Design optimization of permanent magnet synchronous motors for high torque capability and low magnet volume

Permanent magnet synchronous motors are being manufactured and used increasingly in low to medium power range applications due to their inherent advantages. There is a great deal of opportunity to enhance their merits by design optimization, thus reduce production costs and improve performance of the motors. In this paper a design optimization is performed on interior type permanent magnet synchronous motors to achieve high torque development capability with low permanent magnet consumption. A multi-objective optimization is performed in search for optimum magnet dimensions and location. The design optimization results in a motor structure superior to original motor specifications. Finite element method is used to evaluate the accuracy of the results.     

Operating Limits of Inverter-Driven Permanent Magnet Motor Drives

Recent developments of high-energy permanent magnet (PM) materials such as neodymium-iron-boron have focused attention on the use of PM synchronous motors supplied from inverters for a wide variety of speed control applications. PM motor drives are readily applicable where full torque is required up to full or base speed. They are, however, limited in their ability to operate in the power-limited regime where the available torque is reduced as the speed is increased above its base value. In contrast with the field weakening approach used in dc drives, the magnet is permanent. The torque-speed operating limits of PM motor drives, of conventional design are explored, and then design measures which can substantially extend operation into the power-limited regime are proposed. A trade-off between the low speed-torque limit and the extent of the speed range above base speed is achieved by variations in magnet dimensions and the depth of inset of the magnets in the rotor iron. Experimental results are presented for two motors of different design, each using neodymium magnets and each supplied from a current-controlled inverter with hysteresis control of current waveshape.     

基于瞬态热网络法的细长型永磁电机优化设计研究

本文将瞬态热网络法应用到起重机用细长型外转子永磁电机的优化设计中,以电机效率和成本为优化目标,对一台37.0kW永磁电机进行优化设计。选择永磁体厚度、气隙长度g、电机铁心轴向长度、每槽导体数、导线线规、永磁体厚度六个参数为优化变量,同时约束其槽满率、定子齿部磁密、定子轭部磁密、最大温升、最大转矩在一定范围内。本文分析了细长型永磁电机结构参数对铜损耗和效率的影响,再利用粒子群优化算法对永磁电机进行优化设计。优化结果显示:电机效率提高1.1%,成本也略有下降。最后通过有限元仿真,验证了瞬态热网络法的可行性和准确性。     

自起动稀土永磁电机断相运行时步有限元分析

为了研究自起动稀土永磁电动机断相后的运行特性,建立了断相运行的场一路一运动直接耦合时步有限元模型.以一台22 kW永磁电机为例,分析了其在30%和50%额定负载下断相前后的定子电流、转矩波动及损耗情况.计算结果表明,在负载转矩保持不变的条件下,断相后定子电流接近断相前的2倍,转矩发生大幅度波动,而总损耗分别增加32%和84%.因此,从减小损耗与转矩波动两方面考虑,自起动稀土永磁电机即使轻载工况下也应尽量避免断相运行.实测数据验证了计算结果的正确性.     

Temperature effects on torque production and efficiency of PMmotors using NdFeB magnets

Recent developments in high energy magnets have created widespread interest in the area of permanent magnet (PM) motors. The use of PM synchronous motors or brushless motors to replace conventional DC or induction type motors has not been as speedy as anticipated earlier. This paper deals with the temperature effects of PM motors using neodymium magnets on the torque production capability and on the efficiency of the motor. When PM motors are designed to operate in a wide temperature range, the reversible demagnetization of the neodymium magnets with temperature and the increase in winding resistance with temperature influence the maximum torque capability at rated speed and efficiency of the PM motor. The maximum torque at rated speed is limited due to the fixed DC link voltage of the inverter feeding the motor. In this paper, it is shown that over an operating range of -40°C to 150°C the maximum torque capability and efficiency of the motor can vary over a wide range. It is also shown that for certain designs, a near flat maximum torque versus temperature characteristic may be obtained. The major factors influencing these variations are identified. The discussion in this paper is concentrated on PM motors with a trapezoidal back EMF waveform. The idea could be extended to sinusoidal back EMF motors and to PM DC motors     

