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PMSMs with Non-Overlapping Concentrated Windings: Design Guidelines

and Model References

Article · January 2009

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March 26-29

PMSMs with Non-Overlapping Concentrated Windings:

Design Guidelines and Model References
Florence Meier
School of Electrical Engineering, Electrical Machines and Power Electronics
Royal Institute of Technology, Teknikringen 33, SE-100 44 Stockholm
E-mail: florence.meier@ee.kth.se

Juliette Soulard
School of Electrical Engineering, Electrical Machines and Power Electronics
Royal Institute of Technology, Teknikringen 33, SE-100 44 Stockholm
E-mail: juliette.soulard@ee.kth.se

Copyright © 2009 MC2D & MITI

Abstract: Because of their numerous advantages but also of some undesirable effects, permanent-
magnet synchronous machines (PMSMs) with non-overlapping concentrated windings have recently
been widely investigated. In this paper, the design features specific to 3-phase PMSMs with non-
overlapping concentrated windings are presented. Especially, it is shown that the selections of the
stator core manufacturing method, the number of winding layers, the combination of pole and slot
numbers, and the geometry of the tooth tips are crucial during the design stage of the machine.

Keywords: Permanent-magnet motor, motor design, concentrated windings.

1. Introduction references and tips for the analytical modeling

PMSMs with non-overlapping concentrated
windings have become a competitive alternative
to PMSMs with distributed windings for certain
applications. Non-overlapping concentrated
windings are indeed attractive for several
reasons. Besides the short end-windings, a low
cogging torque, good fault-tolerant capability,
and a high constant power speed range can be
achieved. Therefore, PMSMs with non-
overlapping concentrated windings have
recently been widely investigated. The design of
such PMSMs differs from the design of PMSMs
with distributed windings. The goal of this
paper is to underline the particular design
features of 3-phase PMSMs with concentrated
windings. No analytical model is presented but
relevant references are provided. Especially, the
influence on the design of the combination of
pole and slot numbers is investigated. At first, a
design procedure is proposed, followed with
of PMSMs with concentrated windings. At last,
examples of PMSMs with concentrated
windings are given.
2. Design procedure
When designing PMSMs with concentrated
windings, i.e. fractional-slot PMSMs with non-
overlapping coils, some choices specific to
these machines have to be made in order to
obtain the most suitable design for the
application. Figure 1 summarizes these choices
and their influence on the design. At first, the
designer should select the manufacturing
method of the stator core, which gives an
estimation of the slot fill factor. Then the
number of winding layers should be selected,
followed by the combination of pole and slot
numbers. The rotor manufacturing should be
 From: Select: Influence in the design:
stator core material: iron or SMC?
Table 1 Method to manufacture
slot shape: semi-closed or open slots?
the stator core and coils
value of slot fill factor

end-windings length
Number of
Table 2 resistance and inductance values
winding layers
MMF harmonic content

Combination of winding factor

Figure 2
pole and slot numbers

segmented PMs?
section 2.4 Rotor manufacturing
(to limit rotor losses) laminated rotor iron?

...
Figure 1: Characteristics of the design procedure of PMSMs with concentrated windings.
Table 1: Methods to manufacture the stator core and windings of a PMSM with concentrated windings.

Stator core
Method Windings Slot fill factor
production
Laminated core punching low (≤ 0.5)
needle
Spiral-laminated core punching (patented) low (≤ 0.5)
windings
Joint-lapped core punching (patented) high
Single-tooth segments punching + welding
pre-wound
SMC press high (≥ 0.6)
windings
Open slots punching

