energies

Article
Design and Analysis of Rotor Shapes for IPM Motors
in EV Power Traction Platforms
Myeong-Hwan Hwang 1,2 , Jong-Ho Han 1 , Dong-Hyun Kim 1 and Hyun-Rok Cha 1, *
1 EV Components & Materials R&D Group, Korea Institute of Industrial Technology, 6 Cheomdan-gwagiro
208 beon-gil, Buk-gu, Gwangju 61012, Korea; han9215@kitech.re.kr (M.-H.H.);
jonghohan@kitech.re.kr (J.-H.H.); bjiuh2608@kitech.re.kr (D.-H.K.)
2 Department of Electrical Engineering, Chonnam National University, 77 Youngbong-ro, Buk-gu,
Gwangju 61186, Korea
* Correspondence: hrcha@kitech.re.kr; Tel.: +82-62-600-6212




Received: 7 September 2018; Accepted: 27 September 2018; Published: 29 September 2018


Abstract: The recent increase in the use of permanent magnet rotor motors underlines the importance
of designing a rotor with an interior permanent magnet (IPM) structure, high power, and high
efficiency. This study analyzed the rotor shapes of IPM motors for electric vehicles. Five types of
motor rotors for automobiles were analyzed, including two hybrid vehicles. In order to minimize the
number of variables in the analysis, the size of the motor stators was fixed and only the rotor shapes
were modified to compare torque, torque ripple, efficiency and back-electromotive voltage. When
the motor properties were compared as a function of rotor shape, the rotor shape with the smallest
magnet volume exhibited excellent results for torque, efficiency and torque ripple.

Keywords: traction motor; electric vehicle; interior permanent magnet; vehicle motor;
electromagnetic field analysis; cogging torque

1. Introduction
Various regulations in the car industry are being introduced to respond to environmental changes
caused by global warming [1]; for example, electrically powered powertrains have been developed
to reduce exhausted gas and improve the power efficiency of vehicles. As a result, the demand for
electrical vehicles, which are recognized as environmentally friendly, continues to surge [2]. Electric
traction motors, which represent the most essential of technologies among this changeover, are needed
owing to their wide velocity, high power density, and high efficiency [3–5].
With advances in electrical machines and recent control technologies, AC machines have become
mainstream (as opposed to DC machines) and now dominated the traction machine market. Both
synchronous and asynchronous AC machines are used in commercially available electric-powered
vehicles. Induction machines contain the most mature manufacturing technologies, those that that have
been developed over a number of decades [5,6]. Induction machine technologies are also relatively
lower in cost and offer easier control. However, the conductors of the rotor increase the rotor copper
losses and also the cooling requirement. The conductor usually applies to a lower operating efficiency
as compared with permanent magnet synchronous machines (PMSM); therefore, the majority of
automotive manufacturers are choosing appropriate PMSM for the traction motor in the vehicle [7].
Among the electric traction motors, interior permanent magnet (IPM) motors, which include
rotors with embedded magnets, are increasingly being used as the driving motors for electric vehicles.
The advantages of an IPM motor include its wide velocity and torque variation, high power, light
weight, and energy efficiency. The most influential factor affecting the performance of IPM motors is

