IEEE PEDS 2017, Honolulu, USA

12 – 15 December 2017

Design Considerations on a 36-Slot 28-Pole

Permanent Magnet Drive
Boris Dotz1, Matthias Ippisch2, Dieter Gerling2
1
FEAAM GmbH, Neubiberg, Germany
2
Universitaet der Bundeswehr Muenchen, Germany
b.dotz@feaam.de, matthias.ippisch@unibw.de , dieter.gerling@unibw.de
TABLE 1: MOTOR AND PERFORMANCE REQUIREMENTS
Abstract- High torque permanent magnet drives with short axial
length and large outer diameter are well known to be suitable
for hybrid traction applications. High pole numbers and a large Requirement Target Value
rotor inner diameter allow for direct crankshaft mounting and Total axial length 95 mm
therefore for a compact integration of the electrical machine.
Pole pair numbers vary from four to ten depending on the ratio Stator outer diameter 265 mm
of outer to inner diameter. Decreasing installation space and Rotor inner diameter 184 mm
increasing torque demands require higher pole pair numbers
resulting in higher excitation frequencies and high iron losses. Air gap length (min) 1 mm
This research presents design considerations on a 28 pole 25 kW Rated/ Maximum speed 2400 rpm / 6000 rpm
permanent magnet drive with high short time overload
Power (continuous / 55 s / 10 s) 25 kW / 55 kW / 65 kW
capability. Electromagnetical, mechanical and thermal aspects
are discussed. Torque (continuous / 55 s / 10 s) 100 Nm / 225 Nm / 265 Nm

I. INTRODUCTION Torque ripple <5%

While full electrical vehicles use a broad spectrum of
electrical machines, i.e. induction machines, permanent
magnet (PM) as well as current excited synchronous drives,
PM or PM assisted machines are still state-of-the-art for
hybrid electrical vehicles due to the high power density
requirement. To take advantage of both, combustion engine
and electrical machine, a parallel or series-parallel hybrid
topology is often chosen coming with tight requirements on
the installation space for the electrical machine [1, 2]. Recent
developments show a clear trend towards increasing power to
allow for high performance even in case of large vehicles [3].
For winding topologies, concentrated as well as distributed
windings are used [4, 5]. A crankshaft mounting of the PM
machine is often considered to provide compact integration of
the drive [6, 7], which requires a large rotor inner diameter
and short axial length. Consequently, pole numbers vary from
eight up to 20 depending on the specific power targets,
available installation space and ratio of outer to inner
diameter. This research presents a case study on a 25 kW
interior permanent magnet drive with 28 poles and high
overload capability. The aim of this research is to evaluate
design measures necessary to cope with high electrical
frequencies of up to 1400 Hz and to estimate resulting
efficiencies. The electromagnetical design, as well as
mechanical and thermal aspects are discussed and examined
using finite element analysis.
This paper is structured as follows: Section II and III
present project requirements and preliminary considerations.
Section IV and V discuss stator and rotor topologies,
respectively. Power, losses and efficiency are presented in
section VI, while the thermal evaluation is presented in
section VII.
DC bus voltage 320 V
Reference coolant temperature 60 °C
II. PROJECT REQUIREMENTS
Main project challenges are given by narrow rotor and
stator yoke heights, short axial length (including winding
overhangs) and high peak torque required for up to 55
seconds. Further specifications include low cogging torque
and torque ripple below 5 % over the total torque speed
range. As on-load voltage distortion is known to increase
torque ripple and to decrease field weakening region,
additional attention is drawn on a low over voltage distortion
factor ( ) as defined in [8]. Project requirements are
summarized in Table 1. Please note that project constraints
already define the motor type to a radial flux, inner rotor 28
pole machine. Possibilities on outer rotor or axial flux
machines are therefore not considered. Topologies with 20
poles are well known and are therefore not part of this
study [6]. The task is consequently given by finding a 28 pole
topology which sufficiently fulfills all requirements and
provides adequate efficiency.
III. PRELIMINARY CONSIDERATIONS
Due to the high pole number set by project specifications,
fractional-slot concentrated windings are considered. Possible
winding topologies are summarized in Table 2. 42 slots
topology with slots per pole and phase = 0.5 results in a
low winding factor, high torque ripple and a high on-load
voltage distortion. Therefore, preliminary considerations are