considered in a view to minimize the rotor
losses. The design can then be conducted just
as any PMSM with distributed windings.
However, the tooth tips, if there are any,
should be carefully designed, in order to obtain
an optimal inductance value decisive for a
good flux-weakening capability or to avoid too
high iron losses or torque ripple. These steps
are detailed and discussed in the following
sections.
2.1 Selection of the manufacturing method
The method to manufacture the stator core and
windings should be considered at an early stage
of the machine's design. Indeed, the chosen
method determines the tooth shape (with or
without tips), the slot fill factor or the stator
core material (iron or SMC) of the machine.
The different manufacturing techniques are
presented and analyzed further in [1] or [2].
Table 1 summarizes some possibilities and their
influence on the slot fill factor.
2.2 Selection of the number of layers
Based After reflecting on the manufacturing
methods, the number of layers of the windings
should be chosen. Single-layer windings have
coils wound only on alternate teeth, whereas
each tooth of the double-layer windings carries
a coil. The choice of the number of layers
depends mostly on the application. Table 2
compares some characteristics of single-layer
and double-layer concentrated windings. Ishak
discussed fully these differences for the winding
factor, EMF and inductances in [3] and for the
losses in [4]. In [5], Bianchi defines rules to
transform a double-layer to a single-layer
winding and discusses the advantages of
concentrated windings for fault tolerance.
Single-layer windings are preferred to double-
layers windings when a high fault-tolerance is
required since the phases of the windings are
thermally and electrically isolated, the self-
inductance is high (which limits the short circuit
currents), and the mutual inductance is very low
(which isolate the phases magnetically). Due to
their higher inductance, single-layer windings
are also preferred in applications requiring a
wide speed range of constant power operation.
Otherwise, double-layer windings are preferable
to limit the losses and torque ripple.
Furthermore, there are more possible
combinations of pole and slot numbers to
choose between with double-layer windings
than with single-layer windings. Single-layer
windings with unequal tooth widths are Figure 2: How to select the combination of pole and
interesting for brushless DC operation [6]. The slot numbers.
teeth that are not carrying any coils are thinner
than the other teeth. The winding flux-linkage
and the fundamental winding factor are then Therefore, this combination should be
increased, which gives a more trapezoidal phase carefully chosen in order to maximize the
back-EMF [6]. fundamental winding factor and thus the
torque. For a given combination of pole and
Table 2: Comparison between single and double slot numbers, there are many possibilities to
layer concentrated windings.
arrange the coils of each phase in the slots to
Single- Double- form the winding layout. The most interesting
layer layer winding layout is the one that gives the highest
Fundamental higher lower fundamental winding factor. There are
winding factor different methods to find the winding layout.
End-windings longer shorter One method is similar to the one used for the
Slot fill factor higher lower synchronous machine with fractional slot
Self-inductance higher lower
windings [7], while another method is based
Mutual inductance lower higher
on the star of slots [8]. The first method is easy
Back-EMF more more
trapezoidal sinusoidal to apply for finding the layouts of double-layer
Harmonic content of higher lower concentrated-windings, but it is, in some cases,
MMF difficult to find the layouts for the single-layer
Eddy current losses higher lower windings. However, the method provided in
in the PM [8] allows finding the layout of the single-layer
Overload torque higher lower windings from the double-layer windings
capability layout in all possible cases.
Manufacturing easier more Figure 3 shows the evolution of the
difficult fundamental winding factor as a function of
the number of slots per pole per phase. As can
2.3 Selection of the number of poles and be seen, PMSMs with a low number of slots
number of slots per pole per phase q (q<0.25) can have a high
winding factor. However, the number of poles
As illustrated in Figure 2, the combination of is much larger than the number of slots in
slot and pole numbers can be selected to obtain these cases (for q=1/9, the number of poles is 3
a high fundamental winding factor, many times the number of slots) which limits the
