Design and Mechanical Consideration of an IPM

Machine with Concentrated Windings

L. Chong and M. F. Rahman

R. Dutta

University of new south Wales

School of electrical engineering & telecommunications
Sydney, Australia

CMG Pty. Ltd.

Test laboratory
Melbourne, Australia

Abstract This paper illustrates a general design process used

for implementing non-overlapping concentrated windings in an
interior permanent magnet (IPM) machine for field weakening
applications. This design process was verified by finite element
analysis (FEA) of a 18-slot, 14-pole model. The optimization
process of torque and field weakening performance resulted in a
design with thin inter-pole link sections that might fracture from
magnet and armature reaction force. In this paper, the authors
also included a study on the mechanical aspects of the rotor
under simulated worst case scenario situations.
Keywords-Finite
element
Concentrated windings.

I.

analysis;

IPM

machines;

INTRODUCTION

IPM machines have been a popular choice for present day

applications due to its high torque density, higher mechanical
durability due to buried magnets and excellent field weakening
capability. Distributed windings have been the preferred choice
of windings in present-day IPM machines due to having
sinusoidal magnetomotive force (MMF) waveform. However
the use of concentrated windings has been gaining popularity
due to having non-overlapping coils and its proven ability to
achieve a wide constant power speed range (CPSR) in surface
permanent magnet (SPM) machines.
Recent developments and applications of concentrated
windings are based mostly on SPM machines. Cros and
Viarouge derived in [1], a method to determine optimum
winding layout which produces the optimal emf waveform for
a particular number of slots per pole per phase (Spp).
Magnussen and Sadarangani showed in [2], how winding
factor for different Spp combinations were calculated by emf
phasors and how cogging torque can be minimized by the
lowest common multiple method. El-Refaie et al. did an
extensive study for implementation of concentrated windings
in SPM machines and proved that a 5:1 CPSR is achievable for
a 2/5 Spp winding layout in [3]. Bianchi et al. stated in [4] that
concentrated windings posses the property of reducing phase to
phase faults and also stated some configurations that will result
in poor performance. Some of the studies done on IPM
machines with concentrated winding are as follows: [5] where
Honda et al. concluded that concentrated windings reduces the
size of the machine at the expense of a reduction in the
reluctance torque component. He also mentioned that this
would consequently lead to a very narrow CPSR; [6] where
Kwon et al. stated that concentrated windings has the

characteristic of increasing in Ld but has only a slight effect on

Lq hence the reduction in saliency ratio.
This paper illustrates the implementation of concentrated
windings on IPM machines where past illustrated theories and
proven optimization methods which were used in SPM
machine are conferred to. The benefits and disadvantages of
this implementation have been illustrated in an earlier paper
[7], hence will not be covered in here. This paper covers the
derivation of machine geometry, winding method and machine
sizing; mechanics of the inter-pole link sections under stress
will be simulated by mechanical FE methods. Finally, machine
parameters, torque performance and field weakening
characteristics predicted by multi-static FEA with Flux 2D.
II.

MACHINE GEOMETRY

The machine was designed in an outside-in approach

where the stator outer radius was subjected to a constrained
size based on two presently available UNSW-IPM machines.
The aim of this design is to achieve equivalent or a larger
amount of power compared to the other two designs at the
same time achieve a wide CPSR.
ly
lt
rm
rsi
wt

Figure 1. 18-Slot, double-layer, 14-pole IPM with double-layer windings

The stator was designed based on the relationship between

geometry and maximum allowable flux density [8]. The yoke
length ly, tooth length lt and tooth width wt are expressed in (1),
(2) and (3) respectively.

(1)
(2)
(3)
where,
= Stator inner circumference
= Airgap flux density
= Yoke flux density
= Number of pole pairs
= Machine radius
= Stator inner radius
= Total number of stator slots

From (1) it can be seen that the yoke length is inversely

proportional to the number of poles in the design. Therefore a
high pole number would result in a short stator yoke giving
space for a larger rotor radius. The rotor radius can be
expressed simply by (4).