978-1-5090-2364-6/17/$31.00 ©2017 European Union

360
________________________________________________________________________________________________________________________________________________________________________
Fig. 1. a) - d) Rounding of tooth tips to provide a smooth current loading. Final design according to c).
__________________________________________________________________________________________________________________________________________________________________
performed on remaining topologies with
= 3⁄7.
TABLE 2: REASONABLE SLOT/ POLE COMBINATIONS
Slots/pole/phase Slots Poles 2 Winding factor
= 2⁄7 24 28
= 3⁄7 36 28
= 1⁄2 42 28
For the comparison, two stators are designed applying
basic sizing equations, assuming an air gap flux density of
= 1 T, a maximum iron flux density of 1.5 T and a current
density of 9.0 A/mm . Total axial length of winding
overhangs is estimated to 30 mm and 40 mm for 36- and 24-
slot topologies, respectively. The iron sheet is NO20 with loss
data obtained from measurements of punched samples.
Although the 24-slot topology results in a high winding
factor, the comparison proved rotor iron losses to be too high,
mainly due to sub and slot harmonics of ordinal numbers =
1 and = 5. Furthermore, because of wider slots thermal
utilization is expected to be lower for the 24 slots topology
(refer to section V). Consequently, the topology with 36 slots
and 28 poles is selected for further investigations. A similar
topology has been previously considered for an IPM machine
with high field weakening region in [9].
IV. STATOR DESIGN
The optimization of the stator design focusses on three
main aspects, i.e. avoiding saturation, providing required
short time overload and limiting AC and iron losses at high
speed and flux weakening region.
A. Stator Yoke and Teeth Design
After several iterations, yoke thickness and teeth width is
set to 5mm and 9mm, respectively. Resulting flux densities
in yoke and teeth at rated condition are given by 1.49 T and
1.53 T. Stator inner diameter is given by 211 mm resulting in
a split ratio of
= = 0.8
and a slot width ratio of
= = 0.49,
= 2⁄7 and
0.9330
0.9019
0.8660
Fig. 2: Resulting tangential field strength for topologies depicted in Fig.
1. Final design according to c).
where and denote the stator inner and outer diameter,
denotes the teeth width and the slot pitch. The flux
density ratio defined in [10] results in
√
= = 0.54. (3)
Obtained results (1-3) are close to the analytical optima
presented in [10, 11].
B. Design of Slot Opening and Tooth Tips
In [12, 13] it is shown that certain space harmonics can be
damped or even cancelled by choosing a proper slot opening
width. At the same time a minimum slot opening is often
determined by required stray inductance to increase field
weakening performance. Therefore, the optimum slot opening
is set by careful parameter variation using FEA. To allow for
required field weakening, slot opening results in
= 2 mm. (4)
Additionally, tooth tips are rounded off to provide an even
gauss-like current loading distribution along the slot opening.
The design variations on the tooth tips are depicted in Fig. 1.
Using classical theory, it can be shown that a multiplication
of winding factors in the harmonic domain correlates with a
convolution of current loading in space domain. The slot
opening factor can therefore be derived by performing a
Fourier series expansion of the current loading along the slot
(1) opening, which is equal to the tangential field strength
for → ∞. Fig. 2 depicts the current loadings for topologies
shown in Fig. 1. It can be seen that a stronger rounding results
(2) in smoother current loading. Fig. 3 depicts numerically
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 saturation limit, the rotor design must assure a high quality
field. This is discussed in section V. The AC factor is
calculated according to classical equations [16, 17]
,
⁄
= ⁄
, (10)