symmetries in the winding layout, low number of applications for these machines.
amplitude and low number of sub-harmonics in They could be used in the case of magnetic
the MMF distribution and eventually a low gear applications. High fundamental winding
cogging torque. factors can be found when the number of poles
is close to the number of slots (q ≈ 1/3). In this
case, the flux-linkage is maximized since the
A Winding layout and winding factor slot pitch is almost equal to the pole pitch. In
The winding layout and winding factor of a many cases, the winding factor for the single-
PMSM with concentrated windings depends layer windings is equal to the winding factor
on its combination of pole and slot numbers. of the double-layer windings (crosses and dots
are superposed in Figure 3). Around q ≈ 1/3,
 Figure 3: Fundamental winding factor as a function of the number of slots per pole per phase.
the winding factors for some single-layer
windings are higher than those from double-
layer windings for the same value of q. The
highest fundamental winding factor for the
single-layer windings, equal to 0.966, is
obtained for q=2/7 or q=2/5.
B Noise and vibrations
PMSMs with concentrated windings may be
subject to high vibrations and noises
depending on the combination of pole and slot
numbers. The vibration and noise come mostly
from the radial magnetic forces in the airgap.
If the radial magnetic forces are not regularly
distributed along the airgap, their sum results
in an unidirectional pulling force that rotates
with time and generates noise and vibration in
the machine. This resulting force, called
unbalanced magnetic pull, can be due to the
asymmetry in the windings. The combinations
of slots and poles numbers for which the
greatest common divisor between the number
of slots and the number of poles is equal to 1
have a winding layout without symmetry [9]
responsible for an unbalanced magnetic pull in
the machine. Although it is easier to select a
combination of pole and slot numbers that
avoid the problems with the unbalanced
magnetic force, machines with an asymmetry
in the winding can be designed as long as the
unbalanced magnetic force is taken into
account. This force should be carefully
considered, especially when the machine has a
high electric loading [10]. The bearings should
be carefully chosen [11]. Undesired noise can
also occur for modular machines that do not
present any unbalanced magnetic force. In
[12], Wang shows that modular machines may
be subject to low-frequency resonant
vibrations within their operational speed range.
These vibrations occur only at certain speeds
which may or may not be an issue depending
on the application.
C Rotor losses
The main drawback of PMSMs with
concentrated windings is the large rotor losses
they may feature. These losses are caused by
the large harmonic content in the MMF
distribution [13]. The number of sub-
harmonics in the MMF distribution of a
PMSM with concentrated windings depends
on the combination of pole and slot numbers.
Bianchi shows in [13] that for the same slot
number, the rotor losses increase with an
increasing pole number with some local
minima for q ≈ 5/6 and q = 0.5. The choice of
the combination of pole and slot numbers can
then be influenced by the MMF harmonic
spectrum and specially the quantity and
amplitude of the sub-harmonic components
with a view to minimizing the rotor losses.
D Cogging torque and torque ripple
A very low cogging torque can be obtained if
the slot and pole numbers are chosen so that
the least common multiple (LCM) between
them is large [14]. The closer the number of
slots Qs to the number of poles p, the higher
their LCM. Combinations of pole and slot
numbers with p=Qs+k have a higher
LCM(p,Qs) than combinations with p=Qs-k,
though both combinations have the same
winding factors (k being an integer). The value
of LCM(p,Qs) may then be a criteria to select
the combination of pole and slot numbers.
However, a low cogging torque does not
always guarantee a low torque ripple [2].
 obtain the optimal value of this inductance.
E Rotor manufacturing Furthermore, the risk of demagnetization of
PMs under flux-weakening operation should
There are different means to decrease the rotor
be evaluated. As mentioned earlier, PMSMs
losses in PMSMs with concentrated windings
with single-layer concentrated windings have
which are due to the large harmonic content of
higher inductances than PMSMs with double-
the MMF. By segmenting the PMs axially [15]
layer concentrated windings because of the
or circumferentially [16], the reduction of their
high harmonic content of the MMF
losses is significant. In [16] or [17], the PMs
distribution. The value of the inductance can