Energies 2018, 11, 2601; doi:10.3390/en11102601 www.mdpi.com/journal/energies

Energies 2018, 11, x 2 of 12
Energies 2018, 11, 2601 2 of 12
power, light weight, and energy efficiency. The most influential factor affecting the performance of
IPM motors is the rotor shape. Therefore, determining an appropriate IPM rotor shape is essential
the designing
for rotor shape. Therefore,
a highly determining
functional drivingan appropriate
motor IPM vehicles
for electrical rotor shape(EVs)is essential
[8–11]. for designing a
highly functional driving motor for electrical vehicles (EVs) [8–11].
As the importance of IPM motors for EVs continues to increase, various rotor structures have
been As the importance
proposed. Only a few of IPM motors
studies havefor EVs continues compared
comprehensively to increase,the various rotor structures
rotor shapes of IPM motors have
been
in proposed.
order Onlya adesign
to establish few studies haveAccordingly,
standard. comprehensively compared
this study the rotor
attempted shapesan
to identify of appropriate
IPM motors
in order
shape to an
for establish a design
IPM rotor for standard. Accordingly,
EVs by analyzing threethismodels
study attempted
of major EV to identify
motor an appropriate
manufacturers
shape for an
currently IPM rotor
in mass for EVs as
production, by well
analyzing
as twothree models
hybrid of major
models. BasedEVon motor manufacturers
the results currently
of this study, we
in mass
plan to production,
present a designas wellstandard
as two hybrid models.
for rotor Based
shapes thatonappropriately
the results of this study,
reflects thewe plan to present
requirements of
a design
EVs [12]. standard for rotor shapes that appropriately reflects the requirements of EVs [12].
However, the the critical
criticalproblem
problemisisthatthatanalysis
analysisand and improvement
improvement could waste
could bothboth
waste timetime
and cost.
and
Therefore, the magnet arrangement of high-power IPM rotor shape should
cost. Therefore, the magnet arrangement of high-power IPM rotor shape should be analyzed and be analyzed and developed
to reduce time
developed and cost.
to reduce time The
andtorque and torque
cost. The rotationandspeed were speed
rotation analyzedwereaccording
analyzedtoaccording
rotor shape. Each
to rotor
motor stator
shape. had thestator
Each motor samehad sizethe
andsame
winding, withwinding,
size and a motor rotor with of the same
a motor size,
rotor ofbut
thewith
samea size,
different
but
arrangement of magnets [13].
with a different arrangement of magnets [13].
Many studies of rotor shape have aimed to reduce design and analysis time [14]. However, However, this
study focused
focused on ontime
timereduction
reductionwhenwhen selecting
selectingthethe
designdesignconcept. We believe
concept. that the
We believe thatresults of study
the results of
will improve
study design efficiency
will improve by decreasing
design efficiency the initialthe
by decreasing design time
initial and enhancing
design time and torque,
enhancing power, and
torque,
efficiency,
power, anddepending
efficiency,on the shapeon
depending of the
IPMshape
rotor.of IPM rotor.
The remainder
remainder of this paper is organized as follows. The The main
main parameters
parameters of of the
the IPM motor
rotor and
and five
fiveanalysis
analysisrotor
rotormodels
models areareintroduced
introduced in Section
in Section2, followed by aby
2, followed comparison
a comparison of theofbasic
the
characteristics
basic of eachofrotor
characteristics eachinrotor
Section 3. The torque
in Section 3. The and
torque efficiency of rotorsof
and efficiency arerotors
analyzed, in Sectionin
are analyzed, 4.
Finally, 4.
Section conclusions are given in
Finally, conclusions areSection
given 5in Section 5

2. Analysis
2. Analysis Models
Models of
of IPM
IPM Motors
Motors
To analyze
To analyze thethe characteristics
characteristicsof ofIPM
IPMmotors
motorsasasa afunction
functionofof rotor
rotor shape,
shape, thethe outer
outer diameter
diameter of
of each
each rotor
rotor waswas fixed
fixed to ensure
to ensure thethe same
same conditions
conditions andand to minimize
to minimize the the number
number of variables.
of variables. In
In addition,
addition, thethe magnet
magnet arrangement
arrangement ofof the
the rotorwas
rotor wasadjusted
adjustedtotostandardize
standardizethethesize
sizeand
and shape
shape of
of the
the
stator and the windings so that the properties were analyzed under similar conditions.
stator and the windings so that the properties were analyzed under similar conditions. To ensure the To ensure the
accuracy of
accuracy of the
the analysis
analysis using
using different
different magnet
magnet arrangements
arrangements and and rotor
rotor shapes,
shapes, the
the rotor
rotor shapes
shapes and
and
ratios typical of actual cars were maintained as much as
ratios typical of actual cars were maintained as much as possible. possible.
Rotor shapes,
Rotor shapes,shown
shown in Figure 1, are1,general
in Figure shapes, and
are general this study
shapes, analyzed
and this studyeach characteristic
analyzed each
characteristic depending on shape. Additionally, Figure 1d,e was included and analyzed, becausea
depending on shape. Additionally, Figure 1d,e was included and analyzed, because the V-shape has
smaller
the magnet
V-shape has volume
a smaller than othervolume
magnet generalthanshapes [15].
other general shapes [15].

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

Figure 1. Interior
Interior Permanent
Permanent Magnet
Magnet Synchronous
Synchronous Motor
Motor Design
Design Trend:
Trend: (a)
(a) V-shaped
V-shaped rotor
rotor from
manufacturer T; (b)
(b) double
double magnet
magnetshape
shapefrom
frommanufacturer
manufacturerV;V;(c)(c)delta
delta shape
shape from
from manufacturer
manufacturer V;
(d)(d)
V; hybrid delta
hybrid shape
delta based
shape on the
based on Vthe
shape from from
V shape both manufacturer
both manufacturerT and Tmanufacturer N; (e) hybrid
and manufacturer N; (e)
double double
hybrid V shapeVfrom
shapeboth manufacturer
from T and manufacturer
both manufacturer V. These five
T and manufacturer shapesfive
V. These have been previously
shapes have been
analyzed [16].
previously analyzed [16].