where , denote copper length of winding overhangs and

copper length embedded in iron parts, respectively. , is
given by
,
= ( )+ ( ), (11)

with auxiliary functions ( ) and ( ) and vertical number

Fig. 3: Resulting slot opening factors for designs depicted in Fig. 1. Final of layers [16, 17]. The geometry correction factor takes
design according to c). into account round wires and is given by
calculated slot opening factors, where the analytical factor for = (12)
rectangular current loadings according to
( )
( ) ≅ 1 [18]. Calculated AC factors are then given by
for
= (5) , 2000 rpm = 1.031 and , 6000 rpm = 1.281.
Please note that latter value is close to the critical AC factor
of 1.33 indicating optimal copper utilization at high
is shown as well. It is evident that a smoother current loading
speed [16].
leads to less harmonics at high ordinal numbers. Hereby iron
losses are slightly decreased. Additionally, torque ripple is
reduced. The idea of a smooth current loading might explain V. ROTOR DESIGN
the teeth shape presented in [14], where a fully automated Rotor design determined by three main considerations, i.e.
numerical optimization has been performed. providing a high quality air gap field of high flux density,
C. Winding Connection avoiding demagnetization risks and providing reasonable
Field penetration depth for copper at 1400 Hz is given by mechanical strength.
= = 2.1 mm. (6) A. Magnet Configuration and Pole Shape Design
For magnet configurations, V-shape as well as tangential
Due to the small penetration depth it is essential to limit AC magnet topologies are considered. A V-shape configuration is
losses by reducing conductor height. Consequently, four often chosen to increase reluctance torque as well as to
parallel branches are chosen. Using a star connection, = provide flux concentration. Nevertheless, due to the small
19 turns per coil are feasible within the voltage limit, pole pitch and the thin rotor yoke only small saliency
resulting in a wire diameter of approximately 1.95 mm. To ratios can be achieved. Consequently, reluctance torque for
increase the number of turns per coil, a delta connection is such high pole numbers is in the order of a few percent of the
considered, whereby the number of turns can be increased up main torque. Therefore, the focus shifts from a high saliency
to = 32, decreasing wire diameter to 1.50 mm. Let ratio to a low permanent magnet field distortion.
denote the number of phases and the DC phase A tangential magnet topology is therefore chosen for
resistance. Using AC factor , ohmic losses for both setups further optimization. Magnet width and height are optimized
are given by to 20 mm and 5 mm respectively. The magnet material is
, = , , , (7) Vacodym 956TP. Calculated pole coverage results in
, = 0.839. (13)
, = , 1+ , , (8)
,
In [19–22], several pole shapes are discussed which allow to
where denotes the additional circulating current appearing improve the PM field. It is well known that an air gap
in the delta branches with three times main frequency. From function according to
(7-8) it can be seen that despite circulating currents, a delta
connection is preferable when ( )= , where ∈ − ; (14)
( )

,
, = , 1+ ≤ .
(9) provides a sinusoidal air gap field where
, denotes the pole
,
shape coverage. This approach is chosen for the design under
Circulating currents are known to originate from 3 investigation. is fixed to 1 mm. Fig. 4 depicts the air gap
harmonics due to nonsinusoidal rotor field and saturation field for different . To provide insights on the field
effects [15]. While flux density according to IV.A is below improvement Fig. 5 depicts the THD as well as the amplitude

362
 Fig. 6: Final stator teeth and rotor pole design.

Fig. 4: Air gap field for different pole shape coverage .