Whereas for concentrated windings, a packing factor of up to

80% can be achieved [9]. This is due to the property of being
able to separate stator teeth by the use of hinges between teeth
or having separable tooth pieces where compression can be
used to tightly pack the windings.
The method of using hinges, described in [10] allows the
tooth pieces to be opened up as shown in fig. 3a. This increase
the ease and quality of winding the copper wire round the tooth
piece, thus increasing the winding factor. The other method of
increasing the winding factor is by compression of the
windings under pressure as illustrated in [11]. This method
uses powdered iron core instead of laminations. Each tooth
component is molded individually and is split into two parts
enabling the compressed winding to be slotted into the tooth
piece as shown in fig. 3b.
Hinges
Copper
windings

(4)
where,
= Airgap length

During operation, little of no flux is present at the inner part

of the rotor, hence additional air sections are made as shown in
fig. 2.

(a)

Bottom
tooth
piece
Yoke
piece

Compressed
copper windings
Additional
Air sections

(b)
Figure 3. (a) Cross section of stator teeth with hinges, (b) Single tooth
component by compression method

IV.
Figure 2. Flux density plots of model during operation

The purpose of these air sections is to reduce inertia of the

rotor, hence giving better dynamic response. Other purposes of
it could be for heat dissipation to lower the magnet operating
temperature or for reducing vibrations when rubber is slotted
into the air sections.
III.

STATOR WINDINGS

Once the inner and outer diameters of the stator are

decided, the slot area As can then be established. Subsequently
the number of turns and the thickness of the windings can be
obtained. To achieve maximum torque density, it is desirable to
have as many copper conductors as possible in the constrained
slot area. The number of turns that can be achieved depends on
the packing factor. A high packing factor not only increases
machine torque density but also reduces I2R heating losses by
lowering coil resistance. In distributed windings, due the
overlapping coils, it is impossible to split stator teeth, hence a
maximum packing factor of only 40% can be achieved.

STACK LENGTH

Amongst distributed, single-layer concentrated and doublelayer concentrated windings, the latter has the most potential in
terms of reduction in end winding length. Based on the
conductor slot area and the elimination of phase to phase
insulation at end windings, it is estimated that double-layer
concentrated windings would result in a three-fold reduction in
end winding length compared to distributed windings as shown
in fig.4. This enables the machine effective stack length ( ) to
be increased.

Distributed end
winding length (x)

(a)

where,

Stack length

= Material constant
= Exponent usually between 1.5 to 2 (Material dependent)
= Maximum flux density
= Frequency of excitation
= Material constant proportionaal to square of material thickness

2
3

(b)
(c)
w
machines, (b)
Figure 4. (a) End windings of UNSW IPM distributed winding
Top view of distributed winding machine, (c) Top viiew of concentrated
winding machine showing increased stack length

V.

MATERIALS

An important aspect of machine deesign is selecting

appropriate material types for the core and permanent
p
magnet.
The selection of these materials depends on the
t requirement of
torque density, strength, weight, cost, operrating temperature
range and external demagnetization fields.

Br
Intrinsic
Curve

Increasing Temperature

A. Permanent magnets under field weakeninng

Permanent magnet characteristics can be
b described by a
demagnetization curve shown in fig. 5. From
m this curve desired
magnet parameters such as - remanent flux density Br,
coercivity Hc, and recoil permeability r caan be determined.
Critical operating points causing permanent demagnetization
d
of
magnets can also be pointed out.
Normal
Curve

r
H

iHc

For field weakening appplications, the use of higher

excitation frequencies is ineviitable. Therefore an appropriate
choice of material which has a narrower
n
hysteresis loop and the
ability to be made into very thinn laminations is desired.
Non-oriented (N.O) silicon sheet steel is the most common
choice in AC drives. The corres are formed by stacking the
laminations to reduce eddy current
c
losses. Silicon steel is
relatively cheap, has total core loss of between 1 to 2W /Kg at
50Hz, has saturation magnetizaation of up to 1.9T and can come
in sheets as thin as 0.2mm [13]]. Silicon steel has yield strength
between to 450MPa and tensilee strength of up to 570MPa [13].
C. Stator coil material
The ideal coil material is onne with infinite conductivity and
the lowest temperature coefficiient of resistance [14]. Copper is
the ideal choice for coil mateerial due to its low cost, high
conductivity and good mechaniical strength. The amount of I2R
loss per coil can be calculated by
b (6).
2

(6)

where,
= Number of turns per coil
I = Current passing through the conductor
c
= Conductor resistivity
= Cross-sectional area of a wirre
= Machine effective length

The available cross-sectionnal area per wire is found based

on the available stator slot area, slot fill factor Sff and the
number turns per coil shown in (7).

