DESIGN CRITERIA OF HIGH PERFORMANCE SYNCHRONOUS RELUCTANCE MOTORS

A . V a g a t i , (member),
G.Franceschini,
I. Marongiu,
G. P. T r o g l i a ,

Tech. U n i v e r s i t y o f T o r i n o
U n i v e r s i t y of Parma
University of C a g l i a r i
I s o f l u x Servomotors, A s t i

(Italy)
(Italy)
(Italy)
(Italy)

usual f o r high performances machines. If possible, r o t o r

skewing is preferred, not t o compromise automatic winding
facilities.

Abstract- A general design approach i s presented, f o r

synchronous reluctance servomotors.
The choice of
the rotor's
s t r u c t u r e i s extensively
discussed and t h e most suitable solution i s analyzed in
detail.
Optimization
algorithms
are
given,
regarding
minimization of t h e q-axis f l u x and maximization of torque,
at given outside diameter and power dissipation capability.
Expected r e s u l t s are discussed and compared with t h e
state-of-the-art.

3. CHOICE OF ROTOR STRUCTURE

Generally speaking, t h e main design goal i s t o obtain both
high "Ld" and low "Lq" values: at t h i s aim t h e direct-axis
flux must flow into t h e whole r o t o r ' s surface while t h e
quadrature-axis f l u x wouldn't flow at all. The l a t t e r goal
is clearly impossible t o obtain, while t h e former one leads
t o drop-out a simple "salient pole" s t r u c t u r e like in Fig.
2,a).
A s regards t h e q-axis f l u x rejection, i t i s mandatory t h a t
different magnetic potentials are allowed f o r t h e r o t o r
iron: a s a consequence, t h e r o t o r must be magnetically
divided among many "segments". W e will only consider
r o t o r ' s s t r u c t u r e s whose number of segments per pole pair
i s odd, because of s h a f t embedding facilities. In Fig. 2,b)
and c), one and two insulating layers per pole s t r u c t u r e s
a r e shown, respectively. If t h e number of such layers i s
greatly increased, a distributed anisotropy s t r u c t u r e i s
obtained, a s in Fig. 2.d).

1.INTRODUCTION
Although t h e synchronous reluctance concept i s very old
111, a renewed interest i s grown in recent years on t h i s
machine [3-141, with reference t o electronically controlled
drives.
I t has been shown [6,11,141 t h a t a larger torque-per-volume
t h a n f r o m induction motor i s obtainable, provided t h a t t h e
synchronous reluctance machine i s properly designed.
In t h e field of high performance a.c. drives (machine-tool,
robotics etc.
P.M. synchronous (surface mounted) and
induction motors are commonly adopted. The synchronous
reluctance motor should provide a low cost alternative t o
P.M. solution, while maintaining t h e i.m. f l u x weakening
f e a t u r e . A t t h i s aim t h e synchronous reluctance motor's
torque-per-volume has t o be maximized.
In t h i s paper t h e main problems related t o t h e design of
such a machine are considered, with particular attention t o
servomotor applications.
2. STATOR STRUCTURE
Being t h e s t a t o r ' s
purpose t o produce a sinusoidally
distributed m.m.f. wave, i t s s t r u c t u r e i s practically t h e
same as f o r a n induction motor. A little difference can be
found in an increased c a r e t o avoid belt harmonics, because
in t h e synch. rel. motor t h e r o t o r dumping action on these
harmonics i s absent.
Neglecting s l o t effect,
t h e "ideal" phase conductor's
distribution would be t h e one reported in Fig.1: only f i r s t
and "triplen" harmonics are present and t h e m.m.f. increase
with respect t o a purely sinusoidal distribution i s 2 / h .
W e will r e f e r t o t h i s distribution in t h e followings.

C)

d)

Fig. 2. Shematic of r o t o r s t r u c t u r e s (two poles).

Let us observe t h a t t h e so called "axially laminated"
s t r u c t u r e [2-31 may be d i f f e r e n t f r o m t h e distributed
anisotropy
one
[5,10,131,
because
of
the
different
distribution of t h e non-magnetic material.