Consequently, ohmic losses remain constant and can only be
reduced by reducing the air gap height or flux density, or by
increasing stray inductance. Short circuit current for the
machine under investigation is estimated to
= 1.28 p. u. (18)
of the rated current, whereby winding overhangs are not
considered. Equation (18) therefore denotes a worst case
estimation. According to specifications, this current must be
feasible for at least 4 min of operation time. This
consideration is dealt with in section VII.
Demagnetization limit is studied by setting a negative d-
Fig. 5: Resulting rotor THD and main field harmonic over
current while considering remanence flux density at the upper
pole coverage . magnet side. This is done at three different magnet
temperatures, whereby material properties are adjusted
of the main harmonic. It can be seen that a pole shape according to the datasheet. Table 3 shows the knee point
coverage of about 0.7 provide reasonable improvement in remanence density at different temperatures as well as
field quality. The THD is decreased from 21 % down to 2 % evaluated maximum feasible p.u. current. Temperatures
while the main harmonic is decreased by 3 % to = 0.97 T. above 140 °C must be avoided. At maximum temperature,
The air gap function between poles is set according to current limit is given by three times the rated current. For a
sudden short circuit operation, the maximum current for PM
( )= , where ∉ − ; (15) drives is given by twice the continuous short circuit
( ) ( ) current [23].
which gives slight improvements for the chosen coverage of , = 2⋅ = 2.56 p. u. 3 p. u. (19)
= 0.675 and takes into account the trapezoidal field From (19) it can be seen that the machine is save against
distribution of the original topology. irreversible demagnetization at maximum operation
As magnet pockets must be manufactured slightly larger temperature and sudden short circuit condition.
than the magnets, pockets are increased by 0.15 mm in all
directions. Fig. 6 depicts the final pole and teeth shape. TABLE 3: FEASIBLE CURRENTS TO AVOID IRREVERSIBLE MAGNET
DEMAGNETIZATION
B. Short Circuit Current and Demagnetization
For continuous short circuit current, the following holds Max. | |⁄
Temperature ⁄( ° ) Min. ⁄( )
true
100 0 6.6
= ∝ ∝ ⋅ ⋅ , (16) 120 0.2 5.5
140 0.4 3.0
where again denotes the total number of turns per phase.
From (16) it can be seen that continuous short circuit current
can be designed below critical inverter limit by increasing the C. Mechanical Stability
number of turns per coil. Nevertheless, latter approach does Mechanical stability is verified using a 2D rotor section
not hold true for the thermal machine limitation as the phase and evaluating the maximum stress at different rotor speeds.
resistance is Material yield strength of NO20 iron sheets is given by
∝ . (17) 400 MPa. At 7200 rpm, i.e. 120 % of maximum speed

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 Fig. 9: Comparison on simulated rotor iron losses normalized on torque.

Fig. 7: Simulation results for mechanical stress at 7200 rpm.

material stress is evaluated to 222 MPa (Fig. 7), while at

8400 rpm maximum material stress is given by 301 MPa.
Latter corresponds to 75 % of the material yield strength, a
value suggested in [24]. Consequently, the design is
considered mechanical stable. In fact, even thinner bridges
are possible in case the burst speed is fixed to 7200 rpm as
defined by standardization IEC 60034.

