The required power for the motor is calculated as follow.

Force  mass  acceleration

 5 kg  20 m/s2  100 N
Power  Force  Speed
 100 N  2.5 m/s  250 W
The motor power is selected at least 1.5 times the power required and 375 W
is chosen. The speed for motor is 1000 rpm and torque is calculated as follow,
power
T  3.58 Nm
2n sπ
2f
pole 6
ns
The surface mounted permanent magnet is used for this design and the design
parameters for PMSM is as follow.

Specification of PMSM
Rated output power : 375 W
Rated voltage (line to line) : 380 V
Speed : 1000 rpm
Number of pole : 6 poles
Number of phase : 3 phase
Frequency : 50 Hz
Connection of stator winding : Star
Type of rotor : Permanent magnet rotor
The input line to neutral voltage;
380
Vph   219.39V
√3
The armature rated current;
Pout
Ia 
3V1ηcosφ

375
  0.7597A
3  219.39  0.75

Main Dimensions of Stator Frame

The specifications of the main dimensions of the stator frame are:
Specific electromagnetic loading, Am  13000 A/m
Winding factor for full pitch coil, KW1  0.96
Speed of motor in r.p.m, n  1000
Speed of motor in r.p.s, ns  16.667
f
Number of pole pair, p= 3
ns

For the NdFeB PMs is recommended to assume the air gap magnetic flux density
between (0.7…0.9)Br, so assumed Bmg  0.8Br.The remanent flux density (Br) of the NdFeB is
between 1.25 to 1.30 T and coercivity(Hc) is between 950 to 1005kA/m.
The air gap magnetic flux density Bmg  0.8  1.25  1 T
The first harmonic of the air gap magnetic flux density Bmg is
αi
4Bmg sin
Bmg1  2
π
The pole arc to pole pitch ratio α i is assumed as 0.5.

0.5
4  1  sin
Bmg1  2  0.9
π
The output coefficient according to Equation (4.2)

δ p  0.5π 2k w1AmBmgη cosφ

  0.5 2  0.96  1  0.75  13000
 46189.7486 VAs/m3
The relative eccentricity ε is assumed as 0.75.
Pout ε

2
D1in Li
δ pns

375  0.75

46189.7486  16.667
 0.000365 m3
 365 cm3
Li  1.3D1in

365
The internal diameter of the stator D1in  3  6.55cm  66mm
1.3
The effective length of the stator Li  8.515cm  85mm
Design of Stator Winding
The input data, for the design of stator winding are
For number of stator turns per phase,
Voltage per phase, V1  219.393 V
Armature rate dcurrent, Ia  0.7597 A
For number of stator slots,
Giving due considering to various factor, affecting the choice of number of stator slots,
number of slots per pole per phase(q) is assumed as 2.
Thus, total number of stator slots,
Ns  m.p.q
 3×6×2
 36
Number of stator slots per phase  2×6
 12
πD 1in π  66
Pole pitch τ p  
2p 6
 0.0346 m
From the Equation 5.4,
 A m pτ
Armature turn per phase, N1 
p

m 2I a

13000  3  0.0346

3  2  0.7597
 419.046
 420 turns
Conductor per phase = 420  2  840
N1
Conductors per slot, Ncs 
no: of conductor/ phase

820
  70
12
πD 1in
Slot pitch τ s 
Ns

π  66
  0.00314m
36
The peripheral speed,
V  π Dr ns
 π × 66 × 16.667
 3.46 m/s
Therefore, the peripheral speed is within the limit and it is satisfactory. Then, the main
dimensions of the stator frame are the suitable values.
From Equation 4.6,
2
Flux per pole, φ f  τ p L i B mg1
π
2
  0.0346  0.085  0.9
π
 1.685 mWb
The EMF induced by the rotor excitation flux at no load(Ef),

