Permanent Magnet

Synchronous Motor (PMSM)

Design
Part 1 – General Considerations
 Permanent Magnet (PM) Motor

 Characterized by permanent
magnets on rotor
 Known for its simplicity and
low maintenance
 No copper loss on rotor
 High efficiency
 Exploded View of a PM Motor

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

2nd Edition, p. 44, Motor Design Books LLC, 2010.
 Inner Rotor Possibilities (1)

surface radial surface parallel breadloaf ring

magnet magnet magnet magnet
Inner Rotor Possibilities (2)

(e) IPM in Toyota Prius

 Toyota Prius Hybrid Electric Vehicle (HEV)
3

1. Four cylinder combustion engine; 2

2. Generator/starter; J. R. Hendershot and T. J. E. Miller,
3. Electric Motor; Design of Brushless Permanent Magnet
4. Power split device (PSD) Machines 2nd Edition, p. 34, Motor
J. F. Gieras, Permanent Magnet Motor Technology - Design Books LLC, 2010.
Design and Applications, 3rd Edition, p. 282, CRC
Press, 2010.
 Segmented Magnets in Large PM Rotor

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

2nd Edition, p. 94 & 602, Motor Design Books LLC, 2010.
Rotor Skew

stepped magnet
 Magnetization Profile
parallel magnetization radial magnetization

most popular

radial sine magnetization sine angle or sine direction

magnetization
 Halbach Array (1)

R. Krishnan, Permanent Magnet Synchronous and Brushless DC Motor Drives, p. 25-30,

CRC press, 2010.
 Halbach Array (2)

FEA
Halbach Array (3)
Airgap Flux Density

Rotor is outside
 Stator Volume and Size
2
Dl Pout
 V0 T
T m
Typically
V0  8 ~ 9 in / (ft  lb) for 10hp or less (air cooled)
3

V0  4 ~ 5 in / (ft  lb) for 10hp or more (water cooled)

3

The unit for D and L is inch.

If we design D=L, we have the stator bore (inner)
diameter estimated
1
Destimated  (TV0 ) 3

We can pick up D close to Destimated.

 Stator Core Design
 core   gap , per half pole pitch
 /P
 leff  Bg ( a )ris d a
0

D 2  /2
 leff  Bg , pk cos( ae )d ae
2 P 0
D
 leff Bg , pk
P
 core DB g , pk leff
Bcore , pk   (1)
d c k i li Pd c k i li


 tooth  l eff 0
B g ( ae ) ri d  ae  B g , pk  s l eff

 tooth  s B g , pk l eff
B tooth   (2)
t s k i li t s k i li

Take t s  0.5 s , Bcore , pk  0.8 Btooth

D
 dc 
1 .6 P
 Effect of Pole Number on Yoke Flux Density
Finite Element Analysis

with the same dc

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

2nd Edition, p. 106, Motor Design Books LLC, 2010.
 Number of Turns per Coil
V , rated  2 f e Nˆ a  g , pk  4 .44 f e Nˆ a  g , pk
2Bg , pk Dl
where  pk 
P
Nˆ a  kw Na / 1.1
kw  k p kd ks Na  PqNc / C
Na is the number of series turns per phase of armature winding
C is the number of parallel circuits of armature winding
Consider leakage flux
1 . 1V , rated C
Nc 
2 2 f e qk w B g , pk Dl
 Stator Slot Design
General Consideration
D
s 
S
ts ds0ds1 ds
bs0
0.4 s  ts  0.6 s
s
3ts  d s  7ts
Define bs   s  ts

bs 0  (0.1 ~ 0.5)bs
d s 0  (0.1 ~ 0.5)bs
d s1  (0.1 ~ 0.5)bs
 Stator Conductor Size

Stator current density

I a ,rated / C
J s ,copper 
Sa
where Sa is stator (armature) conductor cross section
area and can be determined from the above formula
together with:

Air - cooled : 400A/cm 2  J s ,copper  800 A/cm 2

I a ,rated / C
Sa 
J s ,copper
 Permanent Magnets

 Samarian Cobalt (SmCo)

 Operating temperature of up to 350ºC
 2nd strongest rare earth magnet

 Neodymium Iron Boron (NdFeB)

 Operating temperature of up to 150ºC
 Strongest rare earth magnet
 Permanent Magnet Properties

From Yeadon – Handbook of Small Electric Motors

 Rotor Peripheral Speed

The maximum allowable peripheral speed of the rotor is a central consideration in

machine design. With present-day steel alloys, rotor peripheral speeds of 50,000
ft/min (or about 250 m/s) represent the design limit.
1 ft/min = 0.0051 m/s
 Motor Losses (1)

 Copper loss
 Typical
PCu  I 2 R

 Stray losses
 Electrical phenomenon such as skin and proximity
effect
 Motor Losses (2)