VI. PERFORMANCE EVALUATION Fig. 10: Comparison on simulated total iron losses normalized on torque.

Torque, power and efficiency are estimated using ANSYS

Maxwell. To estimate torque performance and iron losses a
= = 4.47 . (21)
2D model is used, while a 3D model is employed in √
Section B to calculate magnet losses. Active mass is given by 12.5 kg resulting in a rated power to
A. Torque-Speed Performance weight ratio of 2.0 kW/kg and a torque to weight ratio of
Fig. 8 shows the torque and power at rated condition. 8.0 Nm/kg.
Torque ripple is below 3 % over the entire torque speed B. Losses and Efficiency
envelope, while cogging torque is simulated to 0.2 Nm. Iron losses are calculated in post processing, using loss
Therefore, torque requirements are met by presented design. density over frequency tables for the NO20 steel and a 2D
To provide an estimate on voltage distortion, is FEA model. Rotor and total iron losses are depicted in Fig. 9
calculated according to [8] and Fig. 10, respectively. It can be seen that the optimized
design significantly reduces iron losses compared to the
= . (20)
initial basic design. Ohmic losses are calculated analytically
For the entire speed range remains below 3.1 %, which assuming an average copper temperature of 130 °C. AC
verifies high field quality. With current loading , air gap losses as well as circulating currents are taken into account as
flux density and winding factor , Esson’s Number for presented in section IV.C. Magnet losses are simulated using
rated operation is given by a 3D model with axial segmentation of 5 mm. Additional
inverter harmonics are calculated analytically as presented
in [25], whereby a sinus triangular modulation and a
switching frequency of 20 kHz are assumed. Current
harmonics are then fed to the model to get a more adequate
estimation on magnet losses. Mechanical losses are not
considered. Resulting efficiencies are summarized in Table 4.
Main challenges in manufacturing a prototype are given by
increased saturation and iron losses due to steel processing.
Furthermore, larger switching harmonics and related magnet
eddy current losses using lower switching frequencies can
Fig. 8 Torque and power over speed for rated current supply. occur. Efficiencies of 92-94 % should therefore be expected.

364
 drawback of an integral term within an infinite sum. A more
practical solution can be obtained following the calculations
described in [27]. With = 0 and slot width and height
and respectively, the solution is given by

( , )= ⋅
( ( ) )( ( ) )
⋅∑ ∑ sin sin . (24)

The hot spot appears at = ⁄2 and = ⁄2. Because the

double sum in (24) converges quickly, it is reasonable to
consider , ≤ 3. The result is then given by

≈ − + . (25)
Fig. 11: Temperature distribution over slot area, whereby and denote
directions along slot height and width, respectively. Equation (25) allows to calculate copper overtemperature
easily. With (23), it is also possible to calculate the maximum
TABLE 4: ESTIMATED EFFICIENCIES FOR DIFFERENT OPERATION POINTS
current density
⋅
Iron Ohmic ≈ − + . (26)
Op. Point Magnet Losses Efficiency
Losses Losses
Rated operation 412 W 11 W 419 W 96 %
Equation (26) allows to estimate the current density prior to
detailed design and thermal simulations. Also it shall be noted
Max. speed 520 W 41 W 521 W 95 % that average copper temperature can be calculated
Max. torque 55s 551 W 34 W 3262 W 92 % analytically according to

= ( , )d d . (27)
VII. THERMAL EVALUATION
Equation (27) can then be used to define the copper to iron
To provide estimations on feasible current densities, a two- thermal resistance which allows to estimate short time
step evaluation is chosen. First, feasible current densities are transient behavior analytically. The detailed discussion is
estimated analytically. Once the design is fixed, a verification beyond the scope of this paper.
using 2D FEA is performed. Both approaches are described in The main parameter is given by the effective thermal slot
the following. conductivity which is set to a worst case value of
A. Analytical Estimation of Feasible Current Densities 0.10 W⁄(mK). This approach differs from the one described
The analytical estimation of feasible current densities is in [28], as no difference in copper and equivalent insulation is
derived under the following assumptions: a) The slot shape is made. Additionally has to be chosen so that the hot spot
rectangular b) The heat flow is modelled through an effective temperature in winding overhangs is included. With
thermal slot conductivity c) the temperature along the slot a = 18.6 mm and b = 11.6 mm and a maximum copper hot
boundary is constant and d) the machine is of infinite length. spot overtemperature of 80 K, current density results in
Assumption a) is reasonable for many topologies as the J = 7.0 A⁄mm , which is also the value set for the
deviation is rather small, b) is possible for thin wires, where optimized design. Please note that the final current density is
copper and resin are distributed equally along the slot area, c) lower than the 9. 0 A⁄mm set initially for basic designs. The
assumes closed slots with infinite thermal iron conductivity, calculated overtemperature distribution is depicted in Fig. 11.
while d) is common in electromagnetic design and neglects B. Thermal Steady State Evaluation with Finite Element Analysis
end-effects. The thermal problem can now be described by For the thermal FEA iron, copper and magnet losses are
Poisson’s equation considered. Iron losses are taken from electromagnetical
simulations and mapped locally on the 2D thermal model.
Δ = ( , )+ ( , )=− , (22)
Copper and magnet losses are assumed to be distributed
where ( , ) denotes the temperature distribution and the homogeneously. The air gap is modelled by increasing the
loss density, which is assumed to be homogeneous. thermal conductivity of air by the Nusselt number as reported
in [29]
= , (23)
= , (28)
where and denote current density and copper resistivity,
respectively. A solution of (22) has been discussed in 1919 by where denotes the thermal conductivity of air at stand still.
Jakob [26]. Nevertheless, the solution therefrom possesses the This approach neglects the rotor poles, which are expected to

