Synchronous

Permanent Magnet

Motor (PMSM) Design

Part 1 General Considerations

Permanent Magnet (PM) Motor

?
??

Characterized by permanent magnets on rotor

Known for its simplicity and low maintenance

? No copper loss on rotor

Permanent Magnet (PM) Motor

? High efficiency

Exploded Vie

o! a PM Motor

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines nd 2 Edition, p. 44, Motor Design Books LLC, 2010.

"nner #otor Possi$ilities ( )

s!r"a#e radial $agnet

s!r"a#e parallel

"nner #otor Possi$ilities ( )

% &readloa" $agnet

ring $agnet $agnet

'e( )*M in To+ota *ri!s

%oyota Prius &y$rid Electric Vehicle (&EV)

,

1. 2. ,. 4.

-o!r #+linder #o$&!stion engine. /enerator0starter. Ele#tri# Motor. *o1er split de2i#e '*3D(

2 J. R. Hendershot and T. J. E. Miller, Design of Brushless nd Permanent Magnet Machines 2 Edition, p. ,4, Motor Design Books LLC, 2010.

J. -. /ieras, Permanent Magnet Motor Technology - Design and Applications, rd 3 Edition, p. 242, CRC *ress, 2010.

Segmented Magnets in 'arge PM #otor

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines nd 2 Edition, p. 54 6 02, Motor Design Books LLC, 2010.

#otor S(e

#otor S(e

stepped $agnet

Magneti)ation Pro!ile
parallel $agneti7ation radial $agneti7ation

most popular radial sine $agneti7ation

sine angle or sine dire#tion $agneti7ation

Magneti)ation Pro!ile

&al$ach *rray ( )
1%

R. 8rishnan, Permanent Magnet Synchronous and Brushless D Motor Dri!es, p. 29:,0, CRC press, 2010.

&al$ach *rray ( )
14

&al$ach *rray ( )
15

-E;

&al$ach *rray ( )
20 Airgap Flux Density

Rotor is outside

Stator Volume and Si)e

D l T T+pi#all+

?"

T? ?

Pout
m

" ? 4 < 5 in , 0 '"t ? l&( "or 10hp or less 'air #ooled(

0
? 4 < 9 in

"

0 '"t ? l&( "or 10hp or $ore '1ater #ooled(

)" 1e design D$#, 1e ha2e the stator &ore 'inner(

The !nit "or D and # is in#h.

dia$eter esti$ated

D
estimated

? 'T" ( ,
1

0 estimated%

=e #an pi#k !p D #lose to D

Stator Core Design

?
core

?? ? leff ? ? D
2

gap , per half pole pitch

?0P

B '? (r d?
g a is a

eff

2
0

?02

Bg , p& #os'?ae (d?ae

D P leff Bg , p&

B
core , p&

? ? d & ? lc i
core i

DBg , p& leff Pd & l

i i c

'1(

tooth

? leff

? 0
ae tooth

g , p& ? s leff B g '? ae ( ri d ? ? B

? s B g , p& leff

Stator Core Design

'2(

B
tooth

? t l ? &s i i

t l &s i i

t ? 0.9? , B

? 0.4B
core , p& tooth

Take

?d

D ? 1. P

E!!ect o! Pole +um$er on ,o(e -lux Density -inite Ele$ent ;nal+sis

1ith the sa$e d

c J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines nd 2 Edition, p. 10 , Motor Design Books LLC, 2010.

"

+um$er per Coil ? o! %urns ?

? 2 f '>
e
? 4.44

? , rated

g, p&

f '> ?e a

g , p&

1here

? '> ? & ' P

p&

2Bg , p& Dl
01.1

& ?& & ( & p d

s

' ? P)' 0
a c

' is the n!$&er o" series t!rns per phase o" ar$at!re 1inding
a
is the n!$&er o" parallel #ir#!its o" ar$at!re 1inding

1.1" 'c?
? , rated

Consider leakage "l!?

