2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]

Generalized Procedure for BLDC Motor

Design and Substantiation in
MagNet 7.1.1 Software
Carunaiselvane.C S.Jeevananthan
Department of Electrical and Electronics Engineering Department of Electrical and Electronics Engineering
Pondicherry Engineering College Pondicherry Engineering College
Puducherry, India-605014 Puducherry, India-605014
Email: carunaiselvane@gmail.com Email: drsLeee@pec.edu

Abstract- In this paper, a generalized procedure for

KjiU- Slot fill factor
designing a Permanent Magnet Brushless DC motor
(PMBLDCM) based on design equations is presented. L - Active length of the motor in mm
The formulated algorithm can provide a design It - Length of a tum in m
solution either dependent variables or independent
variables are available. A step by step procedure of NPh - Number of phases
the design validation and analysis using the MagNet
ns - Total number of turns in a slot
7.1.1 software is illustrated. The main attention is
dedicated to exploit the MagNet 7.1.1 software as a N,- Number of slots
teaching material to enable the fundamental design of
p -Number of pole pairs
PMBLDCM with interactive screen shots. The design
equations and results such as Projected 3D views,
P - Number of poles
Flux patterns and Cogging torque are presented for �()SS cu - Copper loss in Watts
27 slots, 8 pole and O.7SkW PMBLDCM.
�oss core - Core loss in Watts
Nomenclature
0rs-Flux in one slot pitch in Wb

Ae - Cross-sectional area of a conductor in mm 0t- Flux in tooth in Wb

Aeu - Area of copper conductor in a slot in m2 Peu - Resistivity of a copper in Ohms-cm
Bg - Air gap flux density in the middle120° of a Rph - Resistance of a phase in Ohms

pole in Wb/m2 Rro - Rotor outer radius in mm

Brnax - Maximum flux density in Wb/m2 �i - Stator inner radius in mm
� - Diameter of a conductor in mm Rso - Stator outer radius in mm
Deu - Density of copper in Kg/m3 � - Resistance of a tum in Ohms
ds -Slot depth in mm spp -Slots/pole/phase

Dsteel - Density of steel in Kg/m3 t'e - Coil pitch

Eb - Back emf of the motor in Volts t's - Slot pitch

V -Linear velocity of the rotor in m/sec
Ee -Emf induced per conductor in Volts
Vcu- Volume of copper in m3
E;-Emf induced in a tum in Volts
v"otor- Volume of rotor in m3
g - Air gap in mm

Ie - Current through a conductor in Amps

v'tator -Volume of stator in m3
Wbi - Back iron length in mm
Iphase - Phase current in Amps

Is - Current from DC source in Amps �u - Weight of copper in Kg

J - Maximum current density in Amps/m2 OJm- Angular velocity of the rotor in mlsec

