energies

Article
Synchronous Reluctance Motor vs. Induction Motor
at Low-Power Industrial Applications: Design
and Comparison
Nezih Gokhan Ozcelik, Ugur Emre Dogru, Murat Imeryuz and Lale T. Ergene *
Electrical Engineering Department, Istanbul Technical University, 34469 Istanbul, Turkey;
ozceliknezih@gmail.com (N.G.O.); ugureemre.dogru@gmail.com (U.E.D.); imeryuz@itu.edu.tr (M.I.)
* Correspondence: ergenel@itu.edu.tr; Tel.: +90-212-285-3634




Received: 19 March 2019; Accepted: 4 June 2019; Published: 8 June 2019


Abstract: Although three-phase induction motors are the most common motor type in industry, a
growing interest has arisen in emerging electric motor technologies like synchronous reluctance
motors and permanent magnet motors. Synchronous reluctance motors are a step forward compared
to permanent magnet motors when the cost of the system is considered. The main focus of this study
is low-power industrial applications, which generally use three-phase induction motors. In this study,
the synchronous reluctance motor family is compared at three different power levels: 2.2 kW, 4 kW,
and 5.5 kW. The aim of this study is to design and compare synchronous reluctance motors, which can
be alternative to the reference induction motors. Finite element analysis is performed for the reference
induction motors initially. Their stators are kept the same and the rotors are redesigned to satisfy
output power requirements of the induction motors. Detailed design, analysis, and optimization
processes are applied to the synchronous reluctance motors considering efficiency, power density,
and manufacturing. The results are evaluated, and the optimized designs are chosen for each power
level. They are prototyped and tested to measure their performance.

Keywords: synchronous reluctance motor; induction motor; finite element method; synchronous
motor; reluctance motor

1. Introduction
Increasing attention to energy efficiency makes electric motor technology important when
considering the percentage of their energy consumption. Different types of electric motors are used in
low-power industrial applications dependent on the needs of the system. However, market research
shows that a great majority of industrial motors are still induction motors. Permanent magnet motors
and synchronous reluctance motors are becoming an alternative solution for low-power industrial
applications. Even though permanent magnet motors are more efficient compared to induction motors,
their cost is still higher because of the permanent magnet. Demagnetization is another drawback of
permanent magnet machines. Synchronous reluctance motors (SynRMs) have become prominent since
the rotor does not have any conductor or any permanent magnet. It costs almost the same as the
induction motor, and its efficiency is higher at the same power ratings.
There are many studies on synchronous reluctance machines in the literature. Kostko published
the first paper titled “Polyphase Reaction Synchronous Motors” in 1923 [1]. The theory of synchronous
reluctance machine was established the first time in this paper. However, SynRM was not an alternative
to industrial induction machines in those days due to the lack of starting capacities and relatively low
efficiencies. Cruickshank et al. published a paper titled “Axially Laminated Anisotropic Rotors for
Reluctance Motors” and they proposed the axially laminated SynRM structure [2]. This motor was

Energies 2019, 12, 2190; doi:10.3390/en12112190 www.mdpi.com/journal/energies

Energies 2019, 12, 2190 2 of 20

more efficient than Kostko’s first design and became popular between the 1960s and 1970s because of
its increased capabilities. The axial alignment of laminations required new special production lines, so
this type of motor was not industrially viable in terms of manufacturing. Cruickshank et al. formed
the mathematical theory of the axially laminated SynRM in another study [3]. In this work, it is shown
that axially laminated SynRMs are still a little behind the induction machines even though they have
higher saliency ratios than the transverse laminated SynRM. Honsinger formed the general analytical
model of SynRM in his paper titled “The Inductances Ld and Lq of Reluctance Machines” in 1971 [4]. A
new analytical method was proposed to calculate the axes inductances in this paper. Before this study,
obtaining high saliency ratios, and eventually, higher torque, were arbitrary. SynRM became popular
because of the developments in power electronics and manufacturing technologies in 1990s. Lipo
proposed the synchronous reluctance motor as a viable alternative for AC drive systems [5]. As Lipo
and Matsuo’s research focused on rotor design optimization [6], Miller et al. studied driver designs for
SynRM [7–9]. Vagati et al. had a paper on the design criteria of synchronous reluctance motors [10].
Vagati et al. had also a study on the experimental comparison of induction and synchronous reluctance
motors. They showed that a SynRM can produce 20% to 40% higher torque compared to an IM in
the case of the increased rated current for the same power loss or same temperature [11]. Another
comparison of these two motors for a traction application was evaluated by Kamper et al. [12]. There
are studies carried out only to maximize the saliency ratio [13]. Different optimization methodologies
were evaluated by researchers. Moghaddam et al. evaluated the optimization of barrier shapes [14–16],
Bianchi et al. focused on torque ripple reduction [17], and Lin et al. applied multi-objective optimization
algorithms to a six-phase synchronous reluctance machine to increase the efficiency [18]. A paper was
written by Kamper et al. which remarked on the importance of the finite element method (FEM) to
analyze the SynRM [19]. Another work focusing on the multi-objective optimization algorithm of
synchronous reluctance motors was published by Cupertino et al. [20]. Ergene et al. published a paper
on a permanent magnet assisted SynRM (PMaSynRM), which is designed and prototyped for home
appliance [21].
In this study, the rotors of the synchronous reluctance motors are designed for three different
frames: 2.2 kW, 4 kW, and 5.5 kW. The stators of the SynRMs are kept the same as those of the reference
induction motors at the same frames. The designed synchronous reluctance motors are prototyped
and compared to the reference induction motors in terms of efficiency, losses, power density, active
material, etc.

2. Torque Equations
The synchronous reluctance motor does not have a permanent magnet and conductor in its rotor
compared to the permanent magnet motor and induction motor. The torque is equal to the reluctance
torque, which is produced by saliency between d and q axes inductances. The ratio between d and q
axes inductances is defined as the saliency ratio. This ratio directly affects the torque production of the
synchronous reluctance motor. The general torque equation of this motor is in Equation (1) as [21]:

3p
T= (λqs ids − λds iqs ) (1)
22
where p is the pole pair number, λds , λqs are d and q axis stator flux linkages, ids , iqs are d and q axis
stator currents. Rotor currents are zero at steady-state, so the flux linkages can be expressed as a
function of d-q axis inductances Ld and Lq , respectively, as given in Equations (2) and (3).

λds = Lds ids (2)

λqs = Lqs iqs (3)

 Energies 2019, 12, 2190 3 of 20

The reluctance torque in d-q inductances are given in Equation (4).

Energies 2019, 12, x FOR PEER REVIEW 3 of 20
Energies 2019, 12, x FOR PEER REVIEW 3 p  3 of 20
T =Lq inductances
The saliency ratio between the Ld and Lds − Lqs ihas
ds iqsa vital role in obtaining higher torque(4)
22
values.The saliency ratio between the Ld and Lq inductances has a vital role in obtaining higher torque
The saliency ratio between the Ld and Lq inductances has a vital role in obtaining higher
values.
torque
3. Designvalues.
Methodology and Parameters
3. Design Methodology and Parameters
The design
3. Design methodology
Methodology and consists of three main stages: Electromagnetic, structural, and thermal
Parameters
designs.
TheThese
designdesign stages areconsists
methodology given inofFigure 1 as blocks,
three main stages: and each main block
Electromagnetic, affects and
structural, eachthermal
other.
The design methodology consists of three main stages: Electromagnetic, structural, and thermal
Design
designs. These design stages are given in Figure 1 as blocks, and each main block affects eachblock
criteria block is the input for the electromagnetic design. The electromagnetic design other.
designs. These design stages are given in Figure 1 as blocks, and each main block affects each
includes motor sizing,
Design criteria block optimizing,
is the input and finite
for the element analysis
electromagnetic of theThe
design. optimized motor design.
electromagnetic Ergene
design block
other. Design criteria block is the input for the electromagnetic design. The electromagnetic design
et.al proposed
includes motor a multi-parameter
sizing, optimizing, chart,
and including rotoranalysis
finite element geometric parameters
of the optimized for 2.2 kW
motor motorErgene
design. [22].
block includes motor sizing, optimizing, and finite element analysis of the optimized motor design.
At theproposed
et.al end of the electromagneticchart,
a multi-parameter design procedure,
including rotorageometric
structuralparameters
design procedure
for 2.2 kWbegins.
motorThe
[22].
Ergene et al proposed a multi-parameter chart, including rotor geometric parameters for 2.2 kW
procedure
At the end supplies
of the feedback to previous
electromagnetic design design procedures
procedure, and updates
a structural designtheprocedure
design following
begins. the
The
motor [22]. At the end of the electromagnetic design procedure, a structural design procedure begins.
same designsupplies
procedure steps, respectively.
feedback to previous design procedures and updates the design following the
The procedure supplies feedback to previous design procedures and updates the design following the
same design steps, respectively.
same design steps, respectively.
ELECTROMAGNETIC STRUCTURAL THERMAL
DESIGN
ELECTROMAGNETIC DESIGN
DESIGN
STRUCTURAL THERMAL
DESIGN DESIGN
DESIGN
Pre-Design
Pre-Design
Design Structural Thermal
Analysis Analysis Final
Criteria
Design Optimization Structural Thermal
Analysis Analysis Final
Criteria Optimization

FEM
FEM

Figure 1. Electric motor design procedure.