Ef  π 2fN1k w1φ f

 π  2  50  420  0.96 1.685 103

 150.923 V
 For size of conductor for stator winding
Usual value for current density is 3 to 5 A/mm2. Therefore,
Choose current density, Js  3.5 A/mm2
I
Cross-sectional area of conductor,as  a
J
s
 0.7597
3.5
 0.2169 mm2
πd a2
as 
4
The diameter of the conductor da  0.525 mm
Choose the standard wire guage (SWG) number 25 for round conductor.
For dimensions of the stator slot,
The flux density in the tooth at the gap surface Bt is assumed as 1.8 T.
pole arc
αi = = 0.5
pole pitch
Pole arc  0.5  0.0346  0.0173 m
pole arc
Number of teeth per pole arc Nt 
slot pitch

0.0173
  5.509
0.00314
6
From Equation 4.9,
φ
Width of teeth at gap surface b t 
Bt  Li  N t

1.685  103
 = 0.00184m
1.8  0.085  6
For slot insulation width wise,
Insulation over conductor ∆b1  0.4 mm
Slot liner hn3  0.4 mm
Tolerance  0.15 mm
 Thus, the slot insulation width wise ∆b  0.95 mm
Conductor section  0.2169 mm2
 0.466 mm  0.466 mm
The final width of slot bs  1  0.466 + 0.95  1.416 mm
For depth of slot,
Space occupied by bare conductor = 1.846 mm
Insulation over conductor ∆b1 = 1.6 mm
Slot liner hn3 = 0.4 mm
Insulation between layer ∆np = 1 mm
Wedge = 3mm
Lip = 1mm
Tolerance = 1 mm
Thus, the depth of the stator slot hs 9.864 mm
For the depth of stator core,
1
Flux core section φ c  φ f
2
1.685  103
  8.425  10 4 Wb
2
From Equation 4.10,
φ c  Bc  Li  dc

8.425  104
dc   7.929 mm
1.25  0.085
The outer diameter of the stator is Dout  D1in+2hs+2dc
 66 + 19.728 + 15.858
 101.586 mm  102 mm
For resistance of stator turn,
Mean length of stator turn, L1av  2(Li + L1e )
From Equation 4.13,
pD1in  h1t
L1e  (0.083P  1.217)  0.02
2p
 3  0.066  0.00986  0.02
 0.083P  1.217 
6
 0.0709 m
L1avi = (0.085 + 0.0709)  0.3119 m
Resistance of stator winding,
N1l1av
Rs 
a sδ 1

420  0.3119

47  106  0.2169
 12.8501 Ω
For leakage reactance of the stator winding,
From Equation 4.28,
  b14   b14  
2
4  b14
1  arctan    ln 1   
π  2g  2g   2g  
 
4 1 
  arctan(0.5 )  ln 1.25 
π 2 
 0.153
The Carter’s coefficient is
τs
kC 
τ s   1g

3.14
  1.0512
3.14  0.153
The tooth-top specific permeance (between the heads of teeth) is
From Equation 4.29,
5g/b 14
λ 1t 
5  4g/b 14

 0.556
For full pitch coil, stator coil pitch ω c  τ p  0.0346 m and choose the stator differential

leakage factor τ d1  0.0275.The differential leakage flux according to Equation 4.25,

 mq τ p k 2w1τ
λ 1d 
d1

π gk C k sat
2

3  2  0.0346  0.96  0.0275

2


π 2  1 1.0512  1
 0.0005071
The reaction factor for surface permanent magnet rotor kfd = kaq = 1.Thus d-axis and q-
axis of the armature reaction reactance with magnetic saturation include is the same. From
Equation 4.32,

4mμ 0f(N 1k w1 ) 2τ p Li k fd
X ad  X aq  k fd X a 
π pg

4mμ 0f(N 1k w1 ) 2τ p Li
Xa 
π pg

4  3  0.4π  106  50  420  0.96  0.0346  0.085

2


π  3 1
 0.03825 Ω
Xad  Xaq  0.03825 Ω
From Equation 4.24,

 2ωc 
λ 1e  0.34q1  
 π L1e 
 2  0.0346 
 0.34  21  
 π  0.0709 
 0.4687
The leakage reactance of the armature windings is calculated from Equation 4.23.

N12 Li  L1e 
X1  4πμ 0f  λ1s  λ1e  λ1d  λ1t 
pq  Li 
 1.3343 Ω