losses are more than halved by segmenting
also be increased by adjusting the dimensions
circumferentially the PMs into two pieces. A
of the tooth tips.
laminated rotor should be preferred to a rotor
The influence of the tooth tips' dimensions on
in solid iron. Another solution is to consider
the inductance values is shown for an example
other PM material. Some PMs have a higher
in Figure 4 and Figure 5. In this example, the
resistivity and therefore, lower losses are
dimension of the tooth tip from a surface-
induced in them. Bonded PMs have a much
mounted PMSM with 10-pole 12-slot is varied
higher resistivity than sintered PMs. In [18],
in thickness (the slot opening width is
EL-Refaie compares the performance of
constant), as shown in Figure 4. The d- and q-
PMSMs with sintered PMs (resistivity of 1.5
axes inductances, which are given in Figure 5,
μΩm) and bonded PMs (resistivity of 20
are computed from a blocked-rotor test by
μΩm). In his study, he shows that the losses in
feeding one phase with a sinusoidal current. In
bonded PMs are very low compared to the
this figure, the d-axis inductance from the
losses in the sintered non-segmented PMs. If
geometry with the larger tooth-tip is defined as
the sintered PMs are segmented
a reference equal to 1 p.u. As can be seen, the
circumferentially in 4 pieces, their losses are
thinner the tooth tip, the lower the d-axis
about as high as the losses in the bonded PMs.
inductance. Furthermore, for large negative d-
Some of these solutions could be considered to
axis currents, the d-axis inductance begins to
increase the efficiency of the machine or avoid
drop due to the saturation in the tooth tips, as
too high temperature in the magnets and thus
Figure 5 illustrates for a current of -1 p.u. This
their demagnetization.
drop in the d-axis inductance coincides with
large negative fields in the PMs that risk
F Design considering flux-weakening capability
demagnetizing them. The q-axis inductance
Surface-mounted PMSMs with concentrated begins to drop for higher q-axis current (in
windings are good candidate for achieving a absolute value) when the tooth tip is thin, due
wide constant power speed range under flux- to the saturation in the tooth tip. This is not an
weakening operation, because of their high issue, as the machine has surface-mounted
leakage inductance ([3] or [5]). The capacity PMs and no saliency when the current is zero.
of surface-mounted PMSMs with concentrated At base speed, the d-axis current is zero and a
windings to achieve a wide constant power lower q-axis inductance would actually
speed range has been shown in [19] by improve the power factor. This short study
Magnussen, and in [9] by EL Refaie. In [19], shows that the tooth tips should be designed
Magnussen investigates two PMSMs with carefully as their dimensions can influence
double-layer concentrated windings and show significantly the values of both d- and q-axes
their better field-weakening capability inductances, especially for machines with high
compared to a surface-mounted PMSM with electric loadings. Moreover, a FE tool
distributed windings, using FE simulations. In facilitates greatly the design of the tooth tip.
[9], EL Refaie concentrates on PMSMs with The tooth tips are also the source of iron losses
single-layer windings, which have higher especially under flux-weakening operation
inductances than double-layer windings. He [20]. Decreasing their size may decrease the
shows with measurements that a surface- iron losses but also the d-axis inductance.
mounted PMSM with 36-slot/30-pole can Therefore a compromise should be found.
achieve speeds up to 5 times the base speed
under constant power, and even higher speeds
can be expected.
The flux-weakening capability of the PMSM
depends mainly on the value of its d-axis
inductance. Therefore, the design of the
machine should be conducted in order to
 open-circuit field and armature field for
surface-mounted PMSMs. It accounts for both
overlapping and non-overlapping windings. In
[25], Proca shows how the models from Zhu
can be included in a procedure to design
surface-mounted PMSMs. Thus, the torque
ripple or back-EMF is derived from Zhu's
models. In [9], EL-Refaie presents also a
design procedure based on Zhu's models but
with models specific to PMSMs with non-
overlapping concentrated windings. His
procedure includes also resistance, inductance,
and losses calculations of such machines.
Zhu's models are also implemented in the web-
based design tool Emetor [26]. This tool
allows designing PMSMs with overlapping or
non-overlapping windings. Hints on how to
analytically calculate stator iron losses of
PMSMs with concentrated windings are given
[20].