2 2?f )& B
e ( g , p&

Dl

Stator Slot Design

/eneral Consideration

? ?
s

D ?S

ts

d s

*s0

d
s0 s1

0.4? ? t ? 0. ? ,t ? d ? %t
De"ine

s s

?s

* ?? ?t
s s s s0

* ? '0.1 < 0.9(*

d
? '0.1 < 0.9(*

s s s

s 0 ? '0.1 < 0.9(*

d
s1

Stator Conductor Si)e

3tator #!rrent densit+

+
s ,copper 1here S

, a ,rated 0 ? S
a

is stator 'ar$at!re( #ond!#tor #ross se#tion area and #an &e deter$ined "ro$ the a&o2e

"or$!la together 1ith@

;ir : #ooled @

400;0#$

?+
s ,copper

? 400

;0#$

, Sa ?
+

0
a ,rated
s ,copper

Permanent Magnets

? #perating temperature of up to $%&'C ? (

amarian Cobalt ! mCo"

nd
strongest rare earth magnet

? Neodymium )ron *oron !NdFe*" ? #perating temperature of up to +%&'C ? trongest rare earth magnet

Permanent Magnet Properties

-ro$ Aeadon B Hand&ook o" 3$all Ele#tri# Motors

#otor Peripheral Speed

The $a?i$!$ allo1a&le peripheral speed o" the rotor is a #entral #onsideration in $a#hine design. =ith present:da+ steel allo+s, rotor peripheral speeds o" 90,000 "t0$in 'or a&o!t 290 $0s( represent the design li$it. 1 "t0$in C 0.0091 $0s

Motor 'osses ( )
,,

Copper loss
? ,ypical

P
u

?,

tray losses ? -lectrical phenomenon such as s.in and proximity effect

Core !)ron" /oss

? Hysteresis loss

?
n

-ddy Current loss

?? B f
h

??
c

P
,ron

'Bf (

??
e

'Bf

,02

0echanical loss
? 1indage loss ? Friction loss

-inite Element *nalysis

-!nda$ental har$oni#

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

nd

Edition, p. 1%4:1%9, Motor Design Books LLC, 2010.

Part . Sur!ace Mount #ound

#otor Multi/Pole PM Motor Design

Magnetic Circuit *nalysis

-or a $!lti:pole s!r"a#e $o!nt rotor
D
d
a m

*oles

2 . ? 2. d ? 0 m m g g

? gB

?? .

m m

?0

m m

?B A g g

Bm Am dm ? g ?? ? . A
0 m

0or(ing Point !or Permanent Magnetics (,5)

Ma?i$!$ Energ+ *oint

BB
r

B
m-

?? .
0
B? '..

? .
0
c

? .
m0
? ?0?B ?

Br
c
?

?. (

? B.

Br
c

'..

?.

(.

To get 'B H(

$a?

( ? ' ?B. .

Br .c 2 , .m ? ? 2

rm

r ? .

1??

rm

? 1.2

Load Line@

B ? ? d m Ag ? . 0

Pc is #alled per$ean#e #oe""i#ient

g A ? ? P c ? ?0 . m ? P ?
c

d
m

A
g

A 0g

?
B

R ? R ?
m

*
?
g

m g A
m c

Am 0 d m
? .
0 m m

*
?

De"ine@ B ? ? B
m m

. ? ?'1 ? ? (.
m

? P c? ?

? 1?m ?
m

rm

T+pi#all+ pi#k !p@

0 .9 D

0 .5

? #otor *irgap Magnetic -ield !rom PM

*M e$&ra#e@

ele#tri#al angle

B
B
m

g , rotor

???
PM

? PM
?B
m

?
PM

??
2

?PM
2

??

?PM
2 2? ? 2

PM

?
?PM 2?

de

B B

?
g , rotor

h ?1,,,9...

?B
-h rh
PM

#os'h? ( ? B
de rh

? de ?
-h

#os'h

P 2

? d(
ae ae

?B ?
rh

2 ? B #os'h? (d? ?? ? 02 m ae ae 2?
? PM 02

PM ? ? ? PM 02 ? '? B ? ? ? 02

( #os'h? (d ? ?
m

sin ? h ? PM ? ? ? ? 2 ? 4 ?

pit#h "a#tor "or the

h
m

th

har$oni#

&

? sin ? h ? PM ?

ph

2 ? ?