978-1-4673-021O-4112/$3l.00 ©2012 IEEE 18

 2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]
Wmotor� Weight of motor in Kg
� tatorlrotor � Weight of stator/rotor in Kg
W sbl st � Bottom/top slot width in mm
vt; � Tooth width in mm
1. INTRODUCTION
Brushed DC motors have been in commercial use
since 1886. Brushless DC motors, however, have
only been commercially possible since 1962. Some
advantages of this machine can be listed as their
high performance, higher value of torque per
volume, capability at high speed applications,
electronic driven commutation etc [1]-[2]. These
advantages, combined with the programmed
control have made them very attractive candidates
for various domestic and industrial applications [5].
In recent years, Permanent-magnet BLDC motors
(PMBLDCM) have wide usage areas such as home
appliance: washers, dryers; in automotive: fans,
pumps and blowers etc. Increase in their demand
made many manufacturers around world-wide to
focus on BLDC motor [9-12]. This special motor
brands with different design variations, depending
upon the specific application and requirements
unlike its counterparts (Induction motor,
synchronous motor etc), which are having standard
common design and done in mass production. The
design variations are in terms of silhouette changes
of slots, rotor magnets etc or utilization of different
magnet grades. The only viable way of
substantiation of rough design variation is through
simulation tools like MagNet [6-8], RMxprt™ etc.
To design any machine it is necessary to know the
physical meaning of all the dimensions of that
machine. In such way the text book on "Brushless
Permanent-Magnet Motor Design" by
D.Hanselman provides the complete physical
meaning about all dimensions of a PMBLDCM and
"Brushless Permanent-Magnet Motor Design" by
R.Hendershot Jr. and TJE Miller provides the
methodology as well as the constrains to design a
PMBLDCM. Many authors have proposed design
procedure for some specialized applications. In the
year 2003, Bin Zhang et al have proposed a design
methodology to reduce cogging torque by
combining teeth notching and rotor magnets
skewing technique in PMBLDC with concentrated
windings [3]. Skewing technique has been used to
reduce the cogging torque of PMBLDC with
concentrated windings by combining teeth notching
and rotor magnets skewing. For motors with
concentrated windings, the method of reducing
cogging torque by skewing rotor magnets is not
quite available because of the large slot pitch. Then
the method of teeth notching has also been
19
introduced. At last, a numerical solution solved
with MagNet 3D is presented to verity the validity
of this method.. In 2008, Kwang-Kyu Han et al
have designed a rotor and notch to improve the
Operation Characteristics in Spoke type BLDCM
[4]. The air gap distance has been changed to
achieve a sinusoidal wave of the flux density on
air-gap and additionly a notch was installed on
stator for better operation characteristic. They have
maintained the operating torque as maximum and
the ripple of operating torque has decreased greatly
compared the basic model. Using MagNet software
the cogging torque analysis have been performed
and found it was reduced to 0.14 Nm from 0.42
Nm. Recently in 2011 R.P. Praveen et al have
proposed a design procedure for an optimal surface
mounted PMBLDC motor for Spacecraft
applications [5]. For a spacecraft application the
motor should be highly efficient with small size.
They justified this by achieving zero cogging for
their model. Performances of two types of machine
configurations viz Slotted PMBLDC and Slotless
PMBLDC with Halbach array are compared with
the help of analytical and finite element ( FE)
methods and finally it has been reviewed the
results using MagNet software [6-8]. Based on the
insightful investigation of the BLDC machine
geometry, so far many authors have proposed
various design variations to improve the
performance of the motor [5-6].
The witty solutions archived in literature are
undoubtedly triumph first step in achieving the
goal. While critical evaluation of them through
simulated comparison can bring them to next level
and further induce newer design suggestions.
Hence this study takes of following objectives of
providing a clear step by step general design
procedure for designing a PMBLDC motor. The