2.1. Stator
2.1. Stator Model
Model for
for Analyzing
Analyzing Rotor
Rotor Properties
Properties
Table 11 presents
Table presents the
the specifications of the
specifications of the stator model used
stator model used in
in this
this study
study as
as an
an IPM
IPM motor. The
motor. The
number of
number of slots
slots was
was 4848 and
and the
the rated
rated voltage
voltage is
is DC
DC 650
650 V.
V. The
The same
same electrical
electrical current
current was
was applied
applied to
to
each motor for analysis. The maximum rated current was 200 A. Table 1 also
each motor for analysis. The maximum rated current was 200 A. Table 1 also provides a provides a cross-sectional
view of the 48 slot
cross-sectional viewstator.
of theThe outer
48 slot diameter
stator. of an IMP
The outer motor
diameter ofstator
an IMP is 200 mm.
motor In order
stator tomm.
is 200 formIna
sinusoidal back-EMF (B-EMF) at the stator, distributed windings were designed. As a space factor
Energies 2018, 11, x 3 of 12
Energies 2018, 11, 2601 3 of 12
Energies 2018, 11, x 3 of 12
order to form a sinusoidal back-EMF (B-EMF) at the stator, distributed windings were designed. As
orderor
aofspace
40% tobelow
form
factor of a40%
issinusoidaltoback-EMF
or below
known is known
enable (B-EMF) at
to enable
windings, the stator,
was distributed
windings,
36.80% 36.80% was
adopted windings
for adopted
this were designed.
forby
design this designAsby
considering
a space
considering factor
the insulation of 40%
thethickness.or below is
insulationInthickness.known
addition,In to enable
addition,
nine 0.7 mmninewindings,
coils0.7 36.80%
mmwound
were was
coils were adopted
wound
10 turns for this design
10 turnsthe
to reduce by
to current
reduce
the considering
current the insulation thickness. In addition, nine 0.7 mm coils were wound 10 turns to reduce
density [17].density [17].
the current density [17].
Table
Table 1.
1. Main
Mainparameters
parametersof ofstator.
stator.
Table 1. Main parameters of stator.
48 48
Slot Stator
Slot Stator Parameters
Parameters Unit
Unit Value
Value
48 Slot Stator Parameters Unit Value
Number of Slots Slot 48
NumberofofSlots
Number Slots Slot
Slot 48
48
Outside
Outside Diameter
Diameter mmmm 200
200
Outside Diameter mm 200
Inside
InsideDiameter
Diameter mmmm 122
122
Inside Diameter mm 122
Stack
StackLength
Stack Length
Length mm
mmmm 50
50
50
Air Gap
Air Gap
Air Gap mm
mmmm 0.7
0.7
0.7
Number ofof
Number
Number of Turns
Turns
Turns Turns
Turns
Turns 10
10
10
Number
Number of of Strands
Strands
Number of Strands Turns
Turns
Turns 9
99
Phase
Phase
Phase Resistance
Resistance
Resistance mΩ
mΩmΩ 84.9693
84.9693
84.9693
Slot
Slot Fill Factor % 36.80
SlotFill
FillFactor
Factor % 36.80
36.80
Coil Pitch 6
Coil
CoilPitch
Pitch 66

2.2.2.2.
2.2. Analysis
Analysis of Rotor
Analysis
of Rotor Properties
of Rotor Properties
Properties
TheThe
The outer diameter
outer diameter
diameter of
ofthe
of motor
thethe motor
motor rotor was
rotor
rotor designed
was
was designed
designed toto
bebe
to 120.6
be mm
120.6
120.6 mm
mm forfor
all all
for models
allmodels and
models thethe
and
and air gap
theair
air
wasgap
0.7 was
mm. 0.7 mm.
Figure Figure
2 2 illustrates
illustrates the the
shapes shapes
of of
the the
five five different
different magnets
magnets analyzed
analyzed
gap was 0.7 mm. Figure 2 illustrates the shapes of the five different magnets analyzed in this study. in in this
this study.
study. We
We We
chose tochose
chose to analyze
analyze thethe
the three
to analyze three
most
three mostrepresentative
representative
representative
most shapes
shapesshapes
of IPMof ofrotors,
IPM rotors,
IPM rotors, along
along with
alongtwo with two
twoimproved
improved
with models
improved
models
that used that used
additional additional
magnets. magnets.
As Table 2As Table
shows, 2
all shows,
rotors all
in rotors
this studyin this
had
models that used additional magnets. As Table 2 shows, all rotors in this study had an outside study
an had
outside an outside
diameter of
diameter
120 mm, an
diameter of 120
air gap
of 120 mm,
mm,ofan an
0.7airair
mm, gap
gapand of 0.7
eight
of 0.7 mm,
mm, and
magnet eight
poles
and eight magnet
[18–20].
magnet poles [18–20].
poles [18–20].