Figure 1.
Figure Electric motor
1. Electric motor design
design procedure.
procedure.
In this study, the reference induction motors and the newly designed synchronous reluctance
motorsIn thiscompared
study, the reference induction motors andatthe
2.2newly
kW, 4designed
kW, and synchronous reluctance
Inare
this study, thefor three different
reference power
induction levels
motors and the newly designed 5.5 kW for low-power
synchronous reluctance
motors are
industrial compared for
applications. three
Thethree different
stators power levels at the
and ampere-turns 2.2 kW, 4 kW, and 5.5arekW for low-power
motors are compared for different power levels of induction
at 2.2 kW, 4 kW, motors
and 5.5 kWkept the same
for low-power
industrial
during applications.
synchronous The stators
reluctance motors and ampere-turns
design procedures of the induction motors are kept the same
industrial applications. The stators and ampere-turns of to
themake a fair comparison.
induction The rotors
motors are kept of
the same
during
the synchronous
induction reluctance
motors are designed motors design
againdesign procedures
considering to make
the reluctance a fair comparison. The rotors of
during synchronous reluctance motors procedures to make amotor parameters.The
fair comparison. Therotors
designof
the induction
procedure motors
stepsmotors arein
are given designed
Figure 2again considering the reluctance motor parameters. The design
schematically.
the induction are designed again considering the reluctance motor parameters. The design
procedure steps are given in Figure 2 schematically.
procedure steps are given in Figure 2 schematically.

Number of Rotor Barriers Shape of Rotor Barriers Air gap Insulation Ratio
Number of Rotor Barriers Shape of Rotor Barriers Air gap Insulation Ratio

1 Barriers g=0.25 kq=0.6

Angular
1 Barriers g=0.25 kq=0.6
Angular
g=0.34 kq=0.7
2 Barriers Round
g=0.34 kq=0.7 Design
2 Barriers Round
kq=0.8 Design
3 Barriers Angular Cut-off
kq=0.8
3 Barriers Angular Cut-off
g=0.34
-Round
kq=0.9
4 Barriers -Round g=0.34
kq=0.9
4 Barriers
Synchronousreluctance
Figure2.2.Synchronous
Figure reluctancemotor
motor(SynRM)
(SynRM)electromagnetic
electromagneticdesign
designparameters.
parameters.
Figure 2. Synchronous reluctance motor (SynRM) electromagnetic design parameters.
In the design step, the rotor barrier effect is analyzed by considering a different number of rotor
barriers
In and shapes.step,
the design The the
air gap
rotorisbarrier
also a parameter, although
effect is analyzed by the stator dimensions
considering a differentand the ampere-
number of rotor
turns are and
barriers keptshapes.
the same.
TheUniform
air gap isand
alsosalient air gap although
a parameter, structuresthe
with different
stator radial and
dimensions air gap
the lengths
ampere-
are considered
turns are kept for
thethe design.
same. Lastly,
Uniform the
and insulation
salient ratios
air gap of the synchronous
structures with differentreluctance
radial air motors are
gap lengths
Energies 2019, 12, 2190 4 of 20

In the design step, the rotor barrier effect is analyzed by considering a different number of
rotor barriers and shapes. The air gap is also a parameter, although the stator dimensions and the
ampere-turns
Energies 2019, 12, xare
FORkept the
PEER same. Uniform and salient air gap structures with different radial air
REVIEW gap
4 of 20
lengths are considered for the design. Lastly, the insulation ratios of the synchronous reluctance motors
are evaluated.
evaluated. Efficiency,
Efficiency, cost,
cost, andand power
power density
density ofof each
each designare
design arecompared
comparedtotothose
thoseof
ofthe
the reference
reference
induction motor to obtain the optimum design for low-power industrial applications, such as pumps
and fans.

4. Multi
4. Multi Parameter
Parameter Design
Design Steps
Steps of
of SynRMs
SynRMs
The parameters,
The parameters, such
such as
as barrier
barrier number,
number, end bridge thickness,
end bridge thickness, air
air gap
gap dimension,
dimension, and
and insulation
insulation
ratio, are used on the motor model in FEA to obtain an optimized motor in terms of cost, efficiency,
ratio, are used on the motor model in FEA to obtain an optimized motor in terms of cost, efficiency,
and serial
and serial production
production limits
limits [22]. The rotor
[22]. The rotor design
design parameters
parameters are
are shown
shown inin Figure
Figure 3.
3.

Figure 3. SynRM design parameters.

Some constraints
Some constraints areare imposed
imposed on on each
each step. The outer
step. The outer and
and inner
inner stator
stator diameter,
diameter, the the winding
winding
distribution, the stator slot number, the stator, and rotor material are defined
distribution, the stator slot number, the stator, and rotor material are defined as constant as constant in the analysis.
in the
Specific constraints
analysis. are only used
Specific constraints are ononlycertain
usedsteps. The barrier
on certain steps.number parameter
The barrier number is examined
parameter first.
is
The thickness effect of end bridges is analyzed for two flux barriers.
examined first. The thickness effect of end bridges is analyzed for two flux barriers. The L /L
d q ratio varies due
The Ld/Lq ratio to
both the
varies duefluxto barriers’
both the numbers and numbers
flux barriers’ their shape.andAnother parameter
their shape. Anotheranalyzed
parameteris the flux barrier
analyzed width
is the flux
variation.
barrier width It isvariation.
graduallyItdecreased
is gradually in the outward
decreased inradial direction.
the outward Thedirection.
radial air gap effect
The airis evaluated
gap effect inis
three different models. Two of them are the uniform air gap in the radial direction,
evaluated in three different models. Two of them are the uniform air gap in the radial direction, and and the third model
is the
the cut-off.
third model Each air gap
is the model
cut-off. Eachis employed
air gap model on two different numbers
is employed of barriers
on two different and three
numbers of different
barriers
and three different flux barrier structure. The insulation ratio is the final parameter directly
flux barrier structure. The insulation ratio is the final parameter for the simulations. This ratio for the
influences the
simulations. saliency
This ratio directly /Lq ). Four the
ratio (Ldinfluences different
saliencyinsulation
ratio (Lratios are examined
d/Lq). Four different on four different
insulation ratios
fluxexamined
are barrier motor models
on four with variable
different flux barrierandmotor
constant width
models angular
with fluxand
variable barriers.
constant width angular
flux barriers.
5. Finite Element Analysis Results
5. Finite Element Analysis Results
5.1. Analysis of the Reference Induction Motors
The reference
5.1. Analysis induction
of the Reference motors Motors
Induction have 2.2 kW, 4 kW and 5.5 kW rated power values as listed in
Table 1. These induction motors are the mass production commercial type squirrel cage induction
The reference induction motors have 2.2 kW 4 kW and 5.5 kW rated power values as listed in
motors. The rated voltage is 400 V (line-to-line) for 2.2 kW motor, while it is 690 V for the 4 kW and
Table 1. These induction motors are the mass production commercial type squirrel cage induction
motors. The rated voltage is 400 V (line-to-line) for 2.2 kW motor, while it is 690 V for the 4 kW and
5.5 kW motors. The current must be increased to provide the same amount of power if the voltage is
400 V for 4.4 and 5.5 kW. The motor faces danger if the current exceeds the motor's nameplate ratings.
Energies 2019, 12, 2190 5 of 20

5.5 kW2019,
Energies
Energies
motors.
12,12,
2019,
ThePEER
x FOR
x FOR
current must
be increased to provide the same amount of power if the voltage
REVIEW
PEER REVIEW
is20
5 5ofof20
400 V for 4.4 and 5.5 kW. The motor faces danger if the current exceeds the motor’s nameplate ratings.
Table
Table1.1.Reference
ReferenceInduction
InductionMotors’
Motors’Nameplate.
Nameplate.
Table 1. Reference Induction Motors’ Nameplate.
Power
Power(kW)
(kW) 5.5
5.5 44 2.2
2.2
Voltage
Voltage(V)
Power (V)(kW) 400/690
5.5400/690 4 400/690
400/690 2.2 230/400
230/400
Current
Current (A)
Voltage
(A) (V) 11.1/6.4
400/690
11.1/6.4 400/690 8.3/4.8
8.3/4.8 230/400 8.5/4.9
8.5/4.9
FrequencyCurrent
(Hz) (A) 11.1/6.450 8.3/4.8 50 8.5/4.9 5050
Frequency
Frequency(Hz)(Hz) 50 50 50 50 50
Number
Number ofofPoles
Number Poles
of Poles 4 44 4 44 4 44
Speed (min −1) −1 14651465 1455 1455 1450 1450
Speed (min−1) )
Speed (min 1465 1455 1450
Slip Slip 0.0233
0.0233 0.03 0.03 0.033 0.033
Slip
Efficiency (%) 89.6 0.0233 88.6 0.03 86.7 0.033
Efficiency
Efficiency(%) (%) 89.6
89.6 88.6
88.6 86.7
86.7