3.1. Slotless s t a t o r segmented r o t o r analysis.

\sI',

- -n

- -n

Let us r e f e r t o a slotless s t a t o r and generalized segmented

rotor machine. Because of our hypotheses, the t o t a l m.m.f.
applied t o t h e r o t o r is, in t h i s case, exactly sinusoidal.
Magnetic s a t u r a t i o n i s disregarded.
Let us r e f e r t o q-axis
m.m.f.
only be appla.rl. t h e
situation i s reported in Fig.3, f o r a two pole machine.
Let us r e f e r t o t h e k-th segment: t h e mean p.u. value of
the applied m.m.f. i s indicated by fk, while the r o t o r p.u.
reaction potential i s r k . The "rotor slots" opening has
been disregarded f o r simplicity. Two f l u x components can be
identified: t h e "flowing through" component which e n t e r s

',

n
6

z
.
2

Fig.1. Ideal conductor distribution of one phase.

A s regards
reduced by

s l o t s harmonics, they a r e normally strongly

skewing or other equivalent solutions, a s i s

@7803&34-1/92$03.00

QIEEE

66

ak

ak+l

Fig. 3. k-th segment and related p.u. distributions.

a)
the segment and the circulating component across t h e air
g a p (shaded a r e a l .
On t h e other hand, when a d-axis m.m.f. i s applied t o t h e
rotor, no r o t o r reaction i s present and a sinusoidal
induction distribution i s produced.
By reference t o inductances, Eqs.(l)-(4) a r e valid, f o r a
general 2p-pole machine: a i s a n electrical angle.

Fig. 4. Low r o t o r iron losses structures.

work is reported here, as Eq.(7). These additional losses
are enhanced in the r o t o r by t h e s t a t o r toothing: Eq.(7)
gives t h e r o t o r t o s t a t o r iron losses ratio. This r a t i o
depends on t h e r a t i o of r o t o r t o s t a t o r iron volumes, t h e
slot-per-pole-phase
number q and the permeance oscillation
t e r m 11/10 due t o teeth (F(q)e .5). Let us observe t h a t
skewing doesnt reduce these losses, in practice 161.
The so calculated losses and t h e measured ones were in a
reasonably good agreement.

TI

Ldm=

c o n s t . .J

c o s 2 a doc = const:n

(1)

sina [sina-f(a)lda

(2)

.J s i n a [ f ( a ) - r ( a ) l d a

(3)

-n
n
Lqc= const. .J
-TI

- = - :[

TI

Lqf= const.

-TI

Lqrn= Lqc+

Lqf

b)

(4)

Pr

Vi-

Ps

vs

F ( q ) q2(

z 12]

(7)

3.3. The chosen structure.

Being f ( a ) and r ( a ) staircase functions, i t i s easy t o

obtain [SI Eqs. (5) and (6): the sums a r e performed on half
a pole.

A practical solution which greatly reduces t h e r o t o r

iron
losses consists in using a segmented rotor structure, whose
segments a r e properly related t o t h e s t a t o r toothing as
illustrated in Fig. 4.
Both t h e shown s t r u c t u r e s have been experimented in
practice [61. In t h e followings,we will r e f e r t o t h e b)
s t r u c t u r e only, f o r simplicity. In other words, we will
consider segmented r o t o r structures f o r which the rotors
slot pitch is equal t o (or multiple o f ) the s t a t o r s one. A
simple example i s shown in Fig. 5, where t h e equivalent
circuit i s also reported, whose solution gives the ri and
r2 rotors magnetic potentials t o be used in (6).
Aas i s t h e (electrical) angle related t o one s t a t o r tooth
pitch,
g i s the airgap length, kc the Carter coefficient.
Sk, Ik a r e the equivalent width and depth of t h e k-th
layer.

(5)

(6)
Eq. ( 5 ) i s valid provided t h a t t h e a i r gap can be
considered a s a constant on the whole periphery: if not,
another relationship should be derived.
Let u s observe t h e r a t i o ( 5 ) depend only on number and
width of t h e r o t o r segments: if this number i s greatly
increased this r a t i o tends t o zero. In other words, t h e
r a t i o (5) is null in the case of a distributed anisotropy
r o t o r (Fig. 2,d). Anyway, i t is shown in [SI t h a t a
two-layer-per-pole
structure like the one in Fig.5 exhibits
a r a t i o equal t o ,027 only.
A s concerns t h e r a t i o (6). a direct calculation i s not
possible, because the r k p.u. potentials have t o be f i r s t l y
determined [SI.
Anyway, t h i s r a t i o is poorly affected by the segment number
and mainly depends on t h e total amount of insulating
material embedded into the rotor.
From the above considerations i t should be concluded t h a t
t h e best solution i s t h e distributed anisotropy rotor, once
i t s mechanical problems a r e solved.

u v

Fig. 5. Example of per-unit equivalent circuit.