Phasor Diagram V

?
E

/0 I
S A

B
net B

T+pi #all+ , desi gn #os?

?1 at "!l l: loa d "or

si ? 10, C15.4% ( so that ? '1 0 *M3M. n? '? T ,(T

? B
g, p&

"!ll:load

B ? 0.54 B
r, p& r , p&

p!ll o!t

? #os

B? sin B ? a ? p& 0.,,Br

r, , , p& p &

PM

??

Br, p& ? ? 2 ? m sin ? B ? ?

-ro$@

*ir Gap Si)e and PM %hic(ness 4 ? '>

B ? a , p& >
0 total a P 1.9 2 , A,rated

?g

)nitial total e""e#ti2e air gap si7e@

4 ? gtotal > ?? B
0

'> P a 1.9 2 , A,rated

dm ? P
rm
c

a , p&

-ro$@

g>total

?&gE
c

gE
total total

?g?d 0?
m

'A ?A (
g m

?
Pc ?
m

CarterFs #oe""i#ient

? g ? '1 ? ? ( g E d ?? gE
m m m total total

1??

?r m

rm

g>
& ?
c

E!!ecti1e *ir Gap ?

& gE
c total total

1here the CarterFs #oe""i#ient ?

2* ? ?
2
s

* atan
s0

gE ?

?s?
?

s0

to ta l

2gE
to ta l

*
s0

? ?

? ? ln ?1 ? *s 0 ? ?2gE ?

? ?? ? ? ? to ta l ?

appro?i$atel+ ? *
s

2 s0 &
c

s
s t d

d
s0 s1

? ?s

9 g Eto ta l ? *s 0

s0

g
total

#otor Si)ing
D ?
,otal rotor diameter2 including magnet
r

D?2g

Rotor inner diameter

D ? D ? 2d
i r m

Part 2 % o Pole Super &igh

Speed PM Motor ith Magnet "nserted in #otor Sha!t

Prototype

? ?

Rotor is assembled by heating and cooling3 Rotor is welded and well balanced after assembly3

*ir Gap Si)e

-or a 2:pole *M rotor
r D 3 G

? 2g

2 g eff.
B
eff

g
m

? . mD r? 0
0

?? . D ?0

'A

D 02
g
eff

m m

?A (
m

g
ef f

? ?
D

? .
0 m

? Pc

eff

1 ? ' Pc
? D c
r

1 ? (

2 ? rm
r

D D D CarterFs #oe""i#ient ?&'g? g? r ? r ( c 2 ? rm 2 2

D 2

? &

?
?

?&

'1 ?
c

D 2

rm

2 &c ? 1?&

?
g?

rm ?D
r

1 & P
c

D
c

?
c

rm m pi#k !p@

De"ine@ B ? ? B
m m

. T+pi# ? ?'1 ? ? (.
m

? P c? ?

m? ?

all+

rm

*ir Gap Si)e

? .
0 .9 D 0 .4
0 m

1??
m

E!!ecti1e *ir Gap

g>total ? & g E
c total

g>
total

?g
eff

Dr ?
2? rm

gE
total

Dr ?g?
2? rm

1here the CarterFs #oe""i#ient

& ?
c

2* ? ?

? s 2

* atan
s0

gE ?

?s?
?
appro?i$atel+

s0

to ta l

? ?
?

2gE
to ta l

*
s0

? ? ln ?1 ? *s 0 ? ?2gE

? ?? ? ? ? ? to ta l ? ?

&

? s 2

? ?
s

* 9gE

s0

t d
s0

d
s0 s1

?*
?
s

*s0

to ta l

total

Example / Speci!ications
Design a 2k=, 100krp$, Gd-eB:,4 *M3M, 2 pole , H ter$inal 2oltage, A #onne#ted, 50I e""i#ien#+.