First, the
First, the numericalmodelsmodels of the motors builtare built using a two dimensional (2D) finite
First, thenumerical
numerical modelsofofthe themotors
motorsare are builtusing
usinga atwo
twodimensional
dimensional(2D)(2D)finite
finiteelement
element
element method
method (FEM) (FEM) based
based commercial
commercial softwaresoftware (FLUX2D)
(FLUX2D) withwith
2D 2D time-steppingvector
time-stepping vector potential
method (FEM) based commercial software (FLUX2D) with 2D time-stepping vector potential
formulation. The
formulation. The 3D effects
effects like the
the end turns
turns of stator winding are included using lumped circuit
formulation. The3D 3D effectslikelike theend
end turns of statorwinding winding are included using lumped circuit
parameters in the software. The
parameters The lumped circuit circuit parameters of of the motors
motors
parameters in the software. Thelumped lumped circuitparameters
parameters ofthe the motorsare arecalculated
calculatedusing
using
SIEMENS-SPEED
SIEMENS-SPEED software (V11.04.010, SPEED Laboratory, University of Glasgow, Glasgow, Scotland),
SIEMENS-SPEEDsoftware software(V11.04.010,
(V11.04.010,SPEED SPEEDLaboratory,
Laboratory,University
UniversityofofGlasgow,
Glasgow,Glasgow,
Glasgow,
which is anwhich
Scotland), analytical motor modelling tool. The outputs are injectedare
to FEM. Whole motor geometries
Scotland), whichisisanananalytical
analyticalmotor
motormodelling
modellingtool. tool.The
Theoutputs
outputs areinjected
injectedtotoFEM.
FEM.Whole
Wholemotor
motor
are considered
geometries are for numerical
considered foraccuracy.
numerical accuracy.
geometries are considered for numerical accuracy.
Both the rotor and stator laminations’ magnetic material are Cogent SURA M700 35A silicon steel
Boththe therotor
rotorand
andstator
statorlaminations’
laminations’magnetic
magneticmaterial
materialareareCogent
CogentSURASURAM700 M70035A35Asilicon
silicon
for these
steel three motors, and its magnetic flux density density
and magneticmagnetic
field intensity intensity
values are shownare in
steelfor
forthese
thesethree
threemotors,
motors,andanditsitsmagnetic
magneticflux flux densityand and magneticfieldfield intensityvalues
values are
Figure 4a.
shown in Only the
Figure 4a. 5.5
OnlykWtheinduction
5.5 kW motor hasmotor
induction a doublehas cage
a rotor,cage
double as the other
rotor, astwo
the motors
other have
two deep
motors
shown in Figure 4a. Only the 5.5 kW induction motor has a double cage rotor, as the other two motors
rotor deep
have bars. The mesh of themesh
4 kW reference induction motor is given in isFigure 4b.
have deeprotor rotorbars.
bars.The
The meshofofthe the4 4kWkWreference
referenceinduction
inductionmotor
motor isgiven
givenininFigure
Figure4b.
4b.

(a)
(a) (b)
(b)
Figure
Figure4.
Figure 4.4.(a)
(a)B-H
(a) B-Hcurve
B-H curveof
curve ofofthe
theM700
the M700Si-steel;
M700 Si-steel;(b)
Si-steel; (b)The
(b) Themesh
The meshdiscretization
mesh discretizationof
discretization ofof44 4kW
kWmotor.
motor.

The
Theequi-flux
equi-fluxlines
linesshowing
lines showing
showingthe
the
thefour-pole
four-pole distribution
four-poledistribution
distributionand
and
andcolor
colorshade
shade
color ofofflux
shade offluxdensities
densities
flux densities =
atattat
t =t0.3 s
=0.3
0.3
sfor
sforthe
for three
the
the reference
three
threereference
referenceinduction
inductionmotors
inductionmotors
motorsare given
are
aregiveninin
given Figure 5. 5.5.
inFigure
Figure

(a)
(a) (b)
(b) (c)(c)
Figure
Figure 5.5.The
Figure5. The
The equi-flux
equi-flux
equi-flux lines and
lines
lines andand flux
flux densities
flux densities
densities ofof2.2
of (a) (a)(a)
2.2
2.2kW,
kW, kW,
(b) 4 (b)
(b)4and
kW, 4kW,
(c)and
kW, (c)(c)5.5
andkW
5.5 5.5kW
kWInduction
Induction Induction
motors.
motors.
motors.

The
Thenormal
normalcomponents
componentsofofthe
theair
airgap
gapflux
fluxdensities
densitiesfor
fora ageometrical
geometricalcycle
cycleatatt t= =0.5
0.5s sand
andthe
the
torque
torque profiles of the motors are presented in Figure 6 for the rated load at the rated voltageand
profiles of the motors are presented in Figure 6 for the rated load at the rated voltage and
Energies 2019, 12, 2190 6 of 20

The normal components of the air gap flux densities for a geometrical cycle at t = 0.5 s and the
Energies 2019, 12, x FOR PEER REVIEW 6 of 20
torque profiles of the motors are presented in Figure 6 for the rated load at the rated voltage and speed
given in Table 1. Four pole distributions with the slotting from Figure 6a,c,e can be easily seen for
speed given in Table 1. Four pole distributions with the slotting from Figure 6a,c,e can be easily seen
each motor.
for each motor.

1.5
45.0
1.0
25.0
0.5
Flux Density [T]

Torque [Nm]
0.0 5.0
0.0 0.0 0.1 0.1 0.2 0.2 0.3 0.3 Time [s]
0.02 0.04 0.06 0.08 0.10 0.12 0.14
-0.5 -15.0

-1.0
-35.0
-1.5
Airgap Path
-55.0

(a) (b)
150.0

2.0
100.0
1.5
1.0
Flux Density [T]

50.0
Torque [Nm]

0.5
0.0
0.0
-0.02
-0.5 0.03 0.08 0.13 0.18 0.23 0.28 0.33
0.02 0.04 0.06 0.08 0.10 0.12 0.14
-1.0 -50.0 Time [s]
-1.5
-2.0 -100.0
Airgap Path

-150.0

(c) (d)
200.0
1.5
150.0
1.0
Flux Density [T]

100.0
0.5
Torque [Nm]

0.0 50.0
0.00 0.10 0.20 0.30 0.40
-0.5 0.0
0.04 0.06 0.08 0.10 0.12 0.14
-1.0 -50.0
Time [s]
-1.5
Airgap Path -100.0

-150.0

(e) (f)
Figure
Figure 6.6.The
Thenormal
normalcomponent
component of of the
the flux
fluxdensity
densityininthe
theair
airgap
gap(a)(a)
2.22.2
kW, (c)(c)
kW, 4 kW, and
4 kW, (e) (e)
and 5.5 5.5
kWkW
motors and torque variation of (b) 2.2 kW, (d) 4 kW, and (f) 5.5 kW
motors and torque variation of (b) 2.2 kW, (d) 4 kW, and (f) 5.5 kW motors. motors.

TheThe FEM
FEM analysis
analysis results
results ofof
thethe motors
motors areare compared
compared to to
thethe test
test results
results to to validate
validate thethe motor
motor FEM
FEM models. The test bed for the motor tests is given in Figure 7. The test bed has a
models. The test bed for the motor tests is given in Figure 7. The test bed has a reference inductionreference
induction
motor, motor,eddy
hysteresis hysteresis
currenteddy current
brake, andbrake, and measurement
measurement system. system.
The no-load and rated load tests are performed due to the IEC standard 60034-2-1. The stator
resistances are obtained as given in Table 2. Eight different voltage (1.1, 1, 0.95, 0.9, 0.6, 0.5, 0.4, 0.3 times
of the rated voltage) are applied and measured for the no-load test. No-load stator current and no-load
input power are measured for each voltage. The first four voltages (1.1, 1.0, 0.95; 0.90 times of the rated
voltage) are used to calculate the iron losses (Pfe ). The last four (0.60, 0.50, 0.40, 0.30 times of the rated
voltage) are used to calculate the friction and windage losses (Pfw ). The no-load test measurements and
calculated loss terms are given in Tables 3–5 for 2.2 kW, 4 kW, and 5.5 kW reference motors, respectively.
Energies 2019, 12, 2190 7 of 20
Energies 2019, 12, x FOR PEER REVIEW 7 of 20

Figure 7.
Figure Test bench.
7. Test bench.

Table 2. Stator resistances per phase for the reference induction motors.
The no-load and rated load tests are performed due to the IEC standard 60034-2-1. The stator
resistances are obtained as given in Table
Initial 2. Eight different voltage (1.1,
Condition 1, 0.95,Regime
Thermal 0.9, 0.6, 0.5, 0.4, 0.3
Power
times of the rated voltage) are applied
Temperature ( C) and
◦ measured
Resistance for the no-load
(Ohms) test. (No-load
Temperature ◦ C) stator current
Resistance (Ohms) and
no-load2.2
input
kW
power are measured
22
for each voltage.
1.91
The first four voltages
64.1
(1.1, 1.0, 0.95; 0.90
2.196
times
of the rated
4 kWvoltage) are used22to calculate the iron
2.35losses (Pfe). The last four (0.60, 0.50, 0.40,
72.8 3.1590.30 times
of the rated
5.5 kWvoltage) are used
22 to calculate the1.32
friction and windage 67 losses (Pfw). The1.603 no-load test
measurements and calculated loss terms are given in Tables 3–5 for 2.2 kW, 4 kW, and 5.5 kW
reference motors, respectively.
Table 3. No-Load Test results of 2.2 kW induction motor.

V2 resistances
V (V)Table 2. Stator I (A)per phase
P0 for
(W)the reference
Pcu0 (W) Pfe + Pfw0 (W)
induction motors.
120 14,400 0.86 43 4.9 38.1
160 Initial
25,600 Condition
1.13 55 8.5 Thermal Regime
46.5
Power
Temperature
200 (°C)
40,000 Resistance
1.43 (Ohms)70 Temperature
13.5 (°C) Resistance
56.5 (Ohms)
2.2 kW 240 22 57,600 1.73 1.91 88 19.6
64.1 68.4 2.196
4 kW 305 22 93,025 2.28 2.35 124 34.1
72.8 89.9 3.159
370 136,900 3.02 178 60.2 117.8
5.5 kW 400
22 160,000 3.49
1.32 210
67
80.1 129.9
1.603
435 189,225 4.22 271 117.5 153.5
Table 3. No-Load Test results of 2.2 kW induction motor.