3.2. Slotted s t a t o r , distributed anisotropy rotor.

3.4. Simplified analvsis.

The above conclusion is different i f a practical slotted

s t r u c t u r e is considered, together with a d.a. rotor.
Large iron losses have been found in this case by
experiment l6,91. Furthermore, a simplified mathematical
model of these losses has been presented recently [131,
valid for a two-pole machine. The final equation of t h a t

Coming back t o Eq.(6), this can be modified in order t o

give an approximated solution which doesnt need t o solve
f o r a n equivalent circuit. In practice,the p.u. r o t o r
magnetic potential r k doesnt differ very much f r o m t h e
applied p.u. m.m.f. fk. This is t r u e no matter the pole
number is.
number i s o r the stators slot-per-pole-phase

67

This consideration will be used t o simplify (6) By

introducing t h e "flux" (pk as in Eq.(8) (see also Fig.51,
Eq.(6) can be w r i t t e n as in (9).
(pk

= (fk- r k ) - A d Acts

(8)

Eq.19) can be modified by introducing t h e increment

Afkzfk-fk-1 and t h e internal fluxes (pw-i between adjacent
segments, which are proportional t o Afk, if t h e airgap drop
i s disregarded. After some passages, Eq. (10) is found,
where s k / l k i s t h e p.u. permeance of t h e k-th layer and r
i s t h e r o t o r ' s radius.

Fig.6. Realistic shape of a n optimized f o u r pole (p=2) two

slots-per-pole-phasemachine(q=2).
(10)

A s r e g a r d s t h e layer's shape, i t i s also possible t o find

a n approximated optimization procedure. Once t h e r o t o r
radius "1"' and t h e s h a f t radius "a" are given, t h e t o t a l
allowed non magnetic length along t h e q-axis (r-a) h a s t o
be split into magnetic (lyr) and non magnetic (la) lengths.
lyr depends on t h e d-axis
flux: if t h i s i s given, la also
i s given and t h e constraint (11) holds.
in order t o
I t i s then possible t o calculate Ik(sk),
minimize Eq.(lO). By substituting t h e constraint (11) into
(10) and equating t o zero i t s p a r t i a l derivatives with
respect t o lk(k=1,2, ...,n-1). t h e system (12) i s obtained,
whose solution i s straightforward.

(11)

a(-)

Sn

Sk

Ldm

A f t + -

-a--

AfE=O

(12)

Ik

Being k a n d j two generic segments, t h e condition f o r

minimum reduces t o (13). By substitution of (13) into (101,
Eq. (14) i s found a f t e r some passages.

Ik

Afk
(13)

Eq. (13) states t h a t t h e depth of a layer i s proportional

t o t h e square root of i t s (equivalent) width and t o t h e
applied m.m.f .. Being both quantities decreasing, going
f r o m d t o q axis, t h e insulating material amount also must
rapidly decrease. Of course, t h e practical application of
(13) s t i l l requires some "trial and error" procedure, being
s k a n "equivalent"
width, because of t h e not constant
layer's depth.
A s example, f o r a four-pole,
two slot-per-pole-phase
machine, such a procedure leads t o t h e shape qualitatively
shown in Fig. 6.
The corresponding (X-1' value in (14) i s about 0.6: I t
leads t h a t a Lqf/Ldm value of 0.04 i s obtainable, with an
a i r g a p value which is normal f o r induction motors. On t h e

o t h e r hand, (14) clearly states t h e importance of t h e

parameter la, which in t u r n depends on r and lyr. A s a
consequence, t h e r o t o r cannot be optimized by itself, but
s t a t o r and r o t o r laminations have t o be optimized as a
whole. This will be done in t h e followings.
A t l a s t , l e t u s observe t h a t Eq. (14) would give infinity,
in t h e limit case of a solid (isotropic) rotor. This i s
clearly due t o t h e previously made approximation of
disregarding t h e m.m.f. drop on the airgap. The e r r o r i s
very poor,
f o r a practical case, but a reasonable
correction i s t o modify (14) as in (151, which gives 1 f o r
t h e solid rotor.

