solver of the mechanical design module will Outer stator diameter 120 mm
Stack length 70 mm
perform calculation of the periodic, mechanical deformation of Number of turns 78 -
the PMSM.
In Fig. 2, a print screen of the user interface is presented, TABLE II. THE MAIN GEOMETRIC PARAMETERS OF THE MACHINE
showing the main menu of the platform where inputs, Parameter Value Unit
constraints and materials (for permanent magnets, rotor and Inner stator diameter 80 mm
stator core) parameters are introduced. Airgap length 0.7 mm
Outer rotor diameter 73.2 mm
Taking into account the multiple domains that are Shaft diameter 30 mm
interconnected and influence each other, high torque density, Slot height 12 mm
very low cogging torque, low torque pulsations, low acoustic PM height 3 mm
noise and high energy efficiency are expected. Isthmus height 1 mm
PM width 36.5 mm

At the end of sizing procedure a report which contains all

the machine parameters, materials and in chase is done the
results of analytical validation based on Magnetic Equivalent
Circuit (MEC). Table II shows a small part of the machine
geometrical parameters Design Report extracted at the end of
Sizing procedure.

B. Electromagnetic design
The electromagnetic analysis is performed for refining and
validation of the analytical sizing procedure results. It is
carried-out using FEM-based numerical simulation in JMAG
Designer.
The interface was design to be flexible, so the user can
import data from Machine Design or he can manually
parameterized with data from other design software.
Fig. 2. The user interface of the CAD Platform.
An overview to Electromagnetic Design tab is presented
further in Fig. 3. As it can be seen in left part on two columns

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are the parameters extracted at the end of Machine Sizing
procedure and in the right are the materials. From this part,
users can chose from two analyses based on Chopped current
sine wave and Current sine wave.
The results presented in this chapter are extracted from
JMAG analysis based on sinusoidal current wave.
Due to the PMSM symmetry and to speed up the analysis
the model was developed and run for one pole only [6]. Several
aspects are to be analyzed: cogging torque waveform, induced Fig. 6. Current sinusoidal waveform.
electromotive force, average torque, torque ripple content,
airgap magnetic flux density waveform and harmonics. First
step is to consider the no-load regime. The cogging torque and
induced electromotive force are depicted in Fig. 4 and Fig. 5.
Second step addresses the load regime, considering the
PMSM fed with sinusoidal currents (Fig. 5).

Fig. 7. Magnetic flux density distribution and magnetic flux lines.

The magnetic flux density map distribution and the

magnetic flux lines of the machine working at rated load force
are presented in Fig. 6. The maximum value of the magnetic
flux density is around 1.8 T.
Airgap magnetic flux distribution is presented in Fig. 7. Its
main space harmonics are influenced by the combination of
Fig. 3. The user interface of the CAD Platform, Electromagnetic design tab.
stator slots and rotor pole number and they have an important
effect also on the radial forces distribution along the inner
surface of the stator.
Rated electromagnetic torque is presented in Fig.8. It
oscillates between 3.6 - 4.8 Nm and has a torque ripple factor
of 27%.
Fig. 9 presents the space harmonics which have a
fundamental of 15.932 (1/m). The fundamental was computed
by the following equation:

f=Γ/2πD (1)
Fig. 4. Cogging torque.
where: Γ is pole pitch and D is the inner stator diameter.

Fig. 5. Induced electromotive force.

Fig. 8. Airgap magnetic flux density (radius) (T).

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Fig. 9. Space harmonics.
Fig. 10. Rated electromagnetic torque.
The torque ripple content, as well as the radial forces
distribution along the inner surface of the stator, is directly
connected to the high-frequency harmonics of the stator
currents [2]. Therefore, a deeper analysis is necessary for the
machine under different control strategies, each of them
inducing specific harmonic content of the stator currents.
C. Control design
To study the control strategy effect on the performances of
the electrical drive, three strategies were implemented in
MATLAB-Simulink two with constant inductance based on
equation: Field Oriented Control (FOC) and Direct Torque
Control (DTC) [5],[8],[9], and one with variable inductance
based on FEM analysis in JMAG called Field Oriented
Control (FOC).
After the sizing procedure has ended, all the electrical
circuit parameters as well as mechanical ones (inertia, viscous
damping and static friction) are sent to control design where
PMSM is integrated in an electric drive with, as an example,
FOC strategy [10].
Fig. 11. The user interface of the CAD Platform, Control Design tab.
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Fig. 12. FOC, Matlab-Simulink results.
In Fig. 11, an image of the Control Design tab of user
interface is presented, showing the main menu of the platform
where the user can choose by importing Sizing data or to
introduce manually. In the right are the buttons links to the
three control strategies.
Fig. 12 presents, as example, the results of testing the
PMSM starting from zero and achieving the rated speed at a
rated load. As it can be noticed the PMSM follows the speed
reference with the imposed rated load force.
The result chopped current waveform is imported in
JMAG, where electromagnetic FEM analysis is performed, in
order to evaluate the impact of the control strategy on torque
ripple and radial forces.
D. Mechanical Design
The radial forces resulted from electromagnetic analysis are
exported to the mechanical and vibro-acoustic module of the
platform (Virtual.Lab Designer software).
The radial forces, for the sinusoidally fed PMSM are
presented in Fig. 13.
Fig. 13. Radial forces distribution along the air gap at the base stator teeth.
 IV. CONCLUSIONS
Simulations, analysis and models, provided by the CAD
multiphysics design platform offer important information about
the machine in terms of electromagnetic, control and
mechanical behavior.
Using the platform it is expected to reduce the needed time
to design, analyse and validate PMSM for different
applications with important geometrical and/or environmental
constraints, but also to increase the torque density, reduce the
cogging torque, lowering acoustic noise and improve energy
efficiency.
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