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

(a) (b) (c) (d) (e)
Figure 2. Five different shapes of Interior Permanent Magnet (IPM) rotors: (a) V shape from
Figure
Figure 2. Five
Five different
manufacturer different shapes
shapes
T; (b) double of
of Interior
magnet Interior
shape Permanent
Permanent
from Magnet
V; (c)(IPM)
Magnet
manufacturer (IPM) rotors:
rotors:
delta shape (a)
with(a)a V
V shape
bar magnetfrom
shape from
in
manufacturer
manufacturer T; (b)
a V shape; and double
double
(d,e) magnet
magnet
improved shape
shape
shapes from
from
using manufacturer
a manufacturer
delta V;
V;
shape and (c)delta
a(c) delta
double shape
Vshape with
with
shape, a abar
barmagnet
respectively.magnetinina
aVVshape;
shape;and
and(d,e)
(d,e)improved
improvedshapes
shapes using
using a delta
a delta shape
shape and
and a double
a double VV shape,
shape, respectively.
respectively.
Table 2. Comparison of outer diameter and air gap of rotor.
Table 2. Comparison of outer diameter and air gap of rotor.
Table 2. Comparison of outer diameter
Double and air gap ofImproved
Delta-Shape rotor. Improved Model
V-Shape
Magnet-Shape
Double (Manufacturer Model (T+N
Improved (T+V Double
Improved V
(Manufacturer
V-Shape T) Double Delta-Shape
Delta-Shape Improved ImprovedModel
Model
V-Shape Magnet-Shape
(Manufacturer V) N) Model (T+N
Delta Shape) (T+V Double
Shape)
(Manufacturer T) Magnet-Shape (ManufacturerN)
(Manufacturer Model (T+N (T+V Double V
Number of (Manufacturer T) (Manufacturer V) Delta Shape) V Shape)
8 (Manufacturer
8 V) N)8 Delta 8Shape) Shape)
8
MagnetofPoles
Number
Number of 88120.6
Outside
Magnet (mm)
Poles 88
120.6 88
120.6 88
120.6 88
120.6
Magnet Poles
Air Gap
Outside (mm)
(mm) 120.60.7 0.7
120.6 0.7
120.6 0.7
120.6 0.7
120.6
Outside (mm)
Air Gap (mm)
120.6
0.7
120.6
0.7
120.6
0.7
120.6
0.7
120.6
0.7
Air Gap (mm) 0.7 0.7 0.7 0.7 0.7
Since the volume of the magnet is the most influential factor in production cost and quality of
anSince
IPM themotor,
volumethe magnet
of volumes for most each design are factorcompared in Table 3costandand Figure 3. The
Since of the
the magnet
magnetisisthe the mostinfluential
influential factorinin production
production cost and quality of an
quality of
IPM magnet
motor, volume
the magnetis directly related
volumes to
for each manufacturing
design cost.
are comparedSo, the magnet
in Table volume is a key factor to
an IPM motor, the magnet volumes for each design are compared in 3Table
and Figure
3 and 3. The magnet
Figure 3. The
reduce motor cost; furthermore, to achieve maximum torque per ampere (MTPA) by minimum
volume is
magnet directlyisrelated
volume directly torelated
manufacturing cost. So, thecost.
to manufacturing magnet volume
So, the is a volume
magnet key factoris to reduce
a key motor
factor to
volume of motor, optimization of the rotor shape and reduction of magnet volume is necessary
cost;
reduce furthermore,
motor cost; to achieve maximum
furthermore, to torque
achieve per
maximum ampere (MTPA)
torque per by minimum
ampere (MTPA) volume
by of motor,
minimum
[21,22]. The V-shaped rotor had the smallest magnet volume (52,464 mm3), while the delta-shaped
optimization
volume of theoptimization
rotor shape andthe reduction of magnet volume is of necessary [21,22]. The V-shaped
rotor of motor,
from manufacturer N hadofthe rotor magnet
largest shape and reduction
volume (93,824 mmmagnet
3 ), while the delta-shaped
volume
3). As a small is necessary
volume motor
rotor had
[21,22]. Thethe smallest
V-shaped magnet
rotor volume
had the (52,464
smallest mm
magnet volume (52,464 mm 3),rotor
whilefrom
the manufacturer
delta-shaped
and high efficiency is critical to EVs, the smallest magnet volume would most likely be the most
3 ). As a small volume motor3 and high efficiency is critical
N had
rotor the largest
from magnet
manufacturer
cost-effective motor volume (93,824
N had the
design. mmmagnet
largest volume (93,824 mm ). As a small volume motor
to EVs,
and hightheefficiency
smallest magnet volume
is critical would
to EVs, most likely
the smallest be the
magnet most cost-effective
volume would mostmotor
likely design.
be the most
cost-effective motor design.
Energies 2018, 11, 2601 4 of 12
Energies 2018, 11, x 4 of 12

Table3.3.Analysis
Table Analysis of
of rotor magnet
magnet volume.
volume.
V-Shape Double
Double Improved ImprovedModel
Improved Model
V-Shape Delta-Shape
Delta-Shape Improved Model
(Manufacturer Magnet-Shape
Magnet-Shape (Manufacturer N) Model (T+N (T+VDouble
(T+V Double
(Manufacturer T) (Manufacturer N) (T+N Delta Shape)
T) (Manufacturer
(ManufacturerV)V) Delta Shape) V-Shape)
V-Shape)
Magnet
Magnet 52,464 63,200 93,824 74,864 60,736
Volume (mm
3 )3) 52,464 63,200 93,824 74,864 60,736
Volume (mm

Figure3.3.Comparison
Figure Comparison of Rotor
Rotor Magnet
MagnetVolume.
Volume.