Coming back t o t h e circulating flux,let us remember t h a t

Eq.5 h a s been derived f o r a slotless s t a t o r structure. If
s t a t o r ' s s l o t s are considered, as in t h i s case, t h e m.m.f.
applied by the s t a t o r becomes a near-to-staircase function
too. In addition, i t s shape i s continuously changing, with
respect t o d,q axes, as t h e motor rotates.
Being s t a t o r and r o t o r pitches equal, t h e two extreme
situations a r e easily found, as depicted in Fig.7. In t h e
situation a) s t a t o r and r o t o r teeth are in phase: t h e
circulating f l u x nearly vanishes and flowing-through f l u x
only i s present, whose amount i s calculated through (15)
On t h e contrary, when situation b) occurs, t h e t e e t h are in
q u a d r a t u r e and a circulating f l u x larger than in t h e
slotless case a r i s e s (shaded area).
By comparison of Figs.3 and 7, b) i t can be seen by
inspection t h a t t h e maximum circulating f l u x i s nearly
twice t h a n t h a t in t h e slotless case. On t h e other hand,
when
considering
a
real
(skewed)
machine,
these
i t seems t o be a
oscillations are averaged. Thus,
reasonable approximation t o extend t h e Eq.(5) validity t o

a)

b)

Fig. 7. q-axis f l u x oscillation in t h e slotted case.

t h e slotted case, in order t o calculate t h e "average"

e f f e c t of t h e circulating f l u x component in increasing t h e
q-axis inductance. Being the layer number related t o the
s t a t o r slots-per-pole-phase q , Eq. (51, now, depends on q.

linear function of id. In presence of saturation cross

interaction between d and q axes occurs and a demagnetizing
e f f e c t a r i s e s at high current values. A t t h e present aim,
this
interaction
will
be disregarded.
This
can
be
acceptable in r a t e d conditions, because every c a r e h a s been
taken in reducing t h e q-axis
inductance, but during
overload the e f f e c t would not be negligible. Anyway, owing
t o t h i s hypothesis, the simple relationship (22) can be
written. We've indicated as ks a n additional coefficient,
which i s used t o account f o r iron drops, as discussed
later.

4. OVERALL DESIGN
Let u s consider as main goal the maximization of the
available torque, once t h e power dissipation capability i s
given. Moreover, l e t u s r e f e r t o stall torque, as i t i s
usual f o r servomotors: as a consequence, iron loss will be
neglected, in t h i s optimization procedure.
Our aim i s t o approximately define s t a t o r and r o t o r
lamination shapes. Once t h e s t a t o r radius R i s given, t h e
r o t o r ' s radius r and t h e "design" induction value at t h e
airgap a r e t h e main degrees of freedom.

(22)

4.1. Torque calculation and related hvpotheses.

b = Bd/Bfe

x = r/R

(23)

The torque can be written as in (16). The kdq parameter

(17) comes f r o m t h e previous analysis (5),(15). Stator
s t r a y inductance i s not considered here, because i t doesn't
a f f e c t t h e torque: of course, a practical design must deal
with t h i s subject too.

As -'2 2

(16)

nRz
(17)

(18)

As
-=-

The torque current iq depends on the total allowed current

io and t h e required magnetizing current id. Joule losses
only being considered, t h e io current i s easily written as
in (20). "AS" represents t h e whole slot a r e a , kcu t h e
the winding overlength
copper filling coefficient, I'/l
coefficient and p t h e copper resistivity. The parameter kj
represents the allowed power dissipation W r e f e r r e d t o the
external active surface (21). The square root of the slot
area "As" divided by nRz can be considered a s a p.u.
current.

nR2

bz

(24)

"[

It

2 b x (kt + l/p)

2---

(25)

A s r e g a r d s the kdq coefficient

(5)a r e used t o obtain Eq. (26).

in (241, Eqs. (17),(15) and

Lqc/Ldm (depending on q only) i s clearly an input, as

g.kc/R is. The squared sum in (26) doesn't depend on b o r
x , but depends on p, a t a given la/R. I t can be shown t h a t
t h e p.X2 t e r m slightly increases as p i s increased.
The squared sum i s practically independent of q.
Both It/R in ( 2 5 ) and la/R in (26) a r e functions of b and
x , because of the geometrical constraints on s t a t o r (27)
and r o t o r (28).