V (V)Table 4.VNo-Load
2 Test results
I (A) P0 (W)of 4Pcu0
kW(W)induction
Pfe +motor.
Pfw0 (W)
V (V)
120 2 14,400 I (A) 0.86 43
P0 (W)
4.9 P (W) 38.1 P + P (W)
V cu0 fe fw0
160 25,600 1.13 55 8.5 46.5
120 14,400 0.95 36 8.6 27.4
200 40,000 1.43 70 13.5 56.5
160 25,600 1.49 48 21 27
200 24040,00057,600 1.811.73 8868 19.6 31 68.4 36.9
240 30557,60093,025 2.242.28 12493 34.1 47.5 89.9 45.4
305 37093,025 3.01
136,900 3.02 140
178 60.2 85.8 117.8 54.2
370 136,900
400 4.1
160,000 3.49 210
210 80.1 159.3 129.9 50.69
400 160,000 4.7 263 209.3 53.7
435
435 189,225
189,225
4.22
5.4
271
366
117.5 276.3
153.5 89.7
Energies 2019, 12, 2190 8 of 20

Table 5. No-Load Test results of 5.5 kW induction motor.

V (V) V2 I (A) P0 (W) Pcu0 (W) Pfe + Pfw0 (W)

120 14,400 1.6 68 12.3 55.7
160 25,600 2.1 88 21 67
200 40,000 2.63 120 33.3 86.7
240 57,600 3.22 151 49.8 101.2
305 93,025 4.26 213 87 126
370 136,900 5.62 298 151.8 146.2
400 160,000 6.47 349 201.3 147.7
435 189,225 8.07 434 312.9 121.1

The load curve test is performed after the thermal regime of winding temperatures is achieved.
There are six operating points due to the standard: 1.25, 1.15, 1, 0.75, 0.5, 0.25 times of the rated load are
performed. The input power, Pin ; output torque, Tout ; stator line current, I1 ; phase-to-phase voltage, V;
and speed, n; measurements should be taken for each loading test. The load test results are given for
the reference motors in Tables 6–8, respectively. The output powers for the motors are calculated using
the measured output torque and speed.

Table 6. Load Test results of 2.2 kW IM.

Parameters 25% 50% 75% 100% 115% 125%

Voltage V (V) 402 401 401 401 400 401
Phase Current I1 (A) 3.5 3.82 4.37 4.92 5.83 6.72
Input Power Pin (W) 771 1336 1943 2560 3187 3822
Torque T (Nm) 3.6 7.3 10.9 14.6 18.2 21.9
Speed n (min−1 ) 1487 1473 1458 1445 1427 1410
Output Power Pout (W) 560 1126 1663 2208 2718 3232
Efficiency 72.7 84.2 85.6 86.3 85.3 84.6

Table 7. Load Test results of 4 kW IM.

Parameters 25% 50% 75% 100% 115% 125%

Voltage V (V) 402 400 401 401 400 401
Phase Current I1 (A) 5.19 5.88 6.91 8.22 9.73 11.41
Input Power Pin (W) 1264 2327 3415 4500 5655 6819
Torque T (Nm) 6.6 13.2 19.8 26.3 32.9 39.5
Speed n (min−1 ) 1491 1480 1466 1457 1439 1426
Output Power Pout (W) 1030 2045 3038 4011 4955 5896
Efficiency 81.5 88 89 89.1 87.6 86.5

Table 8. Load Test results of 5.5 kW IM.

Parameters 25% 50% 75% 100% 115% 125%

Voltage V (V) 402 400 399 400 401 400
Phase Current I1 (A) 6.74 7.77 9.27 11.1 13.11 15.24
Input Power Pin (W) 1701 3161 4632 6122 7652 9188
Torque T (Nm) 9.1 18.1 27.2 36.2 45.3 54.3
Speed n (min−1 ) 1491 1484 1476 1467 1455 1445
Output Power Pout (W) 1420 2814 4202 5558 6899 8213
Efficiency 83.5 89 90.7 90.8 90.2 89.4

The FEM and test results of the reference induction motors are given in Table 9 in terms of the
torque, current, power, and efficiency for the rated values. The difference between FEM and test results
are in a 10% range and are acceptable.
 The FEM and test results of the reference induction motors are given in Table 9 in terms of the
torque, current, power, and efficiency for the rated values. The difference between FEM and test
results are in a 10% range and are acceptable.

Energies 2019, 12, 2190 Table 9. Induction Motors’ FEM and TEST results. 9 of 20

2.2 kW 4 kW 4 kW 5.5 kW FEM 5.5 kW Test

Parameter 2.2 kW FEM
Table 9. InductionTest FEMandTest
Motors’ FEM TEST results.
Torque (Nm) 14.6 14.5 26.26 26.3 36.1 36.2
Parameter
Current (Arms2.2
) kW FEM 4.82.2 kW Test4.95 4 kW FEM 8 4 kW Test
8.22 5.5 kW FEM
11.1 5.5 kW Test
11.7
Torque (Nm)
Output Power (W) 14.6 2215 14.5 2203 26.26
3957 3984 26.3 5535 36.1 5482 36.2
Current (Arms ) 4.8 4.95 8 8.22 11.1 11.7
OutputEfficiency
Power (W) (%) 2215 86 2203 86.3 3957 89.53 89.13984 89.8 5535 90.8 5482
Efficiency (%) 86 86.3 89.53 89.1 89.8 90.8
5.2. Analysis of Synchronous Reluctance Motors
5.2. Analysis
After theof analysis
Synchronous Reluctance
of the reference Motors
induction motors, synchronous reluctance motor models are
builtAfter
in three power ratings
the analysis of the for the multi-parameter
reference induction motors, analyses and their
synchronous cross-effect
reluctance analyses
motor modelsat are
the
same time. Complete motor models are used to obtain high precision during pre-modelling
built in three power ratings for the multi-parameter analyses and their cross-effect analyses at the and post-
processing
same time. steps
Completeas in induction
motor modelsmotorare models.
used to obtain high precision during pre-modelling and
Graphical steps
post-processing illustrations of the rotor
as in induction motorbarrier
models.numbers and barrier shapes considered for the
numerical analysis are given in Figure 8. The
Graphical illustrations of the rotor barrier numbers andnumber ofbarrier
flux barriers is analyzedfortothe
shapes considered evaluate
numericalthe
influence on the performance of the motor. The finite element analysis is performed
analysis are given in Figure 8. The number of flux barriers is analyzed to evaluate the influence on the up to four flux
barriers sinceofflux
performance the barriers
motor. Thesaturate
finite after six,analysis
element and Ld-L inductances
isq performed upshow
to fournoflux
difference.
barriersThree flux
since flux
barriers saturate after six, and Ld -Lq inductances show no difference. Three flux barrier shapes are1
barrier shapes are evaluated. Rotor barrier number illustrations are given a to d for barrier number
to 4, accordingly,
evaluated. at section
Rotor barrier (A) and
number barrier shape
illustrations illustrations
are given a to d forare givennumber
barrier e to h for
1 toangular, round,
4, accordingly,
angular-round, and cut-off, accordingly, in Figure 8. The iron guides form an
at section (A) and barrier shape illustrations are given e to h for angular, round, angular-round, and angle with the flux
barriers at the angular (A) barrier shape. Off-centered round pieces create iron
cut-off, accordingly, in Figure 8. The iron guides form an angle with the flux barriers at the angular flux guides at the
round
(A) (R) flux
barrier barriers.
shape. Angular-round
Off-centered (A-R) iscreate
round pieces the last
irondesign, which is
flux guides atathe
combination
round (R)of thebarriers.
flux angular
and round barriers.
Angular-round (A-R) is the last design, which is a combination of the angular and round barriers.

(A) (B)
Figure 8. SynRM design parameters (A The number of rotor barriers per pole: (a) one barrier, (b) two
barriers, (c) three barriers, (d) four barriers, B Barrier Shape: (e) angular, (f) round, (g) angular-round,
(h) cut-off).

The torque characteristic results at rated load are given in Figure 9. The torque ripple due to the
number of flux barriers are listed in Table 10.

Table 10. Output Torques and their ripples due to the rotor barriers’ number for 2.2 kW SynRM motor.

Parameter 1 Barrier 2 Barriers 3 Barriers 4 Barriers

Torque (Nm) 15.1 17.9 19.1 24.4
Torque Ripple (%) 77 46 41 27
 Figure 8. SynRM design parameters (A: The number of rotor barriers per pole: (a) one barrier, (b) two
80
barriers, (c) three barriers, (d) four barriers, B: 2Barrier
1 Barrier BarriersShape: (e) angular, (f) round, (g) angular-round,
(h) cut-off). 3 Barriers 4 Barriers
60
The
Energies torque
2019, characteristic results at rated load are given in Figure 9. The torque ripple due 10
12, 2190 to ofthe
20
number of 40 flux barriers are listed in Table 10.

Torque [Nm]
80
20
1 Barrier 2 Barriers
3 Barriers 4 Barriers
600
0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13 0.14 0.15

40 Time [s]
-20
Torque [Nm]

20
-40

Figure
0 9. Torque profiles of the 2.2 kW SynRM due to the number of rotor barriers (Data from [22]).
0.05 0.06 0.07 0.08 0.09 0.1 0.11 0.12 0.13 0.14 0.15
Table 10. Output Torques and their ripples due to the rotor barriers’ number for Time
2.2 kW
[s] SynRM
-20
motor.

Parameter
-40 1 Barrier 2 Barriers 3 Barriers 4 Barriers
Torque (Nm) 15.1 17.9 19.1 24.4
Figure Torque
Figure9.
9.Torque
Ripple
Torque profiles
(%)
profiles of
of the
the 2.2
2.2 kW
77SynRM due
kW SynRM due to
46
to the
the number
41 27
number of rotor barriers (Data from [22]).