Hc

(7)

Figure 5. Demagnetization curve

There are several types of permanent magnet

m
materials in
the market. Alnico, Samarium-Cobalt andd Neodymium are
more commonly used. Of which, the preferred choice in
present day applications is Neodymium magnets
m
due to its
reasonable cost and very high energy productt. Precautions have
to be taken due to neodymium magnets haave comparatively
low operating temperature. As temperatuure increases, the
demagnetization curve shrinks towards the origin,
o
till the point
where the knee enters the second quadrant. Operation in the
l
magnetization
area of the knee might cause the magnet to lose
irreversibly [12].
B. Core material
The main characteristics of core materiall are mechanical
strength, saturation magnetization, permeabbility, direction of
magnetization, core losses and winding lossses. Core loss Pcore
is made up of two components, eddy currrent loss Peddy and
hysteresis loss Phys elaborated in (5).

(5)

This cross-sectional area is usually rounded off to the

nearest value based on Americaan wire gauge (AWG) standards
of wire sizes. From this gaugge and the estimated length of
required, the stator resistance caan then be calculated.
VI.

MECHANICS

Mechanics of the silicon steeel material has to be studied due

to the thin inter-pole section (fig.6)
(
which might elongate or
even crack due to the attractionn force between the magnets and
stator coils.
Inter-pole linkk

Figure 6. Inter-ppole link sections

Attractive force on the magnet was calcuulated based on the

worst case scenario of the magnet pole directly under a
solenoid (modeled from a single stator toooth) with 1.5T of
airgap flux (fig.7)
Max Stress
304MPa

Tesla
1.5

Coil

Tooth

Coil

Airgap
A
Flux

0.5

-0.5

0.6mm Airgap
Magnet

mm

-1

10

15

(
(b)
Region vecctors results

Quantity : Flux densitty Tesla

Colour scale
26.35732E-3 / 309.69441E-3
309.69441E-3 / 593.03149E-3
593.03149E-3 / 876.36858E-3
15971
876.36858E-3 / 1.1
1.15971 / 1.44304
1.44304 / 1.72638
1.72638 / 2.00972
2.00972 / 2.29305
2.29305 / 2.57639
2.57639 / 2.85973
2.85973 / 3.14307
3.14307 / 3.4264
3.4264 / 3.70974
3.70974 / 3.99308
3.99308 / 4.27641
4.27641 / 4.55975

Figure 8. Maximum principle stresss of inter-pole region (a) Sharp edges

under 2MPa of pressure, (b) Filllet edges under 2MPa of pressure

In the second model, filleet edges were used instead as

shown in fig. 8b. This resultedd in a distribution of force along
the filet, hence a reduction of maximum principal stress by
90MPa. Designs with and withhout the fillets resulted in similar
electromagnetic performance.
VII. FINITE ELEMENT
L
RESULTS

Figure 7. Attractive force on magnet (simulation doone with Flux 2D)

The resultant attractive force acting in the direction normal

to the magnet surface is 1075N. This wouldd be equivalent to
approximately 1MPa of pressure acting norm
mal to the magnet
surface.
A. Stress calculation
For this finite element model, high freqquency vibrations,
lateral and centrifugal force was not takken into account.
Therefore twice the amount of force in the outward normal
direction was used for contingency. The firrst model (fig. 8a)
had sharp edges at the T-junction of the inter-pole section,
which resulted in concentration of forces at thhe edge.