(20)

(Bre/po) z kc k s g
kj

From (18),
(191, ( 2 0 ) and (22) Eq.
(16) i s easily
transformed into (24). The t w o "degrees of freedom" a r e t h e
p.u. induction b and the p.u. radius x (23).Let us observe
t h e subtractive t e r m in (24) has a meaning of "magnetizing
area": t h i s gives
t h e "loss of slot area" due t o
magnetizing.
Before performing t h e optimization i t i s s t i l l necessary t o
define AS and kdq as functions of b and x. A s concerns AS,
w e can proceed as follows. The induction wave in t h e
"yokes" can be considered t o be nearly sinusoidal because
harmonics a r e dumped out by t h e integrating effect. The
maximum value of t h a t wave is chosen as reference induction
value Bfe.
On t h e other hand, being t h e teeth normally overloaded in
t h e design, a "reduction coefficient" of t h e teeth width kt
i s introduced. Eq. (25) i s so found, where I t i s the tooth
length: constant width teeth have been supposed.

The d-axis f l u x linkage Ad i s easily written as (181, in

t e r m s of t h e d-axis peak value Bd of the f i r s t harmonic
a i r g a p induction wave. Harmonics enhanced by saturation
have no e f f e c t on Ad, because of the Fig.1 winding
distribution. The pole span i s assumed n wide, N i s t h e
turns-per-phase
number. Evidence has been given t o p.u.
airgap induction Bd/Bfe and p.u. rotor radius r/R; Bfe i s
t h e base induction value, (Bo/Bfe).(r/R) is a p.u. flux.

kj=

' 2

nz R KCU 1

(21)

2nR1
The relationship between id and Bd i s the more critical.
Disregarding magnetic saturation, Bd would be simply a

It

69

+ lys = R

- r

(27)

la

+ lyr = r - a

are: K, R, a / R and kc.g/R, where K i s given by (32). This

t e r m regards the heat production and dissipation way. For a
fixed external diameter, if the active length 1 i s
increased kj decreases, because the r a t i o of total motor
length on active length normally decreases. However, the
r a t i o l'/l decreases too, in this case: as a consequence
kj*I/l' doesn't
vary so much. On the other hand, a
t e m p e r a t u r e rise increases both kJ and p in a different
way. A s example, the r a t i o ki/p increases of 20% as the
overtemperature goes f r o m 100K t o 130'K. Once the maximum
working t e m p e r a t u r e has been chosen, the p a r a m e t e r K (32)
c a n represent a good measure of the thermic properties of a
s e r i e s of
motors.
With reference t o a n industrial
servomotor series (brushless), i t s value
can be estimated
about 1.7-105, f o r kcu=0.34.

(28)

I t i s possible to impose lys=lyr. This is clearly t r u e in

linear conditions. If some saturation occurs, the r o t o r
should be perhaps more affected, because the flux flows
into many segments in parallel. However, at the present
aim, equal widths seem t o be a reasonable approximation.
Being t h e induction in the yoke considered as sinusoidal,
Eq. (29) is valid, and (301, (31) are easily written.

ly
R

b x
=P

(29)

(30)

K = /kcu

kJ -!

(32)
1'
The torque (24) dependence on the radius R [ml shows the
well known effect of motor's dimensions on magnetizing
requirements. W e will chose 2R=0.115 [ml, which represents
a medium size servomotor series ( 5+15 Nm, with reference
t o brushless motors).
The p.u. s h a f t diameter a/R i s normally chosen in order t o
a
reasonable
range
is
avoid
resonance
frequencies:
0.2iO.25, depending on the maximum speed. The p.u. airgap
kc*g/R depends on mechanical tolerances and slot opening: a
practical range could be 0.007+0.01.
A s regards t h e pole pair, i t s effect on the magnetizing
c u r r e n t i s clearly shown in (24). Its effect on kdq i s more
involved, as seen,because p also is present in the '2 t e r m
(26). Taking into account the non-constant
layer depth
(Figi6) by suitable increase of the physical sk values, a
p.X t e r m going f r o m 1.2 t o 1.5 can be roughly estimated,
if p i s increased f r o m 2 t o 3.
A s seen, t h e p a r a m e t e r Lqc/Ldm depends on the number of
insulating layers per pole, which in t u r n depends on the
slot-per-pole-phase
number q. When the airgap i s not
constant in the q-axis direction, as in Fig.6, Eq.5 should
be slightly modified because of some reduction in the flux
circulating across the q-axis. However, t h i s effect is very
poor and can be neglected.
(q=2) of Fig.6 gives
By (51, t h e t h r e e layer structure
lqc/Ldm= 0.023, while a corresponding four layers s t r u c t u r e
(q=3) would give lqc/Ldrn=O.Ol. Of course, the effect on
reactance is
torque i s poor, but the overall q-axis
decreased.