The rotor
Table structure
10. Output is notand
Torques very strong
their mechanically
ripples due to
due to the rotor the flux
barriers’ barriers.
number ThekW
for 2.2 tangential
SynRM end
bridges are designed to reinforce the rotor as shown in Figure 3. Making
motor. Making endend bridges
bridges very
very thin
thin results
results
in problems
problems for
formanufacturing
manufacturingprocesses.
processes.Increasing
Increasingthethe
end bridge
end thickness
bridge of the
thickness rotor
of the causes
rotor the
causes
torque decrease.Parameter
The output torque 1 Barrier
graph for the2 Barriers 3 Barriers 4 Barriers
the torque decrease. The output torque graph forsix
thedifferent structures
six different is given
structures in Figure
is given 10. The
in Figure 10.
normal Torqueof(Nm)
components flux densities 15.1
for for
endend 17.9thickness are
bridge 19.1 24.4
The normal components of flux densities bridge thickness aregiven
givenininFigure
Figure 11.
11. Also,
Also, the
comparativeTorque
torque Ripple
and flux(%) 77 are given46
density results in Table
given in 11. 41
Table 11. 27

The110rotor structure is not very strong mechanically due to the flux barriers. The tangential end
3 Barriers 0.5 mm 3 Barriers 1 mm 3 Barriers 1.5 mm
bridges are designed to reinforce the rotor as shown in Figure
4 Barriers 0.5 mm
3. Making end bridges
4 Barriers 1 mm
very thin results
4 Barriers 1.5 mm
90
in problems for manufacturing processes. Increasing the end bridge thickness of the rotor causes the
torque decrease.
70 The output torque graph for the six different structures is given in Figure 10. The
normal components of flux densities for end bridge thickness are given in Figure 11. Also, the
50
comparative torque and flux density results are given in Table 11.
Torque [Nm]

30
110
3 Barriers 0.5 mm 3 Barriers 1 mm 3 Barriers 1.5 mm
10
4 Barriers 0.5 mm 4 Barriers 1 mm 4 Barriers 1.5 mm
90
-10 0.04 0.06 0.08 0.1 0.12 0.14

70 Time [s]
-30
50
Torque [Nm]

-50
30

Figure 10. Torque outputs of 2.2 kW SynRM due to different end thicknesses for three and four barriers
10
(Data from [22]).
-10 0.04 0.06 0.08 0.1 0.12 0.14
Table 11. Air Gap Flux Densities and average output torque of 2.2 kW SynRM due Time
to different
[s] end
thicknesses
-30 for three and four barriers.

-50 Parameter 3 Barriers 4 Barriers

Thickness (mm) 0.5 1 1.5 0.5 1 1.5
Flux Density (T) 0.78 0.78 0.78 0.79 0.78 0.78
Torque (Nm) 28.9 23.9 19 29.9 24.7 19.8
 4 Barriers 0.5 mm 4 Barriers 1 mm 4 Barriers 1.5 mm
1.2

Energies 2019, 12, x FOR PEER REVIEW 11 of 20

0.7

Flux Density [T]

Figure0.210. Torque outputs of 2.2 kW SynRM due to different end thicknesses for three and four
Energies 2019, 12, 2190 11 of 20
barriers (Data from [22]).
-0.3 0.00 0.05 0.10 0.15 0.20 0.25 0.30

-0.8 3 Barriers 0.5 mm 3 Barriers 1 mm 3 Barriers 1.5 mm

4 Barriers 0.5 mm 4 Barriers 1 mm 4 Barriers 1.5 mm
1.2
-1.3
0.7
Flux Density [T]

0.2
Figure 11. Air gap flux density of 2.2 kW SynRM due to different end thicknesses (Data from [22]).
-0.3 0.00 0.05 0.10 0.15 0.20 0.25 0.30
Table 11. Air Gap Flux Densities and average output torque of 2.2 kW SynRM due to different end
-0.8 for three and four barriers.
thicknesses

Parameter -1.3 3 Barriers 4 Barriers

Thickness (mm) 0.5 1 1.5 0.5 1 1.5
Flux Density (T) 0.78 0.78 0.78 0.79 0.78 0.78
Torque
Figure 11. Air (Nm)
gap flux density of 2.228.9 23.9
kW SynRM 19
due to different 29.9
end 24.7 (Data19.8
thicknesses from [22]).
Figure 11. Air gap flux density of 2.2 kW SynRM due to different end thicknesses (Data from [22]).

The radial air gap width should be proposed as small as possible by considering the mechanical
The radial airGap
gapFlux
width shouldand
be average
proposed as small asofpossible by considering the mechanical
Table 11. Air Densities output torque 2.2 kW SynRM due to different end
limitations. The
limitations. The air
airgap
gapcancan
be uniform
be or cut-off
uniform or in the in
cut-off radial
the direction
radial for the synchronous
direction for the reluctance
synchronous
thicknesses for three and four barriers.
motor designs.
reluctance motor The flux density,
designs. average
The flux output
density, torque,
average andtorque,
output torqueand
ripple for different
torque airdifferent
ripple for gap values
air
are evaluated
gap Parameter
values areinevaluated
detail in Figures
in detail12
inand 3 Barriers
13, respectively.
Figures 12 and 13, respectively. 4 Barriers
Thickness (mm) 0.5 1 1.5 0.5 1 1.5
1 Flux Density (T) 0.78 0.78 0.78 0.79 0.78 0.78
Torque (Nm) 28.9 23.9 19 29.9 24.7 19.8
0.95 4 BARRIERS

Average Output Torque [Nm]Average Output Torque [Nm]

The radial
0.9
air gapmm
g=0.34 widthg=0.25
shouldmmbe proposed
cut-off as small as possible
g=0.34 mm g=0.25by
mmconsidering
cut-off the mechanical
Flux Density [T]

limitations. The air gap can be uniform or cut-off in the radial direction for the synchronous
reluctance0.85
motor designs. The flux density, average output torque, and torque ripple for different air
gap values are evaluated in detail in Figures 12 and 13, respectively.
0.8

1
0.75

0.95
0.7 4 BARRIERS

0.9
0.65 g=0.34 mm g=0.25 mm cut-off g=0.34 mm g=0.25Flux
mmDensitycut-off
Flux Density [T]

a r a-r a r a-r a r a-r a r a-r a r a-r a r a-r

0.85 Barrier Shape a: angular; r: round; a-r: angular-round

0.8
Figure 12. Flux
Flux density
density and
and average
average torque
torque of
of 2.2
2.2 kW
kW SynRM
SynRM for
for different
different number of barriers and air
0.75
gap values.
0.7
The ratio of the sum of flux barrier widths to the sum of iron guide widths in the q-axis direction
as ‘insulation ratio’, kq . If the rotor is completely made ofFlux
is defined0.65 ironDensity
without any saliency, the
kq would be equal to 0. If the total flux barrier width is equal to that of iron segment
a r a-r a r a-r a r a-r a r a-r a r a-r a r width, then kq
a-r
is equal to 1. Output torque characteristics of ther: synchronous
Barrier Shape a: angular; reluctance motors are presented in
round; a-r: angular-round
Figure 14. They are operated at the rated load with rated voltage and speed values given in Table 1.
The average
Figure 12.values at steady
Flux density andstate andtorque
average torqueof ripples as percentage
2.2 kW SynRM are summarized
for different in Table
number of barriers and 12.
air
gap values.
Energies 2019, 12, 2190 12 of 20
Energies 2019, 12, x FOR PEER REVIEW 12 of 20

Figure 13. Torque ripple of 2.2 kW SynRM for different number of barriers and air gap values.

The ratio of the sum of flux barrier widths to the sum of iron guide widths in the q-axis direction
is defined as ‘insulation ratio’, kq. If the rotor is completely made of iron without any saliency, the kq
would be equal to 0. If the total flux barrier width is equal to that of iron segment width, then kq is
equal to 1. Output torque characteristics of the synchronous reluctance motors are presented in Figure
14. They are operated at the rated load with rated voltage and speed values given in Table 1. The
average Figure
values13.
at Torque
steadyripple
state and
of 2.2torque ripples
kW SynRM for as percentage
different are
number of summarized ingap
barriers and air Table 12.
values.
Figure 13. Torque ripple of 2.2 kW SynRM for different number of barriers and air gap values.
200
The ratio of the sum of flux barrier widths to the sum of iron guide widths in the q-axis direction
is defined as ‘insulation ratio’, kq. If the rotor is completely made of iron without any saliency, the kq
would150be equal to 0. If the total flux barrier 2.2
width is equal to 4that
kW SynRM of iron segment
kW SynRM 5.5 kWwidth,
SynRM then kq is
equal to 1. Output torque characteristics of the synchronous reluctance motors are presented in Figure
14. They are operated at the rated load with rated voltage and speed values given in Table 1. The
100
average values at steady state and torque ripples as percentage are summarized in Table 12.
Moment [Nm]

50
200

1500 2.2 kW SynRM 4 kW SynRM 5.5 kW SynRM

0.04 0.06 0.08 0.10 0.12 0.14

-50
100
Moment [Nm]

-100
50 Time [s}

Figure 14. The

The output
output torque
torque variation for different power levels.
0
Table
Table Average Output
12. Average
0.0412. Output
0.06 Torques and
Torques 0.08their
and their torque
torque ripples
0.10 for
ripples for SynRM at
at different
SynRM0.12 differentpower ratings.
0.14
power ratings.