MagNet 7.1.1 is powerful tool where one can
design a motor and perform 2D and 3D models for
magneto static, time harmonic, transient or
transient with motion analysis with reasonably
good degree of accuracy. A step by step
methodology to use this software for designing a
PMBLDC motor and how to perform the analysis is
also studied in this paper.
II. STRUCTURE OF BLOC MOTOR
The construction of modem brushless motors is
very similar to the ac motor, known as the
permanent magnet synchronous motor. The stator
windings are similar to those in a polyphase ac
motor, and the rotor is composed of one or more
permanent magnets. Brushless dc motors are
different from ac synchronous motors in that the
former incorporates some means to detect the rotor
position (or magnetic poles) to produce signals to
control the electronic switches. The most common
 2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]
position/pole sensor is the Hall element, but some
motors use optical sensors.
A. Dimensions ofBLDC motor
Stator outer
diameter
Air
'------+ Gap
Fig. I Key dimensions of BLDC motor
The key dimensions of a BLDC motor are defined
as follows:
Stator outer diameter: The maximum distance
between the center of the motor and the stator
outer circumference is called the stator outer radius.
Twice the stator outer radius is the stator outer
diameter.
Stator inner diameter: The maximum distance
between the center of the motor and the stator
inner circumference is called the stator inner radius.
Twice the stator inner radius is the stator inner
diameter.
Rotor outer diameter: The maximum distance
between the center of the motor and the rotor outer
circumference is called the rotor outer radius.
Twice the rotor outer radius is the rotor outer
diameter.
Rotor inner diameter: The maximum distance
between the center of the motor and the rotor inner
circumference is called the rotor inner radius.
Twice the rotor inner radius is the rotor inner
diameter.
Magnet thickness: The maximum distance between
the mid-point of the top of the magnet and the mid­
point of the bottom of the magnet.
Air gap: Gap between the rotor outer
circumference and the stator inner circumference.
B. Stator slot dimensions
Fig. 2 Stator slot dimensions
Slot width top, wst: The distance between start
point and end point of the slot opening at the top.
20
Slot width bottom, wsb : The distance between start
point and end point of the slot opening at the
bottom.
Tooth width, W,t: The total width of the stator
teeth.
Back iron length, wt : The linear distance between
the stator outer circumference and the stator inner
circumference.
Slot depth, d, : The maximum distance between the
mid-point of the start point and the mid-point end
point of the slot teeth.
III. DESIGN PROCEDURE
In design process, the independent or "input"
variables are usually dimensions, winding turns and
properties of magnet material whereas the
dependent variables (output variables) are usually
performance figures such as torque, current,
efficiency, temperature rise etc. In fact, many more
independent variables involved in the design
process and most of them are assigned their values
by reiteration. That is, the design engineers have to
make certain assumptions, assigning trial values to
independent variables and calculating the
dependent values. If the performance is not
satisfactory, the process continues until the desired
performance is achieved. Another method to design
is, the dependent variables are fixed and
accordingly the independent variables are derived
with the help of equations.
In this section, a generalized procedure for
designing a PMBLDCM, either having the
dependent variables or arriving the independent
variables or vice versa is proposed. Before a BLDC
motor design can begin, several important
decisions must be made regarding the features of
different types of brushless motors and the
availability of different magnetic materials .A step
by step procedure is provided as a flow chart in
Fig.3.
IV. DESIGN EQUATIONS
A. Torque Expression ofBLDC motor
Force on a current carrying conductor in a
magnetic field is given by,
F=lLxB (1)
where,L is length of the conductor, B is magnetic
flux density, and I is current through the conductor.
The magnitude of the force is
F=BILsinB (2)
where Bis the angle between L and B.
 2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]