(31)

4.2. Choice of input uarameters.

Eqs. (241, (251, (26) and (31) clearly define a torque
which i s a function of the t w o variables b and x, in
addition t o a set of "input parameters".
Let u s consider, at f i r s t , the choice of the reference
induction Bfe. If ks=kt=l are posed, m.m.f. drops in the
iron are disregarded. Consequently, the previous equations
should define a machine f o r which the whole iron works at
at maximum value of B f d . 9 5 T (if the "iron filling
coefficient" i s .95, as example). The calculated torque in
t h i s case can be "reasonable" or not, depending on the
chosen Bfe value, and the related (disregarded) iron drops.
This "linear procedure" cannot give a final design, but can
be used all t h e same t o analyze in an easier way the torque
sensitivity t o other design parameters, mainly t o x and b.
On t h e other hand, if m.m.f. drops in the iron are t o be
considered, the procedure can be as follows.
For a given geometry (b,x) and given Bfe and kt, t h e
magnetic problem i s defined and additional m.m.f. drops can
be calculated, f o r example as proposed by Alger 1151. Yoke
and r o t o r drops depend practically on Bfe, while teeth drop
depends on kt too. This way, a k. 0 1 ) value i s found, in
order t o still have the same airgap induction Bd as in t h e
linear case. Of course, if torque optimization i s wonted, a
"trial and error" procedure i s necessary and the problem
must be solved by numerical methods.
As regards T(x,b) optimization, once the pole pair and the
r o t o r ' s shape are fixed, the parameters influencing optimum
~

4.3. Maximum toraue design.

Let us show some numerical examples of the previously
discussed procedure. We've chosen as reference case a
medium size servomotor, whose parameters a r e listed in t h e

~~

gkc/R

a/R

1.66.105

,0575

.008

.2

.503

2,35.105
.0725
.012

.25
3
3

T(Nm)

ly/R

lt/R

la/R

,503

7.483

.1265

.3705

. 1765

,500 . 5 8 6

11.794

. 1465 .3535 .1535

.501

,534

13.927

.1338

.3652

. 1672

.524

.402

6.220

.lo53

.3707

.2187

.525

.482

7.278

. 1265 . 3 4 8 5

. 1485

,502

.504

7.591

,1265

.3715

.1755

,532

.426

6.922

,0755

.3925

.2565
__

TBL.l. Optimum t o r q u e d e s i g n a n d p a r a m e t e r s e n s i t i v i t y (1=.12 m ) .

70

f i r s t r o w of TBL.1.
The reference induction Bre has been chosen equal t o 1.4 T.
Although not strictly necessary, reference has been made t o
a n axial active length 1=0.12 m. This t o give more physical
insight into t h e results.
In t h e second row a double power dissipation capability has
been introduced. Although forced cooling is not used in
servomotors, i t s effect on T and b values can be pointed
out. The third row r e f e r s t o a larger outer diameter: t h e b
value i s increased, because of the "stronger" m.m.f. Fourth
row shows t h e inverse sensitivity t o a 50% increase in t h e
equivalent airgap. The torque and b reduction due t o s h a f t
increase a r e shown in f i f t h row. A q increase t o 3 produces
a 1.5% torque increase, mainly due t o lower Lqc. In the
case of a s i x poles machine, larger x and lower b a r e
shown, f o r maximum torque: but t h e torque is lower than in
t h e f o u r pole case.
A general consideration about t h e shown results regards the
quite low "optimal" p.u. rotor diameter, always near t o
0.5. The situation i s similar t o the case of a brushless
motor, and quite different from the case of an induction
motor: optimal p.u.rotor diameters of 0.6 o r more a r e
common in t h i s case.
In t h e synchronous reluctance motor, in f a c t , t h e x value
comes f r o m a trade-off between low Lqc values (high x ) and
large slot a r e a (low x): t h e l a t t e r requirements a c t s here
in a stronger way. In other words, the "optimal" motor
should have not so high Ldrn/Lqrn r a t i o but a lot of copper
in the s t a t o r . Unfortunately, this leads t o high q-axis
reactance. For the reference case in TBL.l, t h e Lqrn/Ldrn
value i s 0.09. The s t a t o r slot reactance can be estimated,
in t h i s case t o give a n additional contribute of 0.03. By
adding t h e end connection contribute, a not so low value is
reached: this can be double than in t h e case of a
correspondent induction motor.

