2017 IEEE Transportation Electrification Conference and Expo, Asia-Pacific (ITEC Asia-Pacific)
Electromagnetic Design of a Novel Hybrid Flux
SMCs PMSM
Jiang Shanlin, Hu Jianhui, Wang Baochao, Zhao Meng, Shang Jing
Department of Electrical Engineering, Harbin Institute of Technology, Harbin, 150080, China
Jiangshanlin@hit.edu.cn; hujianhui@hit.edu.cn; wbc_hit@126.com;
zhaomeng@hit.edu.cn; shangjing@hit.edu.cn
Abstract—The hybrid flux PMSM includes both axial flux
and radial flux, so its design method is different from the
traditional cylindrical permanent magnet synchronous motor. In
this paper, based on the analysis of the structure and operation
principle of the hybrid flux motor, the design principle of the
motor is given. The authors study the effects of slotting,
permanent magnet thickness, and pole-slot match on the motor
and determine the important parameters of the motor. Finally,
the finite element method is used to verify the electromagnetic
performance of the motor, and the correctness of the proposed
design principle is verified.
Keywords—Soft magnetic composites; Hybrid
Electromagnetic design; Finite element analysis
I. INTRODUCTION
Soft magnetic composites (SMCs) are a new type of soft
magnetic material developed in the 1990s. It is the international
name of the metal powder parts that have been pressed and
heat treated with three-dimensional magnetic properties[1-3].
SMCs consist of surface-insulated high-purity iron particles.
These particles are compressed and an isotropic part with a
complex profile can be formed in one step. SMCs use powder
metallurgy technology to mold high purity iron powder and
organic material, and the surface of iron powder particles is
covered with insulating layer and organic material which is
bonded. Compared with silicon steel, SMCs has many
advantages: magnetic properties of isotropic; to allow complex
shapes; eddy current loss is small; good heat transfer; low cost
and so on. These advantages provide the possibility to
manufacture permanent magnet motors with complex magnetic
circuits.
The idea of applying SMCs to electric motor dates back to
the 19th century, but it was not until the 1980s that the idea
was taken seriously. In 1990, Kordecki and Weglinski
introduced several soft magnetic powder composites and
suggested some of their application problems[4]. Jansson
reported the processing and characteristics of SMCs applied to
AC magnetic circuits in 1992[5]. Since then, the development of
SMCs and its application to the motor has become a hot spot.
They study a variety of different structures and uses of SMCs
motor, and made a lot of research results[6-9].
M.Sc. Tobias Kellerer et al. Developed the axial flux
switched reluctance motor using the characteristics of SMCs
[10]
. They solved the problem that the axial magnetic field
reluctance motor was difficult to use the traditional stamping
laminar mass production and the motor structure complex, and
Supported by National Natural Science Foundation of China under
Project 51407045, 51377031 and 51607045.
978-1-5386-2894-2/17/$31.00 ©2017 IEEE
978-1-5386-2894-2/17/$31.00 ©2017 IEEE
tested the static and dynamic performance of the motor. In
[11], it is proposed to apply SMCs in a double stator single
rotor axial field motor. That is, using SMCs as the stator teeth,
and then combined with the formation of the stator core of the
stator core yoke, effectively solve the slotted axial motor stator
core manufacturing problems. Not only improve the motor slot
full rate, but also make the winding production more
convenient. Fabrizio Marignetti et al. compared the differences
between the two axial flux permanent magnet synchronous
motors (AFPMSM) using solid steel and SMCs, respectively
[12]
. The results show that the rotor with SMCs can reduce the
flux; motor loss, improve the motor power density and efficiency,
the motor no-load loss reduced by 19%, the motor efficiency
increased by 12%. Jan Doering et al. developed a transverse
flux reluctance motor (TFRM) with SMCs and a rotor disc[13].
This motor does not require permanent magnets; the rotor is
not excited, with high torque density, high power density and
compact structure. However, the fundamental frequency of the
motor is high and the torque fluctuation is large, making it
difficult to control the motor. In [14], a new low-cost claw pole
permanent magnet motor is proposed. The output power of the
motor is 675W and the output torque is 1.8Nm, but the total
cost of the motor is only 9.8 USD. The purpose of this motor is
to replace the traditional permanent magnet motor in air
conditioning compressor through the use of SMCs and ferrite
to significantly reduce costs. In this motor, the rotor spoke
structure can make the ferrite produce a very high airgap flux
density. Sweden G. Nord and others use the characteristics of
SMCs to develop two vertical motor prototypes[15]. The first
prototype did not meet the requirements. The number of
airgaps in the second prototype increased from 1 to 2,
achieving several improvements. Inductance, motor size, and
current are reduced, while efficiency is improved. The second
motor basically reaches the design target. Although the torque
of the vertical motor is larger than that of the conventional
motor, the airgap is larger than the traditional motor and the
motor core is longer. Therefore, the power density and mass
density of the motor are relatively small.
In this paper, a novel permanent magnet synchronous motor
using SMCs combined with axial flux and radial flux is
proposed. We analyze the structure and operation principle of
this motor, and study the design principles and steps of the
motor.
II. NEW HYBRID FLUX PMSM BASED ON SMCS
A. The structure of Hybrid Flux PMSM
 2017 IEEE Transportation Electrification Conference and Expo, Asia-Pacific (ITEC Asia-Pacific)