Determine aplication requirements

The 3 phase inverter is operated in 1200
conduction mode i.e. two phase carry current at any
given time. Thus the total torque developed by the
I nterior-rotor, exterior rotor, or axial-gap
motor wiJ] be
configuration
(8)
Select magnet Grade In this design, the coils of same phase are
connected in series. Also 1200 conduction mode are
Select number of Poles used.

(9)
Select number of Stator slots and phases
(10)

Perform rough sizing estimate B. Back EMF Expression ofBLDe motor

Select air gap length and determine
magnetic Loading
Design rotor and determine flux/pole
In the same manner the back emf can be
calculated as torque expression of the motor:
Emf in one conductor, Ee =Bg Lv
(11)
Emf in one conductor, Ec = Bg Lwm R.
(12) .'II

Emf in one tum, Et =2Bg Lw R.

Lay out stator lamination dimensions (13) m Sl

Emf in one coil, Eco/., =2Bg Ln.0 wm R..01

(14)
Solve for number of conductors and Emf in one phase, E hase = P Bg Lns wm R'i
turn/coil p (15)
Back emf of the motor, Eb =2PBg Ln.0 wm R..01
(16)
Calculate wire size, resistance and
inductance/phase Eb is the back emf seen by the DC voltage source.

Calculate the performance C. Stator Winding design

The conductor wire gauge will be decided by
Check temperture rise, current density, flux the maximum current density.
densities, demagnetization of magnet
Ae Ie '. ... De 2 fA:
J V-;-
= =

Modify design and reiterate until-­

(17)
oblectives met Actually RMS value i.e. I fi should have been
Fig.3 Flow chart for design procedure
e

V3
The BLOC motor works on same principle as
used. However, Ie is taken leading to a
a DC motor i.e. armature current and magnetic field conservative design. Now using standard wire
are kept orthogonal to each other in space( B=900 gauge (SWG) table select a gauge with next higher
). Thus the force on one conductor in the BLDC diameter (De *) than what has obtained.
motor is given by,
A*-�(D*)2
-4
c
.A -
... - ns xA -
c ,
- ns xA *
ell ell c

(3) (18)
:. Torque on a conductor is given by, Aeu is area of copper in a slot. Now approximate
r: = B/c LR,;
(4) overhang length is calculated. It is assumed that
A tum consists of 2 conductors, one above winding overhang is equal to coil pitch.
north pole and other above south. Therefore torque 1 1
Ie 2n:(R" +"2d,) p
on one tum is
=

(19)
(5)
(20)
:. Torque on a coil with turns n s is given by,
D. Stator Slot Design
(6) It is considered that uniform tooth and
Each pole pair has to have all 3 phase coils. approximate the slot area as a trapezoid as shown
Therefore total number of coils per phase is equal in Fig 2.
to no. of pole pairs. A full pitch winding (SPP=I ) The slot area can be calculated as follows
is used to get square mmf wave. Aeu
:. Torque per phase is given by, AS =
Kjil/
(21)
(7)

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 2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]

The slot fill factor takes care of insulation in �oss = 21s 2 Rph
the slot as well as all the approximations that are
_CII
(38)
made while choosing slot area as trapezoid. Using Core loss:
this area the various dimensions shown in Fig I and As compared to copper losses, core losses
Fig 2 can be calculated as follows: are very difficult to calculate as they consist of
hysteresis and eddy current losses which vary
(22) nonlinearly with frequency and magnetic flux
2JrRSI . density. Fortunately manufacturers provide
r • S 1 ot PItch (23)
S '
= __

Ns coreloss/kg data of the steel at various values of

Tooth has to carry all the flux in the slot pitch, flux density and frequency which we can use to
approximately calculate the core losses. Core losses
i.e. 0,s =0I =>rsLBg = wLB I max (24) occur only in stator.

. w ---
B, �ossJore =coreloss / kg(fe,Bmax)xw'la,or
(39)
t - � r·w - s -wt
s' sb-r
Bmax
• •

(25)
v. MAGNET SOFTWARE AND
The area of the trapezoid is the slot area.
DESIGN STEPS
I
.'. A, = "2 (WSI + wsb) xd,
(26) MagNet is the most advanced package
2Jr(Rs i + ds) (27) currently available for modeling electromagnetic
I
_

W W
,,- NS devices on a personal computer. It provides a
"virtual laboratory" in which the user can create
Substitute Wst in As and solve the quadratic models from magnetic materials and coils, view
equation obtained to get "ds "and "Wst ".The displays in the form of field plots and graphs, and
get numerical values for quantities such as flux
maximum flux that the stator back iron has to carry
linkage and force. A MagNet user needs only an
is half the pole flux.
elementary knowledge of magnetic concepts to
1 2JrR. B JrR
LB =wLB b �wb =_g si model existing devices, modify designs, and test
g l max i B
--_
." ___

2 P P max
new ideas.
MagNet is designed as a full 3D-modeling
(28) tool for solving static magnetic field and eddy­
Actually pole flux density profile is
current problems. Many devices can be represented
trapezoidal in nature. Here it is assumed to be same
very well by 20 models, so MagNet offers the
all along the pole pitch.
option of 20 modeling, with a substantial saving in
(29) computing resources and solution time. With 2D
This fixes all the dimensions of the machine. Now models, MagNet can also handle problems with
the weight of the motor is calculated. automated design optimization and provides
Rotor: thermal simulations and vibration analysis in
addition.
- ltL1)�o 2L
Vrotor - (30)
A. Modelingflow chart
w"Olor = D"ee' X Vro1or (31)
Step 1

This includes shaft and PM weight approximately

Stator:
Step 2
-E Set the drav.ing space
Oraw the geometry
Sweep the components
'-_'/