-50
4 Barriers
4 Barriers
Parameter Parameter
2.2 kW2.2 kW 4 4kW
kW 5.5 kW 5.5 kW
Torque (Nm)Torque (Nm) 14.1 14.1 25.2
25.2 35.03 35.03
-100
Torque Ripple (%) Ripple (%)18 Time
Torque 18 [s} 1717 22 22
Structural analysis of the
Figure newly
14. The designed
output motors is
torque variation foranother
differentimportant issue to be considered.
power levels.
The stress analysis of the prototyped motors is simulated in ANSYS
Structural analysis of the newly designed motors is another important issue in order to satisfy
to be the motor’s
considered.
The stress
Tableanalysis of the
12. Average prototyped
Output Torques motors
and theiristorque
simulated
ripplesinfor
ANSYS
SynRMin
at order to power
different satisfyratings.
the motor’s
−1
mechanical integrity. The simulation is performed at 1500 min and the mechanic characteristics of
4 Barriers
the rotor are given in Table 13. Parameter
2.2 kW 4 kW 5.5 kW
Torque (Nm) 14.1 25.2 35.03
Torque Ripple (%) 18 17 22
Structural analysis of the newly designed motors is another important issue to be considered.
The stress analysis of the prototyped motors is simulated in ANSYS in order to satisfy the motor’s
 Energies 2019, 12, x FOR PEER REVIEW 13 of 20

Energies 2019, 12, 2190 13 of 20

mechanical integrity. The simulation is performed at 1500 min−1 and the mechanic characteristics of
the rotor are given in Table 13.
Table 13. Mechanical Characteristics of Rotor Si-Steel.
Table 13. Mechanical Characteristics of Rotor Si-Steel.
Parameters M700
Parameters M700
Mass Density (kg/m3 ) 7800
Mass Density (kg/m3) 7800
Young Modulus (GPa) 210
Young Modulus (GPa)
Poisson Coefficient
210 0.31
Poisson(MPa)
Tensile Yield Strength Coefficient 0.31 300
Tensile
Tensile Ultimate Yield Strength
Strength (MPa) (MPa) 300 410
Tensile Ultimate Strength (MPa) 410

The mechanical analysis is performed to see the total deformation and the equivalent stress on
The mechanical analysis is performed to see the total deformation and the equivalent stress on
the rotor under the rated operation condition. The simulations and results for total deformation of
the rotor under the rated operation condition. The simulations and results for total deformation of
2.2
2.2kW
kWmotor
motorare
aregiven
givenin
inFigure
Figure 15
15 and Table 14,
and Table 14, respectively.
respectively.The
Theminimum
minimumtotal
total deformation
deformation and
and
maximum elastic strain values are listed for one and four barriers. A four-barrier structure
maximum elastic strain values are listed for one and four barriers. A four-barrier structure is moreis more
robust
robustthan
thanaasingle
singlebarrier
barrierwith
with the
the safety
safety factor of 12.217.
factor of 12.217.

(a) (b) (c) (d)

(e) (f) (g) (h)

Figure 15. Structural analysis of 2.2 kW motor with four-rotor barrier per pole (a) total deformation
Figure 15. Structural analysis of 2.2 kW motor with four-rotor barrier per pole (a) total deformation
(axial view), (b) total deformation (radial view), (c) Equivalent Elastic Strain (axial view), (d)
(axial view), (b) total deformation (radial view), (c) Equivalent Elastic Strain (axial view), (d) Equivalent
Equivalent Elastic Strain (radial view), (e) Equivalent Stress (axial view), (f) Equivalent Stress (radial
Elastic Strain (radial view), (e) Equivalent Stress (axial view), (f) Equivalent Stress (radial view),
view), (g) Safety Factor (axial view), (h) Safety Factor (radial view).
(g) Safety Factor (axial view), (h) Safety Factor (radial view).
Table 14.
Table 14. Structural
Structural analysis
analysisresults
resultsofof2.2
2.2kW
kWmotor.
motor.

Parameter Parameter 1 Barrier

1 Barrier 4 Barriers
4 Barriers
Maximum Total Deformation (µm) 29.296 16.755
Maximum Total Deformation (µm) 29.296 16.755
Maximum Elastic Strain (mm/mm) 1.942 × 10−4 1.1719 × 10−4
Maximum Elastic Strain (mm/mm) 1.942 × 10−4 1.1719 × 10−4
Maximum
Maximum Stress (MPa) Stress (MPa) 25,424 25,424 24,55524,555
Minimum
Minimum Safety FactorSafety Factor 64.525 64.525 12.21712.217
Maximum
Maximum Safety FactorSafety Factor 15 15 15 15

6.6.Prototype
PrototypeSynchronous
Synchronous Reluctance
Reluctance Motors
Motors
Theoverall
The overallresults
resultsare
areevaluated
evaluated after
after the
the multi-parameter
multi-parameter design
designprocess.
process.The
Thesynchronous
synchronous
reluctance models for prototyping are chosen considering technical parameters like efficiency,
reluctance models for prototyping are chosen considering technical parameters like efficiency, torque
torque
ripple, production process, etc. The same stator, fan, and housing frames of the reference induction
ripple, production process, etc. The same stator, fan, and housing frames of the reference induction
motors are used for newly designed synchronous reluctance motors. Rotor laminations are produced
motors are used for newly designed synchronous reluctance motors. Rotor laminations are produced
by using wire erosion cut. The lamination structure and motor views for three different power levels
by using wire erosion cut. The lamination structure and motor views for three different power levels
are given in Figure 16 and Figure 17a, accordingly.
are given in Figures 16 and 17a, accordingly.
Energies
Energies 2019,
2019, 12,
12, x2190
FOR PEER REVIEW 1414ofof 20
20
Energies 2019, 12, x FOR PEER REVIEW 14 of 20

Figure 16. Prototype motor sample lamination and the rotor [22].
Figure 16.
Figure Prototype motor
16. Prototype motor sample
sample lamination
lamination and
and the
the rotor
rotor [22].
[22].

(a) (b)
Figure
(a)
PrototypeSynRM
Figure 17. (a) Prototype SynRMMotors
Motorsatat
5.55.5
kW,kW, 4 kW,
4 kW, and and 2.2 (b)
2.2 kW;
(b) motormotor
kW;Prototype
(b) Prototype and itsand its
driver.
driver.
Figure 17. (a) Prototype SynRM Motors at 5.5 kW, 4 kW, and 2.2 kW; (b) Prototype motor and its
The ideal motor model achieved from multi-parametric FEM analyses is the angular four
driver.
variable-width
The ideal motor barriersmodel rotor that has kqfrom
achieved = 1 insulation
multi-parametric ratio. The FEM 4-kW prototyped
analyses is the motor
angular and its
four
test set are
variable-width shown in
barriers Figure
rotor 17b.
that The
has test
k = system
1 has
insulation a generic
ratio.
The ideal motor model achieved from multi-parametric FEM analyses is the angular four
q The variable
4-kW frequency
prototyped motor driver.
and its The
test
inverter
set are shownis supplied
variable-width in
barriers by a rotor
Figure variable
17b. that
The AC source.
test
has kqsystem However,
has a generic
= 1 insulation the
ratio.input voltage
variable
The of the inverter
4-kW frequency
prototyped motoris fixed
motor and during
driver. itsThe
test
the test.shown
inverter
set are Insupplied
is the in inverter
Figureby operating
a 17b. The menu,
variable AC the output
test source.
system has a power
However, generictheand speed
input
variable level of themotor
voltage
frequency motors
inverter are
is set
driver. fixed
Theto
the
duringrequired
the rated
test. In output.
the inverterThe inverter
operating sets
menu, the thespeed
output and
inverter is supplied by a variable AC source. However, the input voltage of the inverter is fixed output
power andpower
speed of the
level device
of the under
motors the
are
test.
set toTwo
during the power
therequired
test. In analyzers
rated
the are used
output.
inverter Thefor
operating themenu,
inverter measurements
sets
thethe speed
output inpower
the
andtest systems.
output
and power
speed Theoffirst
level the one
device
of the is located
motors underare
between
the test. the
Two variable
power AC source
analyzers and
are the
used inverter,
for the and the
measurements
set to the required rated output. The inverter sets the speed and output power of the device undersecond inone
the is located
test between
systems. The the inverter
first one is
and
located the motor.
the test.between
Two power Thus, the
the variable motor
analyzers ACareefficiency,
source
usedand inverter
for the efficiency,
the inverter,
measurements and system
and theinsecondthe test efficiency
one can
is located
systems. be obtained
Thebetween
first onethe is
separately.
inverter andAs
located between thea motor.
result,
the SynRM
Thus,
variable ACtheefficiency
motor and
source is the
calculated
efficiency, inverter
inverter, byand direct
the measurement
efficiency,
second and onesystem of converter
efficiency
is located between output
can thebe
power,
invertercorresponding
obtained separately.
and the motor. As toaThus,
motor
result, input
the SynRM power
motor (Pin ) and
efficiency
efficiency, the mechanical
isinverter
calculated power
by direct
efficiency, and output
systematefficiency
measurement theofmotor shaft
converter
can be
(P
output ).
mech power,
obtained The test
separately. system
corresponding has a
As a result, torque
to SynRM sensor
motor input to measure
power
efficiency the output
(Pin) and the
is calculated torque
by mechanicalof motor.
direct measurement The measurement
power output at the
of converter
is performed
motor
output shaft
power, (Pdue ).toThe thetest
corresponding
mech IECsystem
standards
to motorhas a60034-2-3
torque
input loading
sensor
power (Pto test. the
in) measure
and Six mechanical
operating
the output points
powerare
torque of performed
motor.
output atThe
the
due to
measurement the standard:
is performed 1.25, 1.15,
due 1,
to 0.75,
the IEC 0.5, and
standards25 times
60034-2-3
motor shaft (Pmech). The test system has a torque sensor to measure the output torque of motor. Theof the rated
loading load
test. at
Six the rated
operating speed.
points The
are
input
performed power,
measurement due Pisin ; the
output
toperformed torque,
standard: due1.25,Tout
to the ; stator
1.15, line 0.5,
IEC1,standards
0.75, current;
and I1 ;times
25
60034-2-3 phase-to-phase test. voltage,
of the rated
loading load
Six V; and
at the
operating ratedspeed,
speed.
points aren;
measurements
The
performed due are
input power, to Pthetaken
in ; outputfor torque,
standard: each loading.
1.25, T 1,The
out; stator
1.15, 0.75, load
line test
and results
0.5,current; are
of given
I1; phase-to-phase
25 times the ratedin Tables at15–17
voltage,
load the for 2.2
V;rated
and kW,
speed,
speed.
4The
n; kW, and power,
measurements
input 5.5 kW are SynRMs,
P taken respectively.
in; output for each T
torque, loading.
out; stator The
lineload test results
current; are given involtage,
I1; phase-to-phase Tables V;15–17
and for
speed,2.2
kW, 4 kW, and 5.5are
n; measurements kWtaken SynRMs, respectively.
for each loading. The load test results are given in Tables 15–17 for 2.2
kW, 4 kW, and 5.5 kW SynRMs, respectively.
Energies 2019, 12, 2190 15 of 20

Table 15. Load Test results of 2.2 kW SynRM.

