Permanent Magnet

Synchronous Motor (PMSM)

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

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

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

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

surface radial surface parallel breadloaf ring

magnet magnet magnet magnet
Inner Rotor Possibilities (2)

(e) IPM in Toyota Prius

 Toyota Prius Hybrid Electric Vehicle (HEV)
3

1. Four cylinder combustion engine;

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

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

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

stepped magnet
 Magnetization Profile
parallel magnetization radial magnetization

most popular

radial sine magnetization sine angle or sine direction

magnetization
 Halbach Array (1)

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

CRC press, 2010.
 Halbach Array (2)

FEA
Halbach Array (3)
Airgap Flux Density

Rotor is outside
 Stator Volume and Size
D 2l  Pout
 T 
T V
0 m
Typically
V0  8 ~ 9 in3 / (ft  lb) for 10hp or less (air cooled)

V0  4 ~ 5 in3 / (ft  lb) for 10hp or more (water cooled)

The unit for D and L is inch.
If we design D=L, we have the stator bore (inner)
diameter estimated

Destimated  1
3
(TV0 )
We can pick up D close to Destimated.
 Stator Core Design
core   gap, per half pole pitch
/P
 leff Bg (a )ris da
D
0

l 
cos( )d
2 /2
B
ef g, ae ae
2 P
D
f
 0
pk


l ef Bg ,
P f
pk

 DBg , pk leff
B  (1)
core

core ,
pk dckili Pdc kili

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

 tooth  s Bg , pk leff
B  (2)
toot 
h
t s k i li t i li

Tak ts  0.5 s , Bcore ,  0.8Btooth

e pk

 dc
D
 1.6P
 Effect of Pole Number on Yoke Flux Density
Finite Element Analysis

with the same dc

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

2nd Edition, p. 106, Motor Design Books LLC, 2010.
 Number of Turns per Coil
V ,rated  2  f e Nˆ a  4.44 f e Nˆ a
g, g , pk
pk
 
2Bg, pk Dl
where pk  P
Nˆ  kw Na /1.1
a
kw  kpkdks Na  PqNc / C
Na is the number of series turns per phase of armature winding
C is the number of parallel circuits of armature winding

1.1V ,rated C Consider leakage flux

N c  22  f e qk w B g , pk Dl
 Stator Slot Design
General Consideration
D
s 
ts d ds1 S
ds
bs0 s0
0.4  t  0.6
s s s
s
3ts  d s  7ts
Define
bs    ts
s

bs 0  (0.1 ~ 0.5)b
s
d s 0  (0.1 ~ 0.5)b
s
ds1
 (0.1 ~ 0.5)bs
 Stator Conductor Size

Stator current density

Js,copper Ia,rated / C
 S
a

where Sa is stator (armature) conductor cross section

area and can be determined from the above formula
together with:

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

Ia,rated / C
Sa 
J s,copper
 Permanent Magnets

 Samarian Cobalt (SmCo)

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

 Neodymium Iron Boron (NdFeB)

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

From Yeadon – Handbook of Small Electric Motors

 Rotor Peripheral Speed

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

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

 Copper loss
Typical
PC  I 2 R
u

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

 Core (Iron) Loss

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

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

Fundamental harmonic

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

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

dm
Da
g
D
Poles

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

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

Maximum Energy Point B

Br

Bm
R

0Hc 0Hm 0
R
H
B ( H  H c)  ( H  H c) H
Br 
Br
BH
H
c (BH) ( BH
To get )
 Br Hc
Hc ,H

0 B  
max m m
H 2 2
 Working Point for Permanent Magnetics (2)

Br
rm
0 H

c

1  1.2
rm

d m Ag
Load Line: B   H  P is called permeance coefficient
m 0 c
g Am
dm
  Pc   0 H m P  Ag Ag / g Rm Pg
  
 c
g A A /d R P
m m m g m

Define: B   B H  (1   )H
 P  
Bm

m

m m r m m c
 c
 H 1 rm

0 m m
Typically pick up:  m 0.5 0.
 9

 Airgap Magnetic Field from PM Rotor
PM electrical angle
Bg , rotor PM embrace:

Bm   
PM
  PM
2
 PM  PM PM PM

2 2  de
 Bm 2 2 P
2   
2
B
g , rotor
  B
Rh
de
2
d

h 1,3,5...
P
B  B cos(h )  B cos(h  )
Rh rh de rh d
2
B  )d 
2  PM /2 
cos(h )d )cos(h
    
   PM /2
rh B
  /2 mae B (
 ae /2 m ae ae

2  PM PM 
 PM 
4 sin h  pitch
th factor for the
 2
   h harmonic
B

kph  sin   PM 
m
h
2
h

 
 Phasor Diagram
V Bnet

 
jXS I A BS

E A BR
Typically, design cos  1 at full-load for PMSM.
sin  1/3 =19.47 ) so that  (1 / 3)T
( T

 Bg , pk full-load pull out

 cos Br ,  0.94 Br , pk
 pk
Ba ,  PM 
 sin Br ,  0.33Br , B 
4
sin B
pk
 pk
pk r, pk   m
  2 
 Air Gap Size and PM Thickness
From: ˆ
Ba , pk  4 0 N a 1.5 2IA,rated
 gˆ total P

Initial total effective air gap size:

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

gˆ  dm
kg' g'  g  d / P (A  A )
From: total c total total m rm
g
c g m
m
P  
Carter’s coefficient c
1
m rm

 g  (1  m )g
'total
dm  m g 'total rm
 Effective Air Gap
gˆ total  kc g 'total
where the Carter’s coefficient
kc  s
2b   b
b g'
  
2


s s 0
 ln 1  s 0   
s0
  atan total

 2 g 'total bs 0 2 g 'total   
 
approximately
k  s
c
bs20 d ds1
 s 5 g '  b ts
bs0 s0
ds
total s0

s
gtotal
 Rotor Sizing

Total rotor diameter, including magnet

Dr  D  2g

Rotor inner diameter Di  Dr  2dm

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

Rotor is assembled by
heating and cooling.
Rotor is welded and
well balanced after
assembly.
 Air Gap Size
For a 2-pole PM rotor 2 geff H  H m Dr  0
g

 2 g eff Bm ( A  Am )
Dr   0 H mD r 0
S N g g
eff
D r/ 2 B
   m
 Pc
g eff 0H
Carter’s coefficient
m
Dr Dr Dr D
g   k (g ) g 
eff
c
2 2 2
2  rm rm

1 1 Dr D
 (  ) k  (1  1 Dr
)
k
P  2 c
2 c
2
c rm rm

 D 
kc DD
D
r
1 1k g r
 kc   c
2
Pc  rm
Define: B   B H  (1   )H Bm m
 P    
m m r m m c
 1 rm
c H
0 m m
Typically pick up:  m 0.5 0.
 8

 Effective Air Gap
gˆ k g gˆ g 
Dr
, g g
Dr
' ' 2
total c total total eff total 
2 rm rm
where the Carter’s coefficient
kc  s
2b   b
b g'
  
2


s s 0
 ln 1  s 0   
s0
  atan total

 2 g 'total bs 0 2 g 'total   
 
approximately

kc  s
2
ts d ds1 ds
b
 s 5s g0 '  b bs0 s0

total s0

s

gtotal
 Example - Specifications

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

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