365
 Fig. 12: Thermal evaluation of rated operation at 105 Nm with cooling Fig. 14: Thermal evaluation of short time overload at 225 Nm for 55
temperature of 60 °C. Thermal slot conductivity = 0.1 W⁄(mK). seconds with cooling temperature of 60 °C. Thermal slot conductivity
= 0.1 W⁄(mK) .
improve air drag further. Copper and resin are modelled requirements.
through an effective conductivity . Rotor inner and stator For continuous short circuit operation, resulting current
outer boundaries are modelled applying heat transfer density is given by 9.2 A/mm . The maximum copper
coefficients = 14 W⁄(m K) and = 2 kW⁄(m K). temperature after 240 s results in 167 °C which is below
Because denotes the most critical parameter for the steady maximum temperature of 180° C.
state thermal condition, a parameter study is performed
varying VIII. CONCLUSION
∈ 0.095; 0.12 W⁄(mK). (29) In this paper, design considerations on a 28-pole drive have
Fig. 12 shows the result for rated speed. It can be seen that been presented.
maximum copper temperature remains within thermal To achieve a high quality air gap field with low field
limitation of 180 °C. Average copper temperature is given by distortion, a winding with 36 slots is selected, whereby a delta
129 °C. As winding overhangs are short compared to connection is preferred to limit copper AC losses. Stator teeth
distributed winding topologies and all teeth are wound are rounded off to achieve a smooth current loading and to
individually, an effective thermal conductivity higher than decrease torque ripple. Due to the high pole number, rotor
0.10 W⁄(mK) can be expected, which leads to a decline of design focuses on PM rather than on reluctance torque.
the hot spot temperature as depicted in Fig. 13. Continuous Chosen delta connection as well as high electrical frequency
operation at maximum speed requires a reduction of supplied enforce a rotor topology with a low THD, leading to a design
current by due to increased copper and iron losses. with unequal air gap. Simulations on demagnetization and
Magnet temperature is simulated to 110 °C. mechanical stability show reasonable safety margins.
For short time overload the main thermal limitation is Efficiencies up to 94 % might be achievable according to
given by the copper mass rather than by the thermal calculations, whereby efficiency will highly depend on iron
conductivity. To achieve a torque of 225 Nm a current processing and resulting iron losses.
density of 17.75 A/mm is necessary. To stay within thermal Thermal evaluation has been performed in two steps. An
limits, copper mass must be chosen accordingly. Fig. 14 analytical approach to estimate copper overtemperature is
shows the temperature distribution after 55 s. The maximum derived and allows to easily estimate feasible current
temperature is given by 175 °C validating thermal densities knowing the slot dimensions. Subsequent FEA
simulations prove the hot spot temperature to remain below
the critical temperature of 180 °C for a worst case thermal
conductivity of = 0.01 W⁄(mK).

Fig. 13: Hot spot temperature over effective slot conductivity for steady
state rated operation.
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