Analytical method for the design of a machine with

aligned and skewed permanent magnets

ALMEIDA¹, José Leandro C. N., SOUZA², Teófilo M. de, FORTES³, Z. Márcio

Universidade Estadual Paulista (UNESP) – Campus Guaratinguetá¹²

Avenida Doutor Ariberto Pereira Cunha, 333 – Guaratinguetá – SP – Brazil – P.O. Box 205, Zip Code 12516-410,
Universidade Federal Fluminense (UFF) – Campus Niterói³
Rua Passos da Pátria, 156 - Bloco E - Sala 431 – São Domingos – Niterói – RJ – Brazil – Zip Code 24210-240,

E-mail: leandrocasanova@uol.com.br¹ – teofilo@feg.unesp.br² – mzf@vm.uff.br³

Abstract – This work aims to present the design and the
evaluation of a standard multi-pole machine with permanent
magnets inserted in the rotor by two different geometrical forms:
aligned and skewed magnets. The design (new analytical method)
was based on a standard 250 W three phase 12-pole induction
motor (squirrel cage rotor type), beginning with the original stator
constructive data to calculate the magnetic flux density to
determine the permanent magnets. In the development of the work,
a simple and modular rotor was built reusing the original 12-pole
stator (concentrated windings). The machine was evaluated in a
laboratory for the purpose of checking the quantity and quality of
energy produced with the machine operating as a generator and its
start, torque, and performance working as a motor. In conclusion,
the modular skewed magnet is an option for electrical machines,
for the generation of a reasonable quality, in the context of
decentralized generation and a motor with high torque and low
energetic consumption.
I. INTRODUCTION
angle is calculated according to an analytical method [6] and
the construction elaborated by slicing the rotor into three equal
parts aims to simplify the manufacture without interfering in its
performance. In this context, [7] presented a reluctance
synchronous machine with neodymium permanent magnet
bonded to the rotor surface of modular construction by means
of slicing the rotor in three equal parts, so to permit skewing of
the magnets and their cost reduction.
This work proposes to transform a 220 V three phase
induction motor equipped with a squirrel cage type rotor, 12
poles, and 250 W, exchanging a new one with neodymium
permanent magnets insets in two different geometrical forms.
The design required the construction of two rotor
configurations one with aligned permanent magnet blocks and
the other with magnet blocks axially skewed in relation to the
rotor. It first introduces the methodology and the analytical
method of the adapted three phase induction motor, which was
accomplished without the help of advanced computing tools.

P
ERMANENT MAGNET machines are growing in popularity Finally, all the configurations were evaluated in a laboratory.
on account of advances in their geometries and new
designs. These machines have been found to be more II. DESIGN
adequate for position control and energy generation in
decentralized small plants, and as motors of high performance WEG Inc., manufacturers of electrical motors, furnished the
in industry due to their excellent dynamic capacity, loss machine (Fig. 1) and its technical characteristics as per the data
reduction and high torque/weight relation [1], [2]. in Tables I and II and Fig. 2.
Jahns and Soong [3] presented a revision for the type of
drives (waveforms) for permanent magnets motors and
techniques in the manufacture of magnet motors for the
mitigation of pulsing, ripple, and cogging torques. Recently,
concentrated windings have been in evidence due to the lower
loss in copper and the reduced size in comparison with
distributed windings [4]. Fig. 1 – Standard 12 poles motor
In machines with permanent magnet distributed around the
rotor surface, [5] established a correlation of the combination In the concentrated windings, there is only one slot per phase
effect between the slots and the number of poles versus the per pole. According to [8], concentrated windings have several
inclination angle of the magnet blocks. The optimum inclination disadvantages in view of the inefficient use of all the internal