lower than optimum, t o reduce t h e

consequently iron losses at high speed.
b(x=.503)

iron

and

T/TO

.423

.96

,463

.99

.503

,543

.99

.583

.97

TBL.3. Torque sensitivity t o detuning of b (given

volume

XI.

3i0

T/To

,503

,503

.52

.493

,998

.54

,417

,990

.56

,463

.919

.58

,447

,963

.60

,431

,943

.62

,415

,919

Fig.8. Rated and overload vector diagrams.

A t last, l e t us consider t h e overload condition.
For a servomotor a current overload of t h r e e times i s
considered t o be usual. In this case, a strong q-axis
reaction arises and a more detailed analysis should be
done. Anyway, a trade-off does exist between the r a t e d
torque and the loss in t h e torque coefficient at high
c u r r e n t values. This i s out of the aim of the present
paper.
Let u s observe here t h a t a machine designed t o give maximum
r a t e d torque h a s a power factor which is lower than t h e
maximum one (at a given current vector). During overload
operation, if t h e q-component only of the current vector i s
increased, t h e power f a c t o r firstly increases towards i t s
maximum, before decreasing.
The situation should be t h e one reported in Fig. 8.
The r a t e d current vector r e f e r s t o TBL.1 ( f i r s t row1
design: s t a t o r s t r a y inductances a r e not considered. If y
is t h e angle between current and flux vectors, sin7 varies
f r o m 0.773 ( r a t e d ) t o 0.784 (overload 3). The maximum of
s h y is, in this case, near t o 0.83. corresponding t o an
overload f a c t o r of about 1.7. I t can be then concluded t h a t
the siny and t h e related power f a c t o r maintain reasonable
values f o r t h e usual overload range.
If a different driving strategy is used, e.g. increasing
both i g and id t o counteract the reaction effect, higher
torque but lower power f a c t o r would be obtained.

TBL.2. Torque sensitivity t o detuning of x.

For a practical design, i t is then interesting t o evaluate
t h e sensitivity of the torque t o an increasing of the x
value beyond the optimal one.This should allow a trade-off
between a torque loss and a decreasing in q-axis reactance.
With reference t o TBL.l f i r s t row parameters, some points
of t h e T ( x ) function a r e reported in TBL.2. The imposed b
value is the maximum torque one, f o r each given x.
A s can be seen, f o r x values which a r e common f o r induction
motors (0.6) the torque loss is about 5%. The q-axis
reactance should be s t i l l superior than t h e
induction
motor one, because the magnetizing term Lqrn/Ldrn, although
decreased, is s t i l l superior t o the corresponding induction
motor term: t h e total reactance should be slightly less
t h a n 1.5 the induction motor one, in this case.
I t i s also useful t o evaluate t h e torque sensitivity t o
detuning of b, at a given x. The results a r e reported in
TBL.3: b i s moved across the optimum f o r t h e x value of
0.503.
Let us observe t h e sensitivity be poor, f o r a quite large b
interval. This suggests t o design at b values somewhat
71

a f u r t h e r decrease in t h e optimal x .
Disregarding t h i s e f f e c t , we have introduced 0.5 mm r i b s in
t h e TBL.l, f i r s t row "reference" case, by assuming Bs= 2 T.
The obtained torque i s about 6.9 Nm, showing a torque loss
of 8%. The same has been done f o r t h e TBL.1, s i x poles
example, giving a loss of 177. because of (351.
Even in t h e f o u r pole case, t h e torque loss i s not
negligible, and any e f f o r t has t o be made in reducing t h e
rib's width t o i t s mechanical minimum. On t h e other hand,
serious practical problems may be found in cutting very
thin ribs.
A t last, with reference t o overload condition, l e t u s
observe t h e rib's f l u x cannot increase because of t h e iron
saturation. A s a consequence, t h e % torque loss i s lower,
in t h i s case.
Fig. 9. Rib's profile.
6. CONCLUSIONS