Finite element analysis is used

u
for computation due to the
ability to incorporate compplex material and geometric
properties; higher harmonics and saturation effects are also
taken into account.
A. EMF waveforms
Fig. 9(a) and 9(b) show
ws the emf waveforms and
corresponding frequency spectrrum produced by the distributed
and concentrated winding models respectively. Key
parameters used for these two comparison models are shown
in table 1. By comparing the fundamental term, the
concentrated winding modeel produced a fundamental
component of 25.5V, which iss 0.901 times that produced by
the distributed winding moddel. This corresponds almost
exactly to the predicted windinng factor of 0.902.
Volt
30
20
10
0

Max Stress
M
3
394MPa

-10
-20
-30

(E-3) s.
5

30

10

15

Volt

28.3 V

20

10

(a)

(
(a)

30

TABLE 1
MACHINE MODEL KEY PARAMETERS

Volt

20
10
0
-10
-20

(E-3) s.

-30
5

30

10

15

Volt

25.5 V
20

10

0
0

(b)

Figure 9. EMF waveforms for (a) 42-slot, 14-pole, integral-slot distributed

windings, (b) 18-slot, 14-pole, fractional-slot concentrated windings

Stator/Rotor material *
Saturation magnetization @ 1000A/m*
Magnet material *
Magnet remanent flux density *
Total no. of series turns per phase *
No. of turns per coils (Distributed)
No. of turns per coils (Concentrated)
Stator current *
Stator voltage *
Stator resistance *
Air gap length *
Rotor radius
Machine length *
Machine radius *

* Indicates that parameter is used for both models

B. Cogging torque waveforms

Minimizing cogging torque by the LCM method eliminates
the periodicity of the slots and poles. By observation of Fig. 9,
cogging torque waveforms produced by the concentrated
winding model has a peak to peak magnitude which is about
five times lower than that of the distributed winding layout due
to the former having a higher LCM.

0.06

base = 428.57rpm

Another important aspect of torque performance at various

speeds is the amount of torque ripple produced. Large amount
of torque ripple would lead to controllability issues especially
for small motors with low inertia operating at low speeds. Fig
.10 shows the percent torque ripples produced by the proposed
concentrated winding model at various speeds.

0.04
Torque (Nm)

CPSR

Figure 10. Torque and power Vs Speed for proposed concentrated winding
model

42-slot, 14-pole Distributed

18-slot, 14-pole Concentrated

0.08

N.O. Silicon Steel

1.6T
Sintered NdFeB
1.3T
228 Turns
38 Turns
34 Turns
17Arms
30Vrms
0.2
0.6mm
42mm
65mm
65mm

0.02
0
-0.02
-0.04
-0.06
-0.08
0

0.1

0.2

0.3

0.4
0.5
0.6
Normalized Time (p.u.)

0.7

0.8

0.9

Figure 9. Respective cogging torque waveforms

2.6%

2.7%

5.8%

10.4%

C. Torque and power performance under field weakening

It has been shown above that the proposed model having a
double-layer, 18-slot, 14-pole model configuration produces a
high winding factor and low cogging torque. Another aim for
this design is to achieve a high torque density and to obtain a
wide CPSR.
Machine geometry was created using (1) to (4) and from
there, slot area is known. A packing factor is declared as 60%
assuming that the hinge method is used. Other key parameters
and dimensions for the model are shown in table 1.
Torque and power versus speed is used to determine the
field weakening performance of the machine under steady
state. From the graph shown in fig. 10, a 4:1 wide CPSR
producing over 1kw of power over the wide field weakening
range; a peak torque of 1194kw is produced at 100Hz.

Figure 11. Torque ripple produced by proposed model

VIII. CONCLUTION AND DISCUSSION

A general design process which can be used when
implementing concentrated winding in IPM machines is
illustrated in this paper. This process includes machine
geometry and sizing derivation, stator winding methodology,
material selection and machine losses. Using the described
design process, a proposed double-layer, 18-slot, 14-pole,
concentrated winding model was derived and its performance
was tested with finite element analysis. The proposed model

achieved a 4:1 wide CPSR and produced 1kw of power

throughout the speed range. It was also able to produce
sinusoidal back emf and low cogging torque amplitude. A
mechanical finite element model of inter-pole sections was
studied and the method of minimization of stress concentration
by the use of fillets was also shown. The experimental
verification of the model will be covered in another paper in
near future.
[1]
[2]

[3]

[4]

[5]

[6]

[7]
[8]

[9]
[10]
[11]

[12]
[13]
[14]

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