978-1-4244-6392-3/10/$26.00 ©2010 IEEE 1210

periphery of the stator nucleus. Therefore, the use of extremely Considering the initial data of the three-phase induction
deep slots becomes necessary where the windings are motor of squirrel-cage type the permanent magnets are
concentrated, thus increasing dispersion and reactance of the specified as per the flux chart of Fig. 3 for the adapting the new
stator. One favorable factor is the low relation iron-copper synchronous machine with permanent magnets inserted in the
while the distributed windings reduce the harmonics in the rotor.
output waveform, since the slots are efficiently distributed
around the internal periphery of the stator [9].
TABLE I
MOTOR TECHNICAL SPECIFICATIONS
Induction motor plate data Symbols Values Unity
Power P 250 W
Housing 90L
Angular speed ω 560 rpm
Poles p 12
Efficiency
0,41
Power factor cos Φ 0,43
Voltages V 220/380/440/760 V
Nominal currents I 3.72/2.15/1.86/ - A

TABLE II
STATOR COIL SPECIFICATIONS
Winding construction data Symbols Values Unity
Number of turns by phase 1176
Number of turns by group (coils) 196
Wire diameter 0.35 mm
Slot Q 36
Stator internal diameter Dint est 92.5 mm
Stator internal length Lint est 120 mm
Step 1:4
Windings by phase 1
Groups by phase 6
Frequency f 60 Hz Fig. 3 – Flow chart for the magnet specifications

Figure 2 presents the concentrated windings connections of A. Flux Density

the prototype stator for a 12-pole motor.
In accordance with the stator windings data construction the
flux density was calculated per pole per phase and presented in
Table III. These values were important for the dimensions and
the kind of magnet specifications for which the rotor to be
manufactured. The density of the stator flux per pole per phase
was calculated by (1) and (2).

 2 
Φ =   × Yp × L int est × Be (1)
π 
 D int est × π 
Yp =   (2)
 p 

Fig. 2 – Planed view of the 12-pole motor windings schematics

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 According to [10], the stator magnetic remanence ( B e ) B. Determination of Dimensions and Type of Permanent
varies between 0.3 and 0.6 Wb/m²; in general, 0.45 Wb/m² is Magnet
the most adopted. According to WEG Industry, the initial
magnetic remanence is 0.5 Wb/m². The flux density calculus by Equation (9) determines the magnetic flux density per
(1) had to be corrected and verified according to (3), (4) and magnet pole ( Φ m ) which is the product of the magnetic
(5). remanence ( Bm ) by the magnet area (S). In the prototype it
was admitted that the flux density per pole per phase of the
 V × f d × 10 8  (3) stator ( Φ ) was equal to the magnetic flux density per magnet
Φ =  
 4 , 44 × f × f e × N f  pole ( Φ m ).
Φ m
 180 0  S = (9)
fe = sin   (4) B m

 2 
The area is the measure of the width ( Lm ) by the length
The 180º angle of the winding factor formulae is adopted ( Cm ) of the magnet per pole, as per (10). In the design, the
when the coil step is equal to the polar step per slot numbers.
magnet length is the measure of the rotor package, which is of a
q× β  pre-fixed value. It is only necessary to determine the magnet
sin  
 2  width and the magnetic remanence.
fd = (5)
 β 
q × sin  
 2  S = L m × Cm (10)
Equations (6), (7), and (8) complement (5).
The magnetic remanence depends on its type, dimensions,
Q and the working temperature. Ferrite is a choice that is more
q= (6)
m× p economically advantageous; however, ferrite presents low
remanence values. Alnico and samarium-cobalt permanent
1800 × E magnets were discarded due to their high cost. There is an
β= (7)
indication that the magnet width should not exceed 70% of the
rp
pitch pole ( Yp ), in view of the attachment of these magnets to
Q the rotor. A minimum iron wall (borders) is required between
rp = (8)
p the magnets to withstand the centrifugal forces.
Neodymium was the chosen magnet, as showed in table IV,
as ferrite would not suffice for our demands because its
TABLE III dimensions would exceed the pitch pole. Furthermore, its
CALCULUS OF THE STATOR FLUX DENSITY PER POLE PER PHASE remanence is low (in general up to 0.15 Wb/m²), which would
Main calculus Símbols Values Unity result in a flux density value much below our needs. To suit the
Stator flux density per pole per phase Φ 0.00070232 Wb 120 mm rotor package length, six 19 mm long pieces were
Pitch pole Yp 0.0242 m chosen. With these, the assembly became easier; especially the
Stator length L 0.12 m manufacturing of the magnet blocks in angle.
Magnetic flux stator Be 0.3797 Wb/m² The chosen magnet presented an average remanence of 0.33
Distribution factor fd 1 Wb/m², properly measured with a gaussmeter [11], resulting in
Winding factor fe 1 a magnetic flux of 0.00055 Wb, less than the ideal. During the
Number of windings per phase Nf 1176 measurements, however, it was observed that remanence on the
Total number of windings Nt 3528 magnet edges showed values of 60% (0.2 Wb/m²) of the
Number of winding per group Ng 3 average remanence up 10 to 15% beyond the width of the piece
Applied tension V 220 V (1.4 to 2 mm). With these data admitted in the flux calculus,
Number of slots per pole per phase q 1 there is a rise in the magnetic flux of about 0.00063 Wb, which
Slot step β 60º E would result in a generated voltage of approximately 200 V.
The correct magnet remanence definition, as per the calculus,
Polar step per slot numbers rp 3
should be 0.4 Wb/m², thus defining the N42 neodymium
magnet that presented a higher value and cost than the N35