3. Comparative Analysis
3. Comparative Analysis
In In
order toto
order analyze
analyzethe
thecharacteristics
characteristics of
of IPM
IPM rotors accordingto
rotors according totheir
theirshape,
shape,three
three main
main factors
factors
were analyzed. Table 4 shows the critical factors analyzed in subsequent sections [23,24].
were analyzed. Table 4 shows the critical factors analyzed in subsequent sections [23,24].

Table4.4.Analysis
Table Analysis of
of rotor magnet volume.
rotor magnet volume.

No No Analysis
Analysis Factor
Factor Necessity
Necessity of of Analysis
Analysis
1 1 Back
Back EMF
EMF Determines
Determines the maximum range of
the maximum range of motor
motor rotation
rotation
2 Torque ripple or cogging torque Very influential on noise and vibration
2 Torque ripple or cogging torque Very influential on noise and vibration
As the magnitude of a force generated according to velocity,
3 Torque
As the magnitude
torque is very of a force generated
influential in settingaccording
a domain to
of velocity,
operation.torque
3 Torque
4 Efficiency Closely
is veryrelated to theinpower
influential settingconsumption
a domain of of a vehicle
operation.
4 Efficiency Closely related to the power consumption of a vehicle
For analysis, we used the motor electromagnetic field analysis tool, “JMAG” (ver. 14.1), with data
Forthrough
produced analysis,simulation
we used the motor electromagnetic field analysis tool, “JMAG” (ver. 14.1), with
analysis.
data produced through simulation analysis.
3.1. Analysis of B-EMF as a Function of Rotor Shapes
3.1. Analysis of B-EMF as a Function of Rotor Shapes
A no-load voltage analysis was conducted by applying a rotational speed of 1000 rpm to induce
A no-load
and analyze voltage
linear analysis
voltage wasBased
values. conducted by applying
on the results ofa B-EMF
rotational speed of
voltage 1000 rpm
analysis, to induce
a distributed
and analyze linear voltage values. Based on the results of B-EMF voltage analysis,
winding was designed for the stator so that the B-EMF voltage waveforms were similar to a sinusoid.a distributed
Thewinding
V-shapedwas designed
motor for the stator T
from manufacturer sowas
thatthe
themost
B-EMF voltage waveforms were similar to a
sinusoidal.
sinusoid. The V-shaped motor from manufacturer T was the most sinusoidal.
Table 5 presents B-EMF voltages and constants; a back-EMF analysis was performed for the five
Table 5 presents B-EMF voltages and constants; a back-EMF analysis was performed for the five
rotor shapes, as shown in Figure 4. The improved delta shape, which was based on the V-shape
rotor shapes, as shown in Figure 4. The improved delta shape, which was based on the V-shape from
from manufacturer T, had the highest B-EMF voltage (28.68 V), and the double magnet shape of
manufacturer T, had the highest B-EMF voltage (28.68 V), and the double magnet shape of
manufacturer T showed the lowest B-EMF voltage (20.80 V). As the no-load voltage decreased, the
manufacturer T showed the lowest B-EMF voltage (20.80 V). As the no-load voltage decreased, the
no-load speed increased.
no-load speed increased.
The
TheVVshape
shapefrom
frommanufacturer
manufacturerTTutilized
utilized more magneticflux
more magnetic fluxthan
thanthe
theother
othershapes;
shapes; thus,
thus, it it
had a higher
had B-EMF
a higher B-EMFvoltage
voltagethan
thanthat
thatof
ofthe
the double
double magnet-shape.
magnet-shape. ThisThisindicates
indicates that
that thethe
VV shape
shape
using a small amount of current is suitable for generating high power. Moreover, as
using a small amount of current is suitable for generating high power. Moreover, as the V shape has the V shape
has a more sinusoidal waveform than the delta shape, it likely is more advantageous for minimizing
torque ripples.
 Energies 2018, 11, x 5 of 12

Energies 2018, 11, 2601

a more sinusoidal waveform than the delta shape, it likely is more advantageous for minimizing 5 of 12
torque ripples.

Table 5. 5.B-EMF
Table B-EMFvoltage andconstants.
voltage and constants.

Double Magnet
Double Magnet Improved Improved Model
V Shape
V Shape Delta
Delta Shape Improved Model
Shape
Improved Model
Shape
Shape Model
(T+N (T+N
Delta (T+V
(T+V Double
Double
(Manufacturer T) T)
(Manufacturer (Manufacturer
(Manufacturer N) N)
(Manufacturer V)
(Manufacturer V) Delta Shape)
Shape) V-Shape)
V-Shape)
B-EMF B-EMF Voltage
Voltage
27.13
27.13 20.80
20.80 27.9731
27.9731 28.68
28.68 27.17
27.17
(V_rms)
(V_rms)
B-EMF Voltage
B-EMF Voltage
Constants
Constants 0.0271
0.0271 0.0208
0.0208 0.02797
0.02797 0.02868
0.02868 0.02717
0.02717
(V_rms/rpm)
(V_rms/rpm)

(a)

(b)

FigureFigure 4. B-EMF
4. B-EMF Wave
Wave andand No-LoadVoltage:
No-Load Voltage: (a)
(a)B-EMF
B-EMFWave;
Wave;(b)(b)
B-EMF No-Load
B-EMF Voltage.
No-Load Voltage.