W.IJlQlOr = DSleel X V."lalOr (33) Step3

---c ;���: ���._�=��c��.
Apply the "Make Simple Coil"
commands
01

'----_--"
Windings: Edit the co� propertlllS

�:u = Nphpn,l,Ac (34) Step 4

----c: Oraw and $wetp an iii, bOil that surrounds
the model

'--••..•.••..• � Apply boundary conditions 10 SlJrfaces

(35)
WCll = Dcu xVrotor ----c: Modify the mesh edge subdNisions
Step 5
Overall weight: Modify the element edge ren�lh

Wmo1or = Wro1or + w'lalor + �1I

(36)
This is an approximate value and weight of the
St.p 6 8 ----c I

Solve defaults
Clloose the sower options (Ot accepllhe

Choose the adaptioll op'ions (opliona�

I
frame is not considered.
Step 7
-E View field pl ols
..
VieW and graph glob ! qUilAUiiS
Ind field lnir�ultions

"--"==--� Ir required, you can

rn.nipulal� fields using I� CAlculafor.
Plobe field values.

E. Calculation of losses
Copper losses: Fig.S Flowchart for modeling in MagNet 7.1.1 [ 13]

I
Rt -
- P _ I • R - pns Rf
cll *' ph- B. Design steps
AC
(37)
As 2 phases carry current at any given time,

22
 2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]

The BLDC motor with 27 slots and 8 poles which
is to be designed is shown in Fig.6 with complete
dimensions and its design parameters are listed out
in Table.1. All dimensions shown in Fig.6 are in
millimeters (mm).
fixed to the component and the necessary materials
are filled in the component as shown in Fig.lD.
Similarly all the components are constructed.

Table . I·. Parameters of the BLOC

Stator Outer Diameter 62mm
Stator Yoke 2mm
Stator Teeth Height 12.5mm
Rotor Outer Diameter 34.5mm
Rotor Inner Diameter 12mm
Magnet Area IOmm

'" 10

/A:v----+... ,."'"'

12 00 62(0

Fig.6 Complete geometric model of BLOC

J) Open a new model

Clicking open the MagNet 7.1.1 software, go
to File and open a new file as shown in Fig.7.

2) Build the geometry model '" n

For building the geometry, go to Tools and - .-

- ,�

select your input as "keyboard input bar" as shown

in Fig.7 where the units of the dimensions say
millimeter, centimeter, meter, etc. is selected. Now
the required geometry is drawn using the
corresponding tools. For example, using the circle
tool a circle of radius 31mm is drawn as shown in
Fig.7.

Fig.IO Filling material

3) Create coils
Coils are then created by using Model tool and
"Make a simple coil" option as shown in Fig. I O.
The parameters of the coil are then set as shown in
Fig. I I .

a geometry

Similarly the entire model is drawn as shown in

Fig.8. Then the geometry is made as different
components as shown in Fig. 9. The parameters are

23
 2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]

Fig. I 0 Creating coils Fig.13 Result

C. Various Analysis

Analysis are performed by changing the rotor

positions shown in Fig.14.All the rotating
components selected and rotated to necessary
degree as shown in Fig.l5.

Fig.11 Fixing parameters for coils

4) Solve
The solving adaptation is done automatically
using "Solve" tools and "Static 2D" option as
shown in 12.
Fig.14 Changing rotor position
l" ... c.:at>-___ o...o: __ ,.... ___ ...

Fig.12 Solving option

5) View the solution results
Fig.13 shows the result page where many datas
say Energy, Torque, Flux Linkages, Ohmic loss,
Iron losses can be viewed.
Fig. 15 Changing the angle of rotor
D.Design overview
The overall view of the constructed
PMBLDCM is shown in Fig.23 (a) sand (b).