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magnet. The prototype was constructed with a N35 magnet
α × D int est × e × π
considering its cost/benefit. Ag = (14)
p
TABLE IV
NEODYMIUM MAGNET SPECIFICATIONS
N35 neodymium Where α is referred to as the polar arc coefficient and is
magnet definitions Símbols Values Unity defined as the rate between the pole arc ( bp ) and the pitch pole
Length Cm 19 mm ( Yp ). In accordance with [13], that coefficient varies from 0.55
Width Lm 14 mm to 0.75.
Thickness e 5 mm
Magnetic remanence Bm 0.33 Wb/m² bp Yp − e
α = = (15)
Yp Yp
The values calculated and presented in Table V are for the
C. Air Gap air gap specification, according to the forms presented by [13],
[14].
Air gap (g) is the clearance between the stator armature and
the rotor magnet as shown in Fig. 4. TABLE V
AIR GAP DEFINITIONS
Data Symbols Values Unity
Magnet thickness e 5 mm
Permeance coefficient PC 8.4
Magnet width Lm 14 mm
Stator internal diameter Dint est 92.5 mm
Poles p 12
Pitch pole Yp 24.2 mm
Calculated
Air Gap g 0.81 mm
Flux concentrated factor Cɸ 0.72
Cross-sectional areas per
pole of the magnet Am 70 mm²
Cross-sectional areas per
pole of the air gap Ag 96.01 mm²
Fig. 4 – Clearance between the stator armature and the rotor magnet Polar arc coefficient α 0.79

According to [12], the relation between the air gap and the Figure 4 shows the air gap variation along the entire rotor
magnet thickness should be less than 10%, for the rectangular circumference. The air gap on the rotor border (steel surface) is
configurations of the magnet poles. 0.25 mm and constant, but in the magnets this clearance is
Based on several studies [12]–[15], the air gap can be variable, as shown in Table VI. It should be noticed that at the
precisely calculated by (11), (12), (13), (14) and (15). edge of the magnets the air gap is 0.25 mm with a progressive
e increase up to a maximum air gap value of 0.78 mm at the
g= (11) center of the magnet. In a general way, analyzing the air gap
PC × CΦ
values presented in Fig. 4 the reference points A, B, C, and D
Where the concentrated flux factor ( CΦ ), are in accordance with the values calculated by Table V.
Am
CΦ = (12) TABLE VI
Ag VARIATION OF THE AIR GAP OVER THE MAGNETS
Reference
Where Am and Ag represent the transversal cut areas by the points Distances Air gap Unity
magnet and the air gap pole respectively, A At magnet center to 7 mm from borders 0.78 mm
B