In this paper, based on the advantages of SMCs As a result of the three fixed, the magnetic lines of the rotor
electromagnetic properties and thermal conductivity, a new flow through the same yoke, there will be ferromagnetic
type of permanent magnet motor is proposed, as shown in Fig material caused by non-linear saturation problem. Therefore,
1. The stator core of the motor is made of SMCs. The internal the saturation problem should be noted in the motor design.
magnetic field is a three-dimensional distribution. It combines
the advantages of the traditional radial flux motor and the axial
flux motor. The annular winding is adopted, the motor space
utilization is higher and the power density is larger. Hybrid
Flux motor is different from the traditional motor. It has more
main flux and leakage flux path and the magnetic field
distribution is more complex. The analysis of the running
characteristics of the motor, the design of the magnetic circuit
and the calculation of the thermal circuit are more complicated
than the traditional motor, so it is necessary to study
systematically and deeply.

Fig. 2 cross-section of the hybrid flux permanent magnet motor

Fig.1 Structure of Hybrid Flux PMSM

B. The operating principle of Hybrid Flux PMSM

As with the traditional motor, the three-dimensional
magnetic circuit SMCs motor which proposed in this paper is
based on electromagnetic induction and electromagnetic force
law to achieve electromechanical energy conversion. Fig. 2
shows a cross-sectional view of a hybrid flux permanent
magnet motor. As can be seen from the figure, the main
magnetic field generated by the rotor is perpendicular to the
three sides of the square winding. When the stator windings
pass in a clockwise direction, the electromagnetic forces
generated by the three sides of the stator windings in the main
magnetic field are perpendicular to the plane of the winding,
resulting in a moment perpendicular to the plane of the winding.
The arrangement of permanent magnets and the distribution of
stator windings of the hybrid flux motor are shown in Fig. 3.
Wherein the black triangle represents the permanent magnets
on both sides of the disc-shaped portion, and the direction of
the triangle represents the direction of the magnetic force lines
emitted by the permanent magnets; circle represents the middle
of the cylindrical part of the permanent magnet, the point
represents the direction of the magnetic field emitted by the
permanent magnet vertical paper face outward, the fork
represents the direction of the magnetic field of the permanent
magnet vertical paper face inward. It can be seen that the three
permanent magnets in the same vertical plane have the same
polarity and are adjacent to three permanent magnets with
opposite polarity.
Fig. 3 The magnet and winding distribution in the circumferential direction of
the hybrid flux motor
III. ELECTROMAGNETIC DESIGN OF HYBRID FLUX MOTOR
A. Design Principles of Hybrid Flux Motor
The stator coil of the hybrid flux motor passes through the
magnetic flux of both sides of the rotor (disc) and the axial
(cylindrical) permanent magnet. From the right hand rule, we
can see that the three-side coil of the magnetic induction line
produces the same direction of the induced electromotive force,
and the induced electromotive force can be superimposed.
E = 2 E1 + E 2 (1)
Among them, E1 is induced electromotive force of the
magnetic flux generated by the magnetic flux on both sides of
the disc-shaped permanent magnet. Both sides of the disc-
shaped structure are completely symmetrical. E 2 is the induced
electromotive force of the magnetic flux generated by the
cylindrical permanent magnet in the coil.