Parameters 25% 50% 75% 100% 115% 125%

Voltage V (V) 396.6 436.5 455.5 452.1 453.8 450.3
Phase Current I1 (A) 2.34 3.25 4.03 4.91 5.95 7.16
Input Power Pin (W) 651 1275 1887 2490 3159 3843
Torque T (Nm) 3.52 7.04 10.56 14.1 17.6 21.1
Speed n (min−1 ) 1500 1500 1500 1500 1500 1500
Output Power Pout (W) 553.1 1106 1659 2212 2765 3318
Efficiency 85 86.8 87.9 88.9 87.6 86.4

Table 16. Load Test results of 4 kW SynRM.

Parameters 25% 50% 75% 100% 115% 125%

Voltage V (V) 461 469 485 478 457 473
Phase Current I1 (A) 3.84 5.59 7.14 8.8 10.9 13.38
Input Power Pin (W) 1147 2240 3326 4413 5540 6745
Torque T (Nm) 6.38 12.75 19.13 25.5 31.88 38.26
Speed n (min−1 ) 1500 1500 1500 1500 1500 1500
Output Power Pout (W) 1001.5 2003 3004.6 4006.1 5007.7 6009.2
Efficiency 87.3 89.4 90.3 90.8 90.4 89.1

Table 17. Load Test results of 5.5 kW SynRM.

Parameters 25% 50% 75% 100% 115%

Voltage V (V) 485 457 469 469.4 462
Phase Current I1 (A) 5.34 7.61 9.59 11.8 13.79
Input Power Pin (W) 1580 3052 4571 6013 7067
Torque T (Nm) 8.83 17.64 26.46 35.3 42.56
Speed n (min−1 ) 1500 1500 1500 1500 1459
Output Power Pout (W) 1387 2770 4156 5550 6501
Efficiency 87.8 90.8 90.9 92.3 92

Since the rated output power levels have been desired to be constant, the input voltage of SynRMs
are obtained slightly higher than the rated values of IMs as given in Tables 15–17.

7. Comparative Results
In this section, the comparative results are given for the reference induction motors and newly
designed synchronous reluctance motors for three different power ranges.

7.1. Performance
Table 18 shows the general motor parameters for both induction motors and synchronous
reluctance motors at the rated speed and torque. The torque is slightly different since the output power
is the same and the speeds are naturally different.

Table 18. Comparative Measured Performance Results (Frame-Size-Power Range).

2.2 kW (4 Pole) 4 kW (4 Pole) 5.5 kW (4 Pole)

Parameter 100 Frame 112 Frame 132 Frame
IM SynRM IM SynRM IM SynRM
Voltage (V) 400 452.1 400 478 400 469.4
Current (A) 4.95 4.91 8.3 8.8 11.1 11.8
Speed (min−1 ) 1450 1500 1455 1500 1465 1500
Torque (Nm) 14.48 14 26.25 25.46 35.85 35.01
cos θ 0.78 0.647 0.79 0.6 0.79 0.6
 IM
IM SynRM
SynRM IM
IM SynRM
SynRM IM
IM SynRM
SynRM
Voltage
Voltage(V)(V) 400
400 452.1
452.1 400
400 478
478 400
400 469.4
469.4
Current (A)
Current (A) 4.95
4.95 4.91
4.91 8.3
8.3 8.8
8.8 11.1
11.1 11.8
11.8
Speed
Speed(min
(min−1))
−1 1450
1450 1500
1500 1455
1455 1500
1500 1465
1465 1500
1500
Torque
Torque (Nm) 14.48 14 26.25 25.46 35.85 35.01
Energies 2019, 12, 2190 (Nm) 14.48 14 26.25 25.46 35.85 35.01 16 of 20
cos θ
cos θ 0.78
0.78 0.647
0.647 0.79
0.79 0.6
0.6 0.79
0.79 0.6
0.6

The
Thereference
referenceIMs IMsand
andnewly
newlydesigned
designedSynRMs
SynRMs are areforced
forcedto tostart
startwith
withfull
fullload condition
loadcondition
conditiontoto
determine the starting
starting capability
capability of
of the
the motors.
motors. As a result, the motors can start at full
determine the starting capability of the motors. As a result, the motors can start at full load conditionload condition
for each
foreach power
eachpower
power rating
rating with
with
rating no
no problems.
no problems.
with The
The controller
The controller
problems. isis not
not designed
is not designed
controller by
by the
by the authors.
designed The
the authors. The
prototyped
authors. The
prototyped
SynRM SynRM
motors are motors
driven are
by adriven
generic by a generic
commercial commercial
controller. controller.
There wereThere
prototyped SynRM motors are driven by a generic commercial controller. There were no problems no were
problems no problems
either for
either
startingfor
orstarting
operating. or operating.
either for starting or operating.
Torque
Torque
Torquevs vs current
vscurrent graphs
currentgraphs
graphsofof IMs
ofIMs and
IMsand SynRMs
andSynRMs
SynRMsareare given
aregiven Figure
givenFigure
Figure18.18.
18.These
Thesedata
datasets
setsare
areevaluated
evaluated
under 1500 min −1
−1 for
for SynRMs
SynRMs and
and near
near 1500
1500 min
min −1
−1 for
forIMs.
IMs.
under 1500 min for SynRMs and near 1500 min for IMs.
−1 −1

25 45
45 50
25 50
40
40 45
45
20
20 35 40
40
35
30 35
35
[Nm]
30

[Nm]
[Nm]

Torque[Nm]

Torque[Nm]
Torque[Nm]

15
15 25 30
30
25
25
Torque

25

Torque
Torque

20
20
10
10 20
20
15
15 15
15
10
10
55 2,2 kW IM
2,2 kW IM
4 kW IM
4 kW IM 10
10 5,5 kW IM
55 5,5 kW IM
2,2 kW SynRM
2,2 kW SynRM 4 kW SynRM
4 kW SynRM
55 5,5 kW SynRM
5,5 kW SynRM
00 00 00
33 88 13
13 44 99 14
22 44 66 88 14
Current
Current[A]
[A]
Current [A] Current
Current[A]
[A]
Current [A]
(a)
(a) (b)
(b) (c)
(c)
Figure
Figure18.
Figure 18.Comparison
18. Comparison of
ofTorque
of Torquevs.
Torque vs.Current
vs. Currentfor
Current for(a)
for (a)2.2
(a) 2.2kW,
2.2 kW, (b)
(b)444kW,
kW,(b) kW, and
kW,and (c)
and(c) 5.5
(c)5.5 kW.
5.5kW.
kW.

IMs
IMsperform
performhigher torque
highertorque values
torquevalues
valuesatatthe
thesame
samecurrent
currentvalues
valuesas
asgiven
givenininFigure
Figure18
18since
sinceSynRMs
SynRMs
have lower power factors. Input power vs. Torque graphs are presented
have lower power factors. Input power vs. Torque graphs arepresented
presentedinin Figure
inFigure 19.
Figure19.
19.

4000 7500
7500 8000
4000 8000
2.2
2.2kW
kWIM
IM 4 kW IM
4 kW IM 5.5 kW IM
5.5 kW IM
3500 2.2 6500 7000
3500 2.2kW
kWSynRM
SynRM 6500
4 kW
7000 5.5 kW SynRM
4 kW 5.5 kW SynRM
5500 SynRM
3000
3000 5500 SynRM 6000
6000
4500
[W]

2500
[W]

4500 5000
[W]
PPinin[W]

2500
PPinin[W]

5000
PPinin[W]

2000 3500
3500 4000
2000 4000
1500 2500
2500
1500 3000
3000
1000 1500
1500
1000 2000
2000
500
500 500
500 1000
1000
11 11
11 21
21 55 25 45
25 45 55 25 45
25 45
Torque
Torque[Nm]
[Nm] Torque
Torque[Nm]
[Nm] Torque
Torque[Nm]
[Nm]

(a)
(a) (b)
(b) (c)
(c)
Figure
Figure19.
Figure 19.Comparison
19. Comparisonof
Comparison ofInput
of InputPower
Input Powervs.
Power vs.Torque
vs. Torquefor
Torque for(a)
for (a)2.2
(a) 2.2kW,
2.2 kW, (b)
(b)444kW,
kW,(b) kW, and
kW,and (c)
and(c) 5.5
(c)5.5 kW.
5.5kW.
kW.

The torque vs. total losses of the motors are given in Figure 20. The total losses of the SynRMs are
less than those of the IMs for the same torque values.
 Energies 2019, 12, x FOR PEER REVIEW 17 of 20

The torque vs. total losses of the motors are given in Figure 20. The total losses of the SynRMs
Energies 2019, 12, 2190 17 of 20
are less than those of the IMs for the same torque values.