 Core (Iron) Loss

 Hysteresis loss
 Eddy Current loss

PIron   h B f
n
  c ( Bf )   e ( Bf )
2 3/ 2

 Mechanical loss
 Windage loss
 Friction loss
 Finite Element Analysis

Fundamental harmonic

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

2nd Edition, p. 174-175, Motor Design Books LLC, 2010.
Part 2 – Surface Mount Round
Rotor Multi-Pole PM Motor
Design
 Magnetic Circuit Analysis
For a multi-pole surface mount rotor

dm
Da
g
D
Poles

2 H g g  2 H m d m  0  gBg  0 H m d m  0 Bm Am  Bg Ag

dm Bm Am
 
g 0 H m Ag
 Working Point for Permanent Magnetics (1)

Maximum Energy Point B

Br

BmR

0 Hc 0 HmR 0 H
Br Br
B (H  H c )  BH  (H  H c )H
Hc Hc

 ( BH ) Br Hc
To get (BH) max   0  Bm  ,Hm  
H 2 2
 Working Point for Permanent Magnetics (2)

Br
 rm 
0 H c
1   rm  1.2

d m Ag
Load Line: Bm    0 H m  Pc is called permeance coefficient
g Am
  Pc   0 H m  Pc 
d m Ag

Ag / g

R m Pg

g Am Am / d m R g Pm
Bm m
Define: Bm   m Br H m  (1   m ) H c  Pc     rm
0H m 1 m
Typically pick up:  m  0.5  0.9
 Airgap Magnetic Field from PM Rotor
PM electrical angle
PM embrace:
B g , rotor 
Bm   PM 
  PM PM

2 2
 PM  PM  PM 2
 2   de
 Bm 2 2 2
P
 de  d
B g , rotor  
h 1,3,5...
B Rh 2

P
B Rh  Brh cos( h de )  Brh cos( h  d )
2
2   PM /2    PM /2
 Brh   B cos( h ) d    (  Bm ) cos( h ae )d ae 
2    PM /2 
m ae ae
   PM /2

   pitch factor for the

sin  h PM 

4  2 B h th harmonic
 h
m

  
k ph  sin  h PM 
 2 
 Phasor Diagram
V Bnet
 
jX S I A BS

EA BR
Typically, design cos  1 at full-load for PMSM.
sin  1/3 ( =19.47 ) so that Tfull-load  (1 / 3)Tpull out


 B g , pk  cos  B r , pk  0.94 B r , pk
Ba , pk  sin  B r , pk  0.33 B r , pk 4  PM 
Br, pk  sin   Bm
  2 
 Air Gap Size and PM Thickness
From: 4 0 Nˆ a
Ba , pk  1.5 2 I A,rated
 gˆ total P

Initial total effective air gap size:

4 0 Nˆ a
gˆ total  1.5 2 I A,rated
 Ba , pk P

dm
From: gˆ total  k c g 'total g 'total  g  d m / rm  Pc ( Ag  Am )
g
m
Pc   rm
1 m
Carter’s coefficient
 g  (1   m ) g 'total
d m   m g 'total rm
 Effective Air Gap
gˆ total  kc g 'total
where the Carter’s coefficient
s
kc 
2 b s 0    b s 0   
2
bs 0 g ' total
s   atan  ln 1    
  2 g ' total bs 0   2 g ' total   
 
approximately
s
kc 
bs20
s  ts ds0ds1 ds
5 g ' total  bs 0 bs0

s
g total
 Rotor Sizing

Total rotor diameter, including magnet Dr  D  2 g

Rotor inner diameter Di  Dr  2d m

Part 3 – Two Pole Super High
Speed PM Motor with Magnet
Inserted in Rotor Shaft
Prototype

 Rotor is assembled by
heating and cooling.
 Rotor is welded and
well balanced after
assembly.
 Air Gap Size
For a 2-pole PM rotor 2 g eff H g  H m D r  0
 2 g e ff B m   0 H m D r  0 ( Ag  Am )
Dr 
Dr / 2
 
Bm
 Pc
S N geff g e ff 0H m
Carter’s coefficient
Dr Dr Dr D
g eff   kc ( g  ) g 
2  rm 2  rm 2 2

1 1 D D 1 D
 (  ) r  kc  k c (1  ) r
Pc  rm 2 2  rm 2
kc
 Dr  D D  Dr
1 1  kc g
kc   2
Pc  rm
Bm m
Define: Bm   m Br H m  (1   m ) H c  Pc     rm
0H m 1 m
Typically pick up:  m  0.5  0.8
 Effective Air Gap
gˆ total  kc g 'total gˆ total  g eff 
Dr
, g 'total  g 
Dr
2 rm 2 rm
where the Carter’s coefficient
s
kc 
 g ' total   b s 0   
2
2 bs 0 bs 0
s   atan  ln 1    
  2 g ' b   2 g ' total   
total s0

approximately

s
kc 
bs20 ts ds0ds1 ds
s  bs0
5 g ' total  bs 0
s

g total
 Example - Specifications

Design a 2kW, 100krpm, NdFeB-38 PMSM, 2 pole

36 V terminal voltage, Y connected, 90% efficiency.