Computer-Aided Design Of A Permanent Magnet Motor

ABSTRACT

Although neodymium-iron-boron (Nd-Fe-B) magnets have high-energy product with suitable magnetic and physical properties for applications in electrical machines, the design of permanent magnet (PM) motors is a complicated problem due to their complex geometries and PM material characteristics. This paper initially compares various PM motor geometries and describes their PM material outlay, armature reaction and mechanical integrity. By the employment of appropriately located air slots to reduce the armature reaction in conjunction with flux enhancement arrangement without detracting from its mechanical integrity, a new rotor geometry for a high-field high-speed PM synchronous motor is proposed. Computer-aided electromagnetic calculation and graphical evaluation are employed for the design and optimization of the proposed PM motor. An idea of ‘computer job delegation’ is proposed and implemented within the computer system to provide full utilization of each computer's capabilities as well as parallel operation of the design and optimization process. The proposed rotor geometry and design philosophy have been implemented to design a 3.2 kW PM synchronous motor.     

轴向磁通永磁电机的设计与优化

本文根据一款家用乘用车的结构和运行性能需求,设计出了额定功率95kW,峰值功率190kW的轴向磁通永磁电机。电机采用内单定子外双转子结构,定子铁心采用分块式设计形式。基于永磁电机设计理论,总结归纳轴向磁通永磁电机的初始设计流程,并对其电磁性能进行初始评估。采用有限元法建立电磁分析三维模型,对采用多种转子结构电机的电磁转矩、齿槽转矩、转矩脉动及永磁体涡流损耗等进行计算和分析。文中所归纳的电动汽车驱动用轴向磁通永磁电机设计流程及降低齿槽转矩、转矩脉动和永磁体涡流措施的效果对比,为此类电机的设计及优化提供借鉴经验。     

Expansion of operating limits for permanent magnet motor by currentvector control considering inverter capacity

The current vector control method of PM (permanent magnet) motors is examined to expand the operating limits associated with inverter capacity. This control method is optimum in the sense of deriving maximum output torque within the voltage and current constraints. The effects of motor parameters are examined by computer simulation. The operating limits are greatly expanded by controlling the d- and q-axis components of the armature current according to the rotor speed. The operating limits are examined considering the demagnetization of the permanent magnet. If the permanent magnet has a straight demagnetization curve, like a rare-earth permanent magnet, the PM motor can be safely operated until the demagnetizing coefficient becomes 1.0. If wide speed range or constant power operation is desirable, a permanent magnetic with a high coercivity and a linear demagnetization curve must be used for the PM motor     

少稀土组合磁极Halbach永磁同步电机性能和材料成本研究

稀土永磁同步电机性能优越,但稀土永磁材料价格昂贵导致电机成本增加。因此,提出了一种新型少稀土永磁同步电机,其永磁体采用组合磁极Halbach结构。分析了少稀土组合磁极永磁同步电机的结构特点,并在此基础上,提出了少稀土T型、HAT型和LREH型三种组合磁极Halbach永磁同步电机拓扑结构。从电机空载反电动势、空载齿槽转矩和额定负载电磁转矩等方面分析了三种拓扑结构少稀土永磁同步电机,并与稀土永磁同步电机进行对比分析。在等转矩条件下研究了钕铁硼和铁氧体两种永磁体厚度对少稀土组合磁极永磁同步电机材料成本的影响。对比分析了稀土永磁同步电机和三种少稀土永磁同步电机的材料成本。有限元仿真结果表明LREH型少稀土组合磁极Halbach永磁同步电机具有更好的转矩性能和更低的材料成本。     

基于NEDC路谱的对称与非对称型永磁同步电机优化设计

用于电动汽车的永磁同步电机不仅需要考虑额定工况的性能,还需要考虑整个路谱下的综合效率。基于此,介绍了一种基于新标欧洲循环测试(NEDC)路谱的非对称V型内嵌式永磁同步电机优化设计方法。将上述非对称电机中永磁体上下两部分的几何参数分别作为独立参数进行参数化建模,然后以NEDC效率和转矩成本比为优化目标,采用遗传算法分别对对称和非对称V型永磁同步电机进行多目标优化。最后,选取帕累托前沿上的最佳设计点进行电磁性能仿真比较。仿真结果表明,与对称结构相比,非对称转子结构由于磁场偏移效应而表现出更强的转矩性能。因此,非对称V型永磁同步电机具有更加优异的电磁性能和更低的制造成本,在电动汽车领域具有广阔的应用前景。     