3.2. Analysis of Cogging Torque and Torque Ripple

Figure 5 shows the results of our electromagnetic field analysis for cogging torque and torque
ripple. Since the improved delta V shape from manufacturer T was designed to arrange the magnets
close to the stator in order to utilize magnetic flux more effectively, it had the highest cogging torque
(2.875 Nm). The best cogging torque was 0.9678 Nm, which was produced by the double magnet-shape
from manufacturer V; the difference between this and the V-shaped rotor was 1.9 Nm. On the other
hand, the cogging torque of the V shape was 1.898 Nm, but the improved double V-shape was
1.798 Nm, a difference of just 0.1 Nm. Consequently, a double magnet-shaped rotor was shown to be
advantageous for cogging torque, and using this shape would likely reduce design time [25].
 close to the stator in order to utilize magnetic flux more effectively, it had the highest cogging torque
(2.875 Nm). The best cogging torque was 0.9678 Nm, which was produced by the double
magnet-shape from manufacturer V; the difference between this and the V-shaped rotor was 1.9
Nm. On the other hand, the cogging torque of the V shape was 1.898 Nm, but the improved double
V-shape was 1.798 Nm, a difference of just 0.1 Nm. Consequently, a double magnet-shaped rotor
Energies 2018,
was 11, 2601 to be advantageous for cogging torque, and using this shape would likely reduce design
shown 6 of 12
time [25].

(a)

Energies 2018, 11, x 7 of 12

(b)

(c)

Figure Figure 5. Analysis

5. Analysis of of cogging torque
cogging torque and
andtorque ripple:
torque (a) Comparison
ripple: of torque of
(a) Comparison ripples;
torque(b) ripples;
Comparison of torque ripples in the analysis of current source at 0° current◦ phase angle; (c)
(b) Comparison of torque ripples in the analysis of current source at 0 current phase angle;
Comparison of torque ripples in the analysis of current source at 40° current phase angle.
(c) Comparison of torque ripples in the analysis of current source at 40◦ current phase angle.
4. Results

4.1. Speed-Torque and Speed-Efficiency Analysis

Another electromagnetic analysis was conducted by applying constant current at a variety of
speeds. The range of the analysis was performed at 1000–10,000 rpm in consideration of B-EMF
Energies 2018, 11, 2601 7 of 12

4. Results

4.1. Speed-Torque and Speed-Efficiency Analysis

Another electromagnetic analysis was conducted by applying constant current at a variety of
speeds. The range of the analysis was performed at 1000–10,000 rpm in consideration of B-EMF
voltages. Initially, the analysis used magnet torques without controlling phase angles. As is
widely known, magnetic reluctance in an IPM motor, i.e., saliency, an additional torque component
is developed. By phase angle control, the torque is increased for a given current magnitude.
Consequentially, maximum torque occurs for a current phase of 35–45◦ ; this study conducted a
comparative analysis at a current phase angle of 40◦ in order to examine the characteristics of
maximum torque.
As shown in Figure 6, in order to analyze the impact of the d-axis and the q-axis, the current of
the q-axis was held at zero and the torque and efficiency due to the d-axis were analyzed. The analysis
showed that the delta-shape from manufacturer N had the highest torque (77.65 Nm) because of its
large magnet volume, and also because it has the widest magnet surface to generate an active magnetic
flux. The V-shape, with the smallest magnet surface for generating active magnetic flux had a torque
of 66.16 Nm, which was lower than that of the delta-shape by 11.49 Nm. Table 6 compares torque
characteristics according to speed.

Table 6. Comparison of speed-torque characteristics according to rotor shapes (phase angle of 40◦ ).

Double Improved Improved

V Shape Delta Shape
Magnet Shape Model (T+N Model (T+V
RPM (Manufacturer (Manufacturer
(Manufacturer Delta Shape) Double
T) (Nm) N) (Nm)
V) (Nm) (Nm) V-Shape) (Nm)
1000 66.12894 55.14583 77.65978 76.62068 71.49971
2000 66.16147 55.16258 77.65832 76.62819 71.514
3000 66.16877 55.16563 77.65658 76.63369 71.51918
4000 66.16998 55.17346 77.66459 76.6316 71.52973
5000 47.48419 38.72789 52.89918 53.16905 50.03325
6000 28.56902 21.60797 29.9703 30.90529 29.45301
7000 21.88614 16.23352 22.45951 23.38148 22.36065
8000 17.2897 12.85844 17.62589 18.32735 17.55764
9000 12.9869 9.78588 13.24661 13.66213 13.08482
10,000 8.28681 6.32922 8.49809 8.67869 8.27965