Table 3: References to analytical models useful for

PMSM design with concentrated windings.
Properties Reference Comments
Open-circuit inner/outer rotor surface-
airgap flux [21,23] mounted with parallel or
Figure 4: Flux density in the tested tooth tips at a density radial PM magnetization
current of -1 p.u in d-axis position. for distributed windings
Armature- [24,27]
(slotless stator)
reaction airgap
for concentrated
flux density [21,27]
windings
calculation of a relative
Slot effects [22,27]
permeance
[7]
Winding layout
[8] based on star of slot
[2,5] from EMF phasors
[9] from winding function
Winding factor
from closed-form
[28]
expressions
Inductances [9,29] 2D-models
DC resistance of single-
[9,30] or double-layer
Resistance concentrated windings
with skin and proximity
[30,31]
effects
Figure 5: d- and q-axes inductances versus d-
Cogging torque [14,27]
respective q-axis current for different tooth tip
dimensions. Unbalanced
[10,12,27]
magnetic pull
Rotor iron
[32] in case of solid iron back
losses
3. Analytical models Rotor magnet
[4,16,33]
losses
Some references for analytical models useful [25] for distributed windings
for the design of PMSMs with concentrated for concentrated
windings can be found in Table 3. This list of Design [9]
windings
procedure
reference is not exhaustive. Additional for distributed and
[26]
references can be found in EL-Refaie's thesis concentrated windings
[9] or in the references given in the table. In
[21-24], Zhu proposes models to calculate the
Table 4: Prototype PMSMs with concentrated windings in literature.
Layer Power Speed
p/Qs q PM Ref. Application
number [kW] [rpm]
2/3 0.5 2 surface 2 18000 [37] vaccum pump
4/6 0.5 2 buried 11 6000 [38] field weakening
6/9 0.5 2 surface 1.4 3000 [39] SMC
8/12 0.5 2 surface 1.6 3000 [39] SMC
10/12 2/5 1&2 surface 0.23 400 [3] -
10/12 2/5 2 buried 45 420 [40] pulp & paper
14/15 0.357 2 surface 20 2000 [41] traction
16/24 0.5 1&2 buried & surface 45 1000 [35] field weakening
20/30 0.5 1 buried 150 ~200 [34] traction
22/24 0.364 2 buried 18.5 1700 [42] automotive
24/18 0.5 2 surface ~0.2 ~150 [43] SMC bicycle
28/24 2/7 1 surface 0.26 250 [44] bicycle
28/24 2/7 1 surface 0.80 250 [2] field weakening
24/36 0.5 2 surface 5 240 [45] wind turbine
26/36 0.462 2 surface 10 200 [45] wind turbine
30/36 2/2 1 surface 6 600 [46] traction

4. Examples fundamental winding factor while avoiding an

PMSMs with concentrated windings can be
used in many applications as in electric
vehicles or wind turbines. Because of their
good fault tolerance capability, they can also
be used in electrical actuators in aircrafts.
Many examples of PMSMs with concentrated
windings can nowadays be found in the
literature. A non-exhaustive list of such
machines on which experimental tests were
conducted is given in Table 4. The most
popular combinations of pole and slot numbers
are those giving a number of slots per pole per
phase q equal to 2/5 or 2/7. PMSMs with
q=0.5 have sometimes an irregular distribution
of teeth as in [34,35] in order to increase the
fundamental winding factor. The modular PM
machine with the lowest number of poles is the
one with 10 poles, 12 slots. Therefore, this
combination of pole and slot numbers is the
obvious choice for the applications requiring
middle-range speeds in order to limit the
nominal frequency. Other publications
showing measurements on 10-pole, 12-slot
motors that are not mentioned in Table 4 are
[5,36].
5. Conclusion
PMSMs with non-overlapping concentrated
windings are attractive for many applications,
especially the applications requiring a low
speed and a high pole number. Indeed,
PMSMs with concentrated windings having
more than 10 poles can feature a high
undesirable unbalanced magnetic pull.
Guidelines to design these machines are
provided in this paper along with relevant
references of analytical models. Particularly, it
is shown that tooth tips should be designed
carefully. Examples of prototype motors that
can be found in the literature are also reported.
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