Formulation and mixing conditions of magnetic composite materials used for magnetic wedges in an interior permanent magnet synchronous motor

An interior permanent magnet synchronous motor (IPMSM) is characterized by its high efficiency. However, torque ripple and loss occur because of the spatial harmonics generated by air-gap permeance fluctuations. This study clarified that slot harmonic components can be suppressed by inserting magnetic wedges made of magnetic composite material in the slot opening of an IPMSM. First, the authors examined the torque and loss characteristics by varying relative permeability and saturation magnetic flux density of magnetic wedges using finite element analysis (FEA). Results indicated that the torque ripple and loss could be suppressed when the relative permeability of the magnetic wedge was μ_r = 10 to 22 and the saturation magnetic flux density was B_s = 0.5 to 0.75 T. Furthermore, the authors produced magnetic composite materials made of various soft magnetic material powders and examined their magnetic properties and viscosities. Results showed that a magnetic composite material with optimal magnetic properties and injectable viscosity could be manufactured using Fe-Si-Al with a low volume fraction.