It can be seen from the above that every permanent magnet
pair of three stator/rotor group has its own magnetic circuit.
The magnetic lines of force are emitted from the N-pole
permanent magnets in each of the stator and rotor groups,
passing through the same stator yoke into the adjacent S-pole.
It can be seen that this hybrid flux permanent magnet
synchronous motor can be seen as three sets of relatively
independent stator/rotor group compound. It can be regarded as
a cylindrical outer rotor permanent magnet synchronous motor
and two disc-shaped axial flux permanent magnet synchronous
motor composite structures. However, the three stator/rotor
 2017 IEEE Transportation Electrification Conference and Expo, Asia-Pacific (ITEC Asia-Pacific)

group is influential to each other, to make the motor continue that K δ changes with b0 / t as δ =1. It can be seen that b0 / t is
to output torque, three parts to cooperate with each other, and
follow a certain design principles. the main factor affecting K δ when the tooth pitch is small. With
1) The number of permanent magnets on the disc-shaped the increase of tooth pitch, the impact of tooth distance on
portion on both sides is the same as the number of poles of the airgap flux density is larger.
permanent magnets of the cylindrical portion, and the poles of
the three-part permanent magnets are the same in the same
plane. That is, both sides of the disc-shaped permanent magnet
N pole correspond to the cylindrical permanent magnet N pole,

Bmax
2B0
and both sides of the disk-shaped permanent magnet S pole
correspond to the cylindrical permanent magnet S pole.
2) This new type of motor has a variety of magnet skewing
and the pole arc coefficient adjusting methods to improve the
motor performance.
3) It is only necessary to follow the principle of the
traditional motor when selecting the pole-slot match and
separating the winding phase. Due to the particularity of the
slot position (yoke ring slot), all the windings around the yoke, Fig.4 The airgap flux density distribution within a tooth pitch
making the winding easy, high slot full rate, save winding,
short winding ends and so on. 3.0 齿尖宽度
与齿距之
比
4) Because the three stator/rotor group share a stator, b0/t=
winding coil is also common, it is necessary to take care of the 2.4
b0/t=
impact of other stator/rotor group when design one stator/rotor 磁密/T
b0/t=
b0/t=
group. b0/t=
b0/t=
It should be noted: 1.8 b0/t=
b0/t=
1) The number of winding conductors of the permanent b0/t=
magnet motor which winding in the yoke is twice that of the b0/t=
b0/t=
conventional cylindrical motor with the windings in the teeth. 1.2
b0/t=
b0/t=
2) The flux generated by the permanent magnet of motor 16 20 24 28
which winding in the yoke is passed through the stator teeth 齿距/mm
and divided into two parts through the yoke of the stator. Fig.5 The curve of K δ with the change of b0 / t
Therefore, only half of the permanent magnet's flux passes
through the coil of the winding. But flux passes through
winding of motor which in the teeth is the flux under the entire C. Choice of pole-slot match and magnet thickness
magnetic pole. If the number of hybrid flux permanent magnet motor pole-
slot match is less or the tooth pitch is larger, through the yoke
From the above analysis we can see that in the case where of the flux will be very large, resulting in the motor yoke is
the stator size, the pole-slot match and the electromagnetic load saturated. In this paper, we select the prototype of the hybrid
is the same, the no-load back electromotive force generated by flux permanent magnet motor with the slot with 8 poles 9 slots.
the motor which winding in the yoke is the same as the motor
which winding in the teeth. For disc-shaped stators/rotor group 1.0
is also true.
0.8
flux density (T)

B. The effect of annular slot on airgap flux density

气隙磁密/T

As a result of the slotting, the permanent magnet flux 0.6

entering the stator is reduced. As shown in Fig. 4, the airgap
magnetic flux density distribution within one tooth pitch. In 0.4
airgap

order to consider the effect of slotting on the airgap flux

density, introducing the Carter factor. 0.2
t(5δ + b0 )
Kδ = (2) 0.0
t(5δ + b0 ) − b02 0 1 2 3 4 5 6 7
永磁体厚度/mm
The equivalent airgap length is δK δ when introduce the Fig.6 Effect of poles thickness on average airgap flux density