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 2012 International Conference on Computing, Electronics and Electrical Technologies [ICCEET]

VII. CONCLUSION

A generalised procedure for designing a Permanent

Magnet Brushless DC (PMBLDC) motor is
proposed in this paper. The dependent variable and
the arrival of independent variablesor vice versa
arepossible inthe proposed procedure. This paper
gives the combination of both the techniques.
A step by step procedure of designing and
(a) (b) analyzing a PMBLDC motor using the MagNet
7.1.1 software is shown. The possible analysis in
Fig.23 (a) Side view, (b) Coil connected MagNet 7.1.1 has been shown. The result has been
discussed in such a way that it is possible to
VI. RESULTS improve the teaching-learning methods in this field
with interactive screens. The MagNet 7.1.1 models
A.
Fluxflow of basic PMBLDC motor is developed and
The flux flow pattern of the designed performance waveforms are obtained. It is evident
PMBLDCM is shown in Fig.24. that the developed tool will help a UG level of
Shaded Plot
181
understanding and performance predictions of
1
PMBLDC motors.

I ;�
1.36714
0.911766
0.45639 REFERENCES
0.00101494

[ I] D. Hanselman, Brushless Permanent-Magnet Motor Design.

McGraw-Hill, 1994..
[2] R.Hendershot Jr. and TJE Miller, Design of Brushless
Permanent-Magnet Motor. Magna Physics Publications &
Clarendon Press, 1994, Oxford.
[3] Bin Zhang, Xiuhe Wang, Ran Zhang, Xiaolei Mou*
M. Ehsan 'Cogging Torque Reduction by Combining
Teeth Notching and Rotor Magnets Skewing in PM
BLDC with Concentrated Windings" IEEE
Transaction on Electrical machines and systems,(IC
EMS),03 VoU pp. 3 189 - 3 192 .Feb.2009
[4] Kwang-Kyu Han Dong-Yeup Lee Gyu-Hong Kang Ki-
Fig.24 Flux yattern Bong Jang Heung-Kyo Shin Gyu-Tak Kim
Dept. of Electr. Eng., Changwon Nat. Univ, Changwon
"The design of rotor and notch to improve the operation
B. Cogging Torque characteristics in spoke type BLDC motor" IEEE
The rotor is rotated from 0 to 360 degrees Transaction on Electrical Machines and Systems(ICEMS).

andcogging torque is measured at each position. pp. 3121-3125. Feb. 2009

[5] R.P. Praveen, M.H. Ravichandran, V.T. SadasivanAchari,
Cogging torque of electrical motors is the torque Dr. v.P. Jagathy Raj, Dr. G. Madhu, Dr. G.R. Bindu, and
due to the interaction between the permanent Dr. F. Dubas" Optimal Design of a Surface Mounted
Permanent-Magnet BLDC Motor for Spacecraft
magnets of the rotor and the stator slots of a Applications"IEEE Transaction on Emerging Trends in
Permanent Magnet (PM) machineIt is especially Electrical and Computer Technology (ICETECT). pp 413 -
419. May 2011
prominent at lower speeds, with the symptom of
[6] Y. Diinmezer and L.T. Ergene Informatics Institute, Istanbul
jerkiness. A waveform is plotted between the rotor Technical University, Istanbul, Turkey. "Cogging Torque

position vs cogging torque as shown Fig.25. Analysis of Interior-Type Permanent-Magnet Brushless DC

Motor Used in Washers", ELECTROMOTION 2009 - EPE
Chapter 'Electric Drives' Joint Symposium, 1-3 July 2009,
Cogging Torque Lille, France..
0.6 [7] PiotrBogusz, MariuszKorkosz& Jan Prokop" A Study of
Design Process of BLDC Motor for Aircraft Hybrid Drive"
0.4 IEEE Transaction on Industrial Electronics (ISlE). pp. 508
-513. June 2011
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o Simulation Software to Engineering-Focused Software:
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-0.2 Design"IEEE TRANSACTIONS ON MAGNETICS, VOL.
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[ 10] URL - http://www.chennaiplc.com/
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[ 12] URL - http://www.anshumantech.netl
[ 13] URL - http://www.infolytica.com/en/products/magnet

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