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Brushless permanent magnet DC motors are being manufactured and used increasingly in everything from home appliances to auto-
mobiles due to their inherent advantages. The merits of these motors could be enhanced further according to another design approach
method which alters the typically used winding parts for low to medium power range motors. This paper deals with the high power
brushless DC motor used for traction in a 48 V golf cart system. The stator is designed with segment rectangular copper winding to
maximize output power within its limited dimensions. In the design process, the closed slot opening and slot-pole combination are inves-
tigated and compared in terms of efficiency and input current density. The developed motor obtained about 120% greater power density
per volume compared to a commercial motor with round winding coils at similar efficiency and variable speed range.
Index Terms—Brushless DC motors, cogging torque, segment magnet wire, slot opening.
I. INTRODUCTION
*Corrected. This paper first appeared in IEEE Trans. Magn., vol. 46, pp.
II. SLOT OPENING
2070–2073, June 2010. Due to a production error, Figs. 1, 2, 5, 6, and 7 were
not correct.
Fig. 1 graphically shows the difference of slot fill factor
Manuscript received October 31, 2009; revised January 08, 2010; accepted and slot structure between rectangular wire and round wire.
January 12, 2010. Date of current version August 20, 2010. Corresponding au- Increasing the slot fill factor means that it can reduce iron loss
thor: Y.-D. Chun (e-mail: ydchun@keri.re.kr). in the parts of the stator teeth and yoke because of the wide flux
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org. path. In the case of segment rectangular copper wires which are
Digital Object Identifier 10.1109/TMAG.2010.2060385 axially inserted into the slot of the stator as shown in Fig. 2, the
0018-9464/$26.00 © 2010 IEEE
3702 IEEE TRANSACTIONS ON MAGNETICS, VOL. 46, NO. 9, SEPTEMBER 2010
Fig. 6. Compared motors. (a) Commercial 1.5 kW round copper motor. (b) De-
veloped 1.0 kW segment copper motor. (c) Commercial 1.0 kW round copper
motor.
TABLE I
DESIGN RESULTS ON SLOT AND POLE COMBINATION