Halbach永磁阵列无刷直流电机转矩的解析计算和分析

Halbach永磁阵列具有灵活配置电机气隙磁通密度、磁屏蔽的特点,将其用于无刷直流电机以增加电磁转矩、降低齿槽转矩。在保角变换求解电磁场基础上,给出无刷直流电机电磁转矩与齿槽转矩的解析计算模型,通过有限元仿真对该模型的准确性进行证明;使用该模型分析每极两块(1P2p)、每极三块(1P3p)Halbach永磁阵列中主磁钢弧角和辅磁钢充磁方向角对无刷直流电机电磁转矩与齿槽转矩的影响,对比分析径向充磁、平行充磁和Halbach永磁阵列的无刷直流电机电磁转矩与齿槽转矩随永磁体厚度的变化规律。分析结果表明,合理配置无刷直流电机Halbach永磁阵列中主磁钢弧角和辅磁钢充磁方向角可提高电磁转矩、降低齿槽转矩,当永磁体厚度增加时,Halbach永磁阵列更有利于电磁转矩增加。     

Design and control system of inverter-driven permanent magnetsynchronous motors for high torque operation

This work describes a current vector control method for permanent magnet (PM) synchronous motors suitable for high-torque operation. The current phase angle is controlled according to load conditions in order to use the reluctance torque effectively. Characteristics such as torque, efficiency, power capability and so on are greatly improved by this control method in comparison with the conventional control method. The performance characteristics are greatly affected by the motor parameters, which depend on the rotor configurations and permanent magnet geometries. The available maximum torque and power capability are also examined for the several types of PM motor, taking into consideration the inverter capacity. The tendency toward magnetic saturation and demagnetization of the permanent magnet is also examined     

Design of Unskewed Interior Permanent Magnet Traction Motor with Asymmetric Flux Barriers and Shifted Magnets for Electric Vehicles

Abstract

Interior permanent magnet synchronous motors (IPMSMs) are commonly used in electric and hybrid electric vehicles. Nissan Leaf electric vehicle (EV) uses skewed-rotor IPMSM as a traction motor. This motor is considered as a benchmark in this work. Although, skewing improves the torque quality of the motor by reducing the torque ripple, it reduces the average torque and increases the motor manufacturing complexity and cost. This article proposes improvements to the benchmark motor torque quality without skewing. The proposed motor uses the same stator winding and rotor magnet topologies of the benchmark motor with the same geometric constraints and magnet volume. Modifications are applied to the placement of the magnets in the rotor and the shape of the flux barriers to achieve the performance requirements. The design procedure of the proposed unskewed design is illustrated. Moreover, the electromagnetic performance of the proposed design is investigated. The design shows competitive performance in terms of the average torque, torque ripple, cogging torque, and efficiency compared to the benchmark motor. The mechanical integrity of the design is also verified. The proposed design is found to be a suitable alternative to the benchmark traction motor with a reduced rotor weight and without skewing.     

Investigation on a choice of stator slot skew angle in brushless PM machines

The paper investigates the effects of stator slot skewing in a permanent magnet brushless DC motor. A simple analytic formula for calculation of the best angle of stack skew, which leads to nearly total reduction of the cogging torque, is developed. The skew angle obtained from this formula is different to that used by the designers of PM brushless motors. The analysis is carried out for a fractional horsepower brushless permanent magnet motor with the surface-mounted magnets using a time-stepping, multi mesh-slice finite element model, to assess the impact of this change. The steady-state characteristics and core losses are analyzed quantitatively using the elaborated numerical model. It is shown that smaller skew angles obtained from the formula lead to noticeable rise in motor overall efficiency and decrease of the core loss. The possibility of accomplishment of the desired effect of skew in a real machine is also a subject of discussion.     