700 1000 800

4 kW IM 5.5 kW IM
2.2 kW IM 900 4 kW SynRM 5.5 kW SynRM
600 2.2 kW SynRM 700
800
500 700 600

Total Losses [W]

Total Losses [W]

Total Losses [W]

600
400 500
500
300 400 400
300
200 300
200
100 100 200
0
0 100
0 10 20 30 40 0 20 40
0 10 20 Torque [Nm]
Torque [Nm] Torque [Nm]

(a) (b) (c)

Figure20.
Figure 20.Comparison
Comparison of
of Total
Total Losses
Losses vs.
vs. Torque for (a)
Torque for (a) 2.2
2.2 kW, (b) 4
kW, (b) 4 kW, and (c)
kW, and (c) 5.5
5.5 kW.
kW.

7.2.
7.2.Active
ActiveMaterial
Material
The
Thesynchronous
synchronous reluctance
reluctance motors
motors werewere designed
designed while keepingkeeping the the same
same stator
stator design,
design,
ampere-turns, and stack heights, with the reference induction motors for
ampere-turns, and stack heights, with the reference induction motors for all three power ranges all three power rangesin
inthis
thisstudy
studyasasindicated
indicatedabove
abovesections.
sections.The
Themain
maindifference
differenceisisthe
therotor
rotorframes
framesbetween
betweenthe thereference
reference
induction
inductionmotors
motorsandandthe
thenewly
newlydesigned
designedsynchronous
synchronous reluctance
reluctance motors. All All other
otheractive
activematerials,
materials,
such as laminations and stator conductors, are kept the same, except for the
such as laminations and stator conductors, are kept the same, except for the rotor conductor.rotor conductor. The rotor
The
ofrotor
an induction motor includes
of an induction magnetic
motor includes steel andsteel
magnetic aluminum alloy as an
and aluminum active
alloy material.
as an The rotorThe
active material. of a
synchronous reluctancereluctance
rotor of a synchronous motor includes
motor only magnetic
includes steel. Since
only magnetic steel.the stator
Since thelamination and stator
stator lamination and
stator windings
windings are keptare
thekept
same, the same,
the only the only difference
difference between between
the IM andtheSynRM
IM andmotors’
SynRMmaterial
motors’ cost
material
is on
cost
the is on
rotor the The
side. rotoractive
side. material
The active material
usage usage
is shown forisboth
shown for motors
of the both of in theTable
motors
19. in Table
This will19. This
give an
willabout
idea give an idea about
material costsmaterial costs of the motors.
of the motors.

Table 19.Rotor
Table19. RotorMaterials
Materialsof
of IM
IM &
& SynRM
SynRM (in
(in pu).
pu).

2.2 kW 2.2 kW 4 kW
4 kW 5.55.5
kW kW
MaterialMaterial
IM IMSynRM SynRM IMIM SynRM
SynRM IMIM SynRM SynRM
Magnetic
Magnetic steel steel 0.79 0.790.79 0.79 0.790.79 0.79
0.79 0.88
0.88 0.88 0.88
Aluminum
Aluminum conductor conductor0.21 0.21 - - 0.210.21 -- 0.11
0.11 - -
Total active
Totalmaterial at rotor at rotor
active material 1 1 0.79 0.79 1 1 0.79
0.79 1 1 0.88 0.88

7.3.Thermal
7.3. ThermalPerformance
Performance
Thethermal
The thermalregime
regime ofof
thethe windings
windings should
should be be reached
reached before
before applying
applying the the performance
performance tests.tests.
The
The thermal test is performed at the nominal load. The ambient and winding
thermal test is performed at the nominal load. The ambient and winding temperatures are measured temperatures are
measured
before before
starting starting
the test. Thethe test.should
motor The motor should be
be operated operated
at the at theuntil
rated load rated
theload until the
winding winding
temperature
temperature does not◦ change ◦ at 1 °K or 1 °C in a half hour measurement period.
does not change at 1 K or 1 C in a half hour measurement period. The motor reaches the thermal The motor reaches
the thermal steady state regime if this condition is satisfied. All the electrical, mechanical,
steady state regime if this condition is satisfied. All the electrical, mechanical, and thermal motor and thermal
motor parameters
parameters are recorded,
are recorded, such assuchinputaspower
input power
Pin (W), Pinoutput
(W), output
torquetorque Tout (Nm),
Tout (Nm), line line current
current I1
I1 (A),
(A), phase-to-phase voltage V (V), speed n (min
−1 −1), frequency f (Hz), stator phase winding resistance
phase-to-phase voltage V (V), speed n (min ), frequency f (Hz), stator phase winding resistance
R1(ohms),and
R1(ohms), andwinding
windingtemperature
temperature(◦(°C).C).
The thermal analysis for the SynRMs
The thermal analysis for the SynRMs is is performed
performed usingusing MOTORCAD
MOTORCAD software software (V10.2.3,
(V10.2.3,Motor
Motor
DesignLimited,
Design Limited,Wrexham,
Wrexham,UK). UK).The Thegeometry
geometryisisapplied
applied with
with cooling
cooling types
types and
and the
the fin
fin thicknesses
thicknesses
as input. The analytical thermal calculations are performed, and the results are compared to those at
as input. The analytical thermal calculations are performed, and the results are compared to those
the rated current values. The initial temperature of the winding for 2.2 kW SynRM is 22 °C and it
at the rated current values. The initial temperature of the winding for 2.2 kW SynRM is 22 ◦ C and it
reaches 55 °C at the end. Similarly, the temperature test is performed for the 2.2 kW induction motor.
reaches 55 ◦ C at the end. Similarly, the temperature test is performed for the 2.2 kW induction motor.
The induction motor reaches higher temperature values at the same ratings. The results are given in
Table 20.
Energies 2019, 12, x FOR PEER REVIEW 18 of 20

Energies 2019, 12, 2190 18 of 20

The induction motor reaches higher temperature values at the same ratings. The results are given in
Table 20.
Table 20. Winding Temperatures of 2.2 kW motors.
Table 20. Winding Temperatures of 2.2 kW motors.
SynRM IM
Parameter SynRM
MOTORCAD Test IM Test
Temperature (◦ C)
Parameter 56.1MOTORCAD55 Test Test
64.1
Temperature (°C) 56.1 55 64.1
The MOTORCAD results are shown in Figure 21 for the 2.2 kW SynRM.
The MOTORCAD results are shown in Figure 21 for the 2.2 kW SynRM.

(a)

(b)

(c)
Figure
Figure21.
21.Thermal
Thermalanalysis
analysisof
of2.2
2.2kW
kWSynRM
SynRM (a)
(a) radial, (b) axial,
radial, (b) axial, (c)
(c) nodal
nodal equivalent
equivalentrepresentation.
representation.

TheThe lack
lack of of rotor
rotor copperbars
copper barsaffects
affects the
the thermal
thermal results
resultsand
andefficiency as as
efficiency well.
well.

7.4. Vibration and Comfort Performances

Since the torque ripple is an important parameter for motor design procedure, after producing
prototype SynRM motors, vibration tests are performed. Permitted vibration accelerations are given
in IEC 60034-14 standards. The upper limit is defined for the motor producers as 2.5 m/s2 for free
suspension between 56 and 132 frame motors [23]. The vibration and torque ripple comparison of
Energies 2019, 12, 2190 19 of 20

7.4. Vibration and Comfort Performances

Since the torque ripple is an important parameter for motor design procedure, after producing
prototype SynRM motors, vibration tests are performed. Permitted vibration accelerations are given
in IEC 60034-14 standards. The upper limit is defined for the motor producers as 2.5 m/s2 for free
suspension between 56 and 132 frame motors [23]. The vibration and torque ripple comparison of
SynRM motors is presented for different power levels in Table 21. The torque ripple results are output
of the FEM analysis. It can be seen that the SynRM motors have higher vibration and torque ripple
values than those of reference IMs.

Table 21. Vibration and Torque Ripple Comparison.

Vibration (m/s2 ) Torque Ripple (%)

Power
IM SynRM IM SynRM
2.2 kW 0.267 1.43 13.5 18
4 kW 0.273 1.67 15.2 17
5.5 kW 0.316 1.82 20 22

8. Conclusions
In low-power industrial applications product groups, efficiency, cost, and power density play an
important role when system requirements are considered. In this study, three different power stage
induction motors (2.2 kW, 4 kW, and 5.5 kW) are taken as the reference motors. The main aim of this
study is to design and make a comparison of synchronous reluctance motors. The main difference
between the induction motors and the synchronous reluctance motors is the rotor structure. The stator
structure and radial air gap length are kept constant for both IMs and SynRMs. Different types of
rotor design parameters are considered to make a complementary design. After the selection of the
best models for each power level, the selected models are prototyped and tested for measuring their
performance. SynRM has slightly higher efficiency than IM since rotor losses are eliminated. Main
drawback of SynRMs are the low-power factors. IMs provides higher torque values at the same current
levels and requires lower input power for the same output power.
As a result, considering losses, cost, and power density, the newly designed synchronous reluctance
motor prototypes give an alternative compared to the reference induction motors. The stator winding
can also be designed for a future work to justify the input voltage levels of SynRMs. Increasing the stack
length would be another solution to decrease voltage levels. The reliability, torque ripple, vibration
improvements, and power factor optimization are worth investigating further.

Author Contributions: All the authors contributed substantially to the paper. Conceptualization, M.I. and
L.T.E.; methodology, M.I. and L.T.E.; software, U.E.D. and N.G.O.; validation, U.E.D., N.G.O., M.I. and L.T.E.;
writing—original draft preparation, N.G.O., L.T.E.
Funding: This research was funded by TUBITAK grant number 1140055 and by ITU-AYP-2014-3 Project financially.
Acknowledgments: The authors gratefully thank to Cenap ERTURK and Hakan GEDİK at ARÇELİK Çerkezkoy
Plant and CEDRAT, France for supporting the R&D studies at universities.
Conflicts of Interest: The authors declare no conflict of interest.

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