Carter factor. Where b0 is the slot opening size, δ is the airgap Fig. 6 shows the trend of average airgap flux density varies
thickness, and t is the tooth pitch. Fig. 5 shows the curve with the thickness of the permanent magnet when the airgap
 2017 IEEE Transportation Electrification Conference and Expo, Asia-Pacific (ITEC Asia-Pacific)

thickness is 1mm and the slot opening width is 0.48 times the
tooth pitch. It can be seen that the permanent magnet has the
highest utilization rate when the thickness of the permanent
magnet is 1 mm. That is, when the thickness of the permanent
magnet is equal to the thickness of the airgap, the utilization
rate of the permanent magnet material is the highest. When the
thickness of the permanent magnet increases, the average
airgap flux density is also increasing, but the increase is
reduced. It can be seen from Fig. 6, when the permanent
magnet thickness of 2mm, the permanent magnet utilization is
high, while the airgap magnetic density is reasonable. On the
other hand, in order to ensure that the hybrid flux Permanent
magnet motor is not overheated, the ratio of outer diameter to
inner diameter has the maximum limit.
transform. It can be seen that the amplitude of the fundamental
wave of the no-load back-EMF is 61.5V. There are three, five,
seven or nine harmonics in each phase potential, and the third
harmonic content is the highest, the third harmonic content is
the second, the fifth harmonic content is the least.With three-
phase star winding, three times and nine harmonics in the line
back EMF are offset. The five times and seven times
harmonics which proportion is very small is an important
factor influencing the torque ripple. The fundamental back
EMF coefficient of the motor is 0.1384V/rad.
100
100
Va
Vb
Vc
50
50

电压/V
D. Finite Element Analysis of Hybrid Flux Motor
00
With the above analysis, the main parameters of the hybrid
flux permanent magnet motors are estimated as shown in table
1. Motor stator core and rotor yoke with Somaloy 500 SMCs, -50
-50
poles using N38SH NdFeB.
Table 1 the main parameters of the prototype
-100
-100
0
0.000 36 72 108 0.002
0.001 144 180 0.003
216 252 0.004
288 324 0.005
360
Name Value Name Value Electrical angle (°)
时间/
Rated voltage 100v Magnet thickness 2mm Fig. 8 no-load back-EMF waveform
Rated power 800w Axial length 53mm 70
Rated speed 3000r/min Airgap length 1mm
60
Rated torque 2.55nm Disc rotor yoke thickness 6mm
Stator outer Cylindrical rotor yoke 50
47mm 5mm
diameter thickness
电压/V

40
Stator inner
27mm Wire diameter 0.9mm
diameter 30
Stator slot
5mm Number of parallel conductor 2
depth 20
Stator slot
12.7mm Turn number 39 10
width

The finite element software is used to simulate the design 0

0 800 1600 2400 3200 4000
of the motor, and the no-load flux vector of the motor is shown
in Fig. 7. It can be seen that the magnetic flux will not first ? ? /H
Fig. 9 FFT analysis of no-load back-EMF
reach saturation in the tooth. That is because that the tooth
structure of the hybrid flux motor differs from the traditional When the motor connection three-phase symmetrical
cylindrical permanent magnet motor, and there is no tooth tip. current source excitation which amplitude is 8.66A, the output
The flux lines of the three stator/rotor groups are closed by the electromagnetic torque shown in Fig. 10. The average torque of
yoke, so the flux density of yoke is the highest. The maximum the motor output is 2.548N and the torque fluctuates by 4.5%.
flux density of the tooth is about 1.3T, and the maximum flux 3.0
density of the yoke has reached 1.65T.
2.5

2.0
Torque/Nm

1.5

1.0

0.5

0.0
0.000 0.001 0.002 0.003 0.004 0.005
Time/s
Fig. 7 Magnetic flux vector diagram in no-load Fig. 10 Electromagnetic torque output under rated operating conditions
The no-load back-EMF waveform of the hybrid flux
permanent magnet motor is shown in Fig. 8, and Fig. 9 is FFT
 2017 IEEE Transportation Electrification Conference and Expo, Asia-Pacific (ITEC Asia-Pacific)
IV. CONCLUSION
In this paper, a new hybrid flux permanent magnet
synchronous motor based on SMCs is proposed, and the
general design principle of the motor is researched.
1) The hybrid flux SMCs motor integrates the internal rotor
permanent magnet motor and disc type Permanent magnet
motor, which improves the power density and electromagnetic
torque of the motor.
2) The winding of the hybrid flux SMCs motor is usually
simpler, the use of concentrated winding, or no end of the
winding, which simplifies the winding production and
installation, but also saves copper costs and improve material
utilization.
3) Because of the particularity of the motor structure, its
operating characteristic differs from the conventional
permanent magnet synchronous motor, and some theoretic
correction is needed in the design calculation.
ACKNOWLEDGMENT
This work was supported by National Natural Science
Foundation of China under Project 51407045, 51377031 and
51607045.
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