A NEW DOUBLY SALIENT PERMANENT MAGNET MOTOR FOR ADJUSTABLE SPEED DRIVES

ABSTRACT

A new type of doubly salient motor is presented in this paper in which the field excitation is provided by permanent magnets. This doubly salient Permanent Magnet (DSPM) motor is shown to be kindred to square waveform permanet magnet brushless dc (PM-BLDC) motors in principle. However, they are different from the latter in that they are capable of a considerable constant power range when properly designed. Finite Element Analysis and Transient Simulation studies are utilized to investigate the characteristics of this new type of PM motor. A prototype DSPM motor is designed and comparison is made between this new type of motor and other types of motor on the basis of performance of the entire drive. By fully exploiting the merits of modern high energy PM material and the doubly salient structure, the DSPM motor can offer higher performance expectation over many existing motors in terms of efficiency, torque density, torque-to-current ratio, torque-to-inertia ratio etc. with a relatively simple structure which is amenable to automatic manufacture.     

A novel permanent magnet motor with doubly salient structure

A new type of doubly salient machine is presented in which the field excitation is provided by nonrotating permanent magnets. This doubly salient permanent magnet (DSPM) motor is shown to be kindred to square waveform permanent magnet brushless DC motors. Linear and nonlinear analyses are made to investigate the characteristics of this new type of PM motor. A prototype DSPM motor is designed and comparisons made between this new type of motor and the induction motor. It is shown that by fully exploiting modern high energy PM material and the doubly salient structure, the DSPM motor can offer superior performance over existing motors in terms of efficiency, torque density, torque-to-current ratio, torque-to-inertia ratio etc., while retaining a simple structure amenable to automated manufacture     

Permanent Magnet DC Motors Design Criteria and Operation Advantages

Permanent magnet dc motors have found many successful applications in industry. In particular, the machine tool industry utilizes the major share of all the permanent magnet motors produced. These motors typically exhibit greater stability of operation, linearity, higher maximum speeds, straightforward design, and higher efficiency. The applications to which these motors are addressed, however, impose fairly sophisticated design choices to maintain high performance along with optimization of unit design. In trying to optimize motor design without loss of performance, the selection of magnet material has the greatest impact upon eventual motor performance, size, and cost. The criteria for selection of permanent magnet material are reviewed, and the major advantages to using this type of motor in comparison with a wound field dc motor are specified.     

永磁球形多自由度电机研究进展综述

简述了永磁球形多自由度电机的优越性能,首次提出了永磁球形多自由度电机的分类,重点介绍了国内外的永磁球形多自由度电机最新研究进展和研究中遇到的问题,并探讨了永磁球形多自由度电机的发展前景和趋势。最后在三维有限元软件环境中对一种永磁球形三自由度电机的转矩特性进行了仿真计算,给出了仿真结果,对电机转矩特性进行了分析和讨论。     

无轴承永磁同步电机的转子磁场定向控制研究

无轴承永磁同步电机由于功率密度大、转矩脉动低等优良特性受到了高度重视。文中针对一类表面贴装式无轴承永磁同步电机，详细推导出径向悬浮力表达式，建立了准确的数学模型。针对电磁转矩和径向悬浮力之间耦合的特点，采用了基于转子磁场定向的控制策略来实现这类无轴承永磁同步电机的非线性解耦控制。实验证明了该控制算法的有效性。该控制算法对插入式转子结构和内装式转子结构的无轴承永磁同步电机的控制系统设计具有一定的借鉴作用。     

Design aspects and performance of a slotless PM motor for hard diskdrives

Slotted motors are presently used in all hard disk drives (HDDs). However, the advantages of a slotless spindle providing low static cogging torque and negligible torque ripples would be required to meet the demands of the HDD industry, as indicated by the trends in increased capacity and smaller formats. The location of the windings in the airgap of a slotless machine resulting in an extended airgap produces lower inductance values, which will provide the drive with better dynamics. These features are discussed in this article. Aspects of the design and construction of a slotless permanent magnet (PM) motor are described and, where appropriate, comparisons are made with a slotted motor. Both motors are intended for use in a 3.5-inch, half-height HDD. The design of the slotless motor meets all the specifications for application in the HDD. The test and performance of the motor show that the slotless motor is superior in performance in comparison with the slotted motor