Next, the impact of the q-axis was analyzed by applying a current phase angle of 40◦ . When
the current phase angle is controlled, magnet torques and reluctance torques are combined, which
enabled us to identify the maximum torque. As shown in Figure 7, the improved double V shape from
manufacturer T had the best torque (107.98 Nm) and also exhibited high torques at rotational speeds
of 5000–10,000 rpm. Data showing a comparison of speed-torque characteristics according to rotor
shape (phase angle of 40◦ ) is shown in Table 7.
 Energies 2018, 11, x 8 of 12

9000
Energies 12.9869
2018, 11, 2601 9.78588 13.24661 13.66213 13.08482 8 of 12
10,000 8.28681 6.32922 8.49809 8.67869 8.27965

(a)

(b)
Figure
Figure 6. Current
6. Current analysisofoftorque,
analysis torque, ripple,
ripple,efficiency
efficiencycomparison,
comparison,andand
magnetic flux density
magnetic at 0˚ ofat 0◦
flux density
phaseangle:
of phase angle: (a) Comparison
Comparisonofoftorque
torqueaccording
according to speed; (b) Comparison
to speed; of efficiency
(b) Comparison according
of efficiency to
according
speed.
to speed.

Table 7. Comparison
Next, the impact ofofthe
speed-torque
q-axis was characteristics according
analyzed by applying to rotor phase
a current shapesangle
(phase
ofangle of 40◦the
40°. When ).
current phase angle is controlled, magnet torques and reluctance torques are combined, which
Double
enabled us VtoShape
identify the maximum torque. As Delta
Magnet-Shape shown Shape
in FigureImproved Model
7, the improved Improved
double Model
V shape
RPM (Manufacturer
from manufacturer T had the (Manufacturer (T+N Delta Shape) (T+V Double
best torqueV)(107.98 Nm) and also exhibited high torques at rotational
(Manufacturer
T) (Nm) N) (Nm) (Nm) V-Shape) (Nm)
speeds of 5000–10,000 rpm. Data(Nm)showing a comparison of speed-torque characteristics according to
rotor
1000 shape107.07544
(phase angle of 40°)84.50443
is shown in Table 104.66107
7. 109.14068 107.98762
2000 107.06992 84.50021 104.66051 109.13429 107.98497
3000 107.07162 84.49209 104.65735 109.13434 107.98034
4000 107.06842 84.50367 104.6514 109.13934 107.97648
5000 70.46591 54.01324 64.72424 70.05181 69.94164
6000 35.90096 28.13232 32.53424 35.60729 35.38056
7000 25.0925 20.39196 23.34639 25.08518 24.78409
8000 18.50735 15.46581 17.69671 18.6181 18.32714
9000 12.98148 10.91558 12.77176 13.1783 12.91309
10,000 7.63406 6.34526 7.66694 7.81597 7.61829
 5000 70.46591 54.01324 64.72424 70.05181 69.94164
6000 35.90096 28.13232 32.53424 35.60729 35.38056
7000 25.0925 20.39196 23.34639 25.08518 24.78409
8000 18.50735 15.46581 17.69671 18.6181 18.32714
9000
Energies 2018, 11, 2601
12.98148 10.91558 12.77176 13.1783 12.913099 of 12
10,000 7.63406 6.34526 7.66694 7.81597 7.61829

(a)

(b)
Figure 7.
7. Analysis
Analysisofoftorque
torqueand
andefficiency according
efficiency to to
according speed (phase
speed angle
(phase controlled
angle at 40°):
controlled ◦ ):
at 40(a)
Comparison
(a) Comparisonof torque
of torque according to to
according speed
speed(phase
(phaseangle
anglecontrolled ◦
controlledatat 40°);
40 ); (b)
(b) Comparison
Comparison of
efficiency according to speed (phase angle controlled at 40 ◦ ).
40°).

4.2. Comparison of Power and Other Factors

The manufacturing cost is mostly influenced by magnet shape and volume of the permanent
magnet. As discussed, the main goal of this study was to increase manufacturing efficiency and
decrease the effort and time needed for selection of the design concept. Therefore, in order to achieve
MTPA with a minimum volume of motor, optimization of the rotor shape and reduction of magnet
volume are important considerations in rotor design.
Figure 8 shows a comparison between power and other factors, based on previous analyses.
As shown in Figure 8a, the double magnet shape had the lowest power, reflecting the lowest torque; the
delta shape was the highest-power rotor shape. Except the double magnet shape, the comparison shows
that power and manufacturing cost have a linear proportional relationship, because of complicated
shapes and relatively high magnet volumes. Based on Figure 8a,b shows a comparison of efficiency
and power. Mechanical power output is calculated based on the torque and speed required, and
magnet volume are important considerations in rotor design.
Figure 8 shows a comparison between power and other factors, based on previous analyses. As
shown in Figure 8a, the double magnet shape had the lowest power, reflecting the lowest torque;
the delta shape was the highest-power rotor shape. Except the double magnet shape, the
comparison
Energies 2018, 11,shows
2601 that power and manufacturing cost have a linear proportional relationship, 10 of 12
because of complicated shapes and relatively high magnet volumes. Based on Figure 8a,b shows a
comparison of efficiency and power. Mechanical power output is calculated based on the torque
electric
and motor
speed efficiency
required, andiselectric
the ratio between
motor outputispower
efficiency and between
the ratio input power. Therefore,
output efficiency
power and input
is mainly related to power, and Figure 8b shows a linear proportional relationship between
power. Therefore, efficiency is mainly related to power, and Figure 8b shows a linear proportional power
and efficiency.
relationship between power and efficiency.