The main problems related t o the design of a synchronous

reluctance servomotor have been examined. The most suitable
r o t o r s t r u c t u r e has been identified, among d i f f e r e n t
alternatives. A simplified but general algorithm has been
found, t o calculate t h e "internal" optimized anisotropy
ratio.
A "maximum torque" design has been illustrated in t h e
design have
general case: practical involvements of t h i s
been pointed out and discussed.
The conclusion i s t h a t a synchronous reluctance servomotor
can be designed and produced, at a cost which isn't higher
t h a n t h a t of a correspondent induction motor.
The obtained torque, superior t o t h e induction motor one
a
[6,11,141, i s
still
slightly
lower
than
that
of
correspondent rare-earth
brushless motor. The reference
case of TBL.l (plus .5 mm ribs) should give about 7 Nm: in
t h e same volume, a commercial SmCo motor gives about 9 Nm.
However, t h e synchronous reluctance servomotor should
easily be flux-weakened, allowing f u r t h e r savings in iron
losses at high speed and in t h e kVA requirements.

5. MECHANICAL PROBLEMS

A t last, let us consider t h e problems related t o t h e

r o t o r ' s mechanical ruggedness.
Of course, t h e Fig.6 s t r u c t u r e i s not self-sustaining. The
e a s i e r way t o built such a r o t o r in an industrial
environment i s t o punch r o t o r laminations as a whole,
leaving thin r i b s between adjacent segments. Of course,
these r i b s will increase t h e q-axis f l u x and consequently
lower t h e torque performance.
Another way is t o proceed as before, then c a s t t h e r o t o r by
a plastic material and finally machine-out t h e ribs. This
way magnetic insulation i s preserved, but many non-magnetic
disks have t o be placed axially t o prevent deformation: as
a consequence, active length i s reduced.
Coming back t o t h e easier solution (ribs) i t i s possible t o
calculate approximately t h e torque loss due t o ribs, once
t h e i r width is defined.
With reference t o Fig.9, a s o f t profile i s chosen, mainly
f o r mechanical reasons. The magnetic analysis i s very
complicate because of non linearity, s t a t o r toothing, etc..
To verify a particular design, a f i n i t e element approach
should be adopted. However, at t h e aim of obtaining rough
r e s u l t s b u t of general validity, a simplified approach can
be adopted.
Provided t h a t sufficient q-axis m.m.f. i s applied, let us
suppose all r i b s be s a t u r a t e d a t t h e same (known) induction
value Bs and have t h e same width. A s a consequence, all
r i b s should conduct t h e same flux, given by (33). Two f l u x
paths in parallel per pole pair exist. Owing t o t h e Fig.1
"ideal winding", t h e additional contribute kr t o linked
f l u x i s reported in (34).

pwk = Bs w 1

hr =

w
fi
4

ACKNOWLEDGEMENT
This research h a s been partially supported by t h e Italian
Ministry of Scientific Research and National Research
Council.
The a u t h o r s a r e also grateful t o Isoflux Servomotors S.P.A.
f o r t h e technical support.
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(33)

1 N Bs

(34)

The torque loss due t o r i b ' s flux can be then evaluated as

in (351, f r o m (22).
Let us observe t h i s loss i s proportional t o p2: t h i s
strongly suggests not t o increase t h e pole number beyond
four.
Moreover,
being
this
loss dependent on t h e
magnetizing requirements, low magnetizing current designs
should be less affected.
AT =

3
2

p hr id =

4 (W

1 Bs) pz Bd (kc g ks)

(35)

cl0

Eq. (35) i s proportional t o t h e r i b s width w, of course:

t h i s depends on mechanical design, mainly on t h e maximum
allowed speed.
The optimization procedure previously described should also
depend on t h e rib's presence: larger r o t o r diameters need,
in f a c t , l a r g e r ribs, at a given speed. This should lead t o
72

l-

a n IPM machine suitable f o r field-weakened operation"

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13