(a) (b)
Comparison of
Figure 8. Comparison of power
power and
and other
other factors:
factors: (a)
(a) Comparison
Comparison of
of manufacturing
manufacturing cost
cost and
and power;
power;
(b) Comparison of efficiency and power.
power.

5. Conclusions
5. Conclusions
This study
This study analyzed
analyzed the the design
design andand electromechanical
electromechanical properties
properties of of IMP
IMP motors
motors forfor electric
electric
vehicles as a function of rotor shape; various factors (e.g., speed, torque, torque
vehicles as a function of rotor shape; various factors (e.g., speed, torque, torque ripple and B-EMF ripple and B-EMF
voltage) were compared. The main goal of this study was to reduce the time
voltage) were compared. The main goal of this study was to reduce the time required to design required to design a rotora
with the
rotor withmaximum
the maximum powerpower
density for an for
density IPManmotor. The findings
IPM motor. of this of
The findings study
this will
study bewill
useful
be for the
useful
confined
for space typical
the confined space of EVs. Further
typical of EVs. study
Furtherwill fabricate
study an actual an
will fabricate V-shaped rotor and rotor
actual V-shaped verifyand
the
reliability of the electromagnetic analysis.
verify the reliability of the electromagnetic analysis
The sizes
The sizes ofof outer
outer diameters
diameters were
were fixed
fixed for
for both
both rotors
rotors and
and stators. The same
stators. The same stator
stator shape
shape and
and
winding design was applied. Different arrangements of magnets were adopted
winding design was applied. Different arrangements of magnets were adopted for each rotor shape for each rotor shape in
order
in orderto obtain
to obtain various results
various in speed,
results torque,
in speed, efficiency,
torque, ripple,ripple,
efficiency, etc. Inetc.
orderIn to analyze
order the impact
to analyze the
of both the d- and q-axis, the current of the q-axis was controlled at zero
impact of both the d- and q-axis, the current of the q-axis was controlled at zero and the and the electromagnetic
characteristics due
electromagnetic to the d-axis due
characteristics weretoexamined.
the d-axisThe
weredelta shape from
examined. The manufacturer
delta shape from N had the highest
manufacturer
torque
N (77.65
had the Nm) up
highest to a (77.65
torque rotationNm)speed
up of
to 4000 rpm, and
a rotation speed a higher
of 4000torque
rpm, andby about 1Nmtorque
a higher between by
5000 and 10,000 rpm.
about 1Nm between 5000 and 10,000 rpm.
The impact
The impact of ofthe
theq-axis was
q-axis analyzed
was analyzed by applying a current
by applying phasephase
a current of 40◦ .of
angle angle When
40°. the
Whencurrent
the
phase angle was controlled, magnet torques and reluctance torques were combined,
current phase angle was controlled, magnet torques and reluctance torques were combined, which which enabled us
to identify the maximum torque. The improved double V shape from
enabled us to identify the maximum torque. The improved double V shape from manufacturer T manufacturer T had the best
torque
had the(107.98 Nm). The
best torque V shape
(107.98 Nm). from
Themanufacturer
V shape from T showed higher torques
manufacturer T showed at rotational speeds at
higher torques of
5000–10,000 rpm. In addition, the V shape had a magnet volume of 52,464 mm3 , while the improved
double V shape had a higher magnet volume of 60,736 mm3 , indicating that the V-shape, with 13.6%
less magnet volume, would be more advantageous for reducing the price of a motor.

Author Contributions: Conceptualization, M.-H.H. and H.-R.C.; Data curation, D.-H.K. and J.-H.H.; Formal
analysis, M.-H.H.; Methodology, S.Y.J.; Supervision, H.-R.C.; Validation, D.-H.K. and J.-H.H.; Visualization,
M.-H.H.; Writing—original draft, M.-H.H.; Writing—review & editing, H.-R.C.
Funding: This research was funded by the support of the Korea Institute of Industrial Technology as “Variable
Architecture Powertrain Platform and Self-driving Factor Technology Development for Industrial EV Self-driving
Vehicle” KITECH EO-18-0020.
Conflicts of Interest: The authors declare no conflicts of interest.
Energies 2018, 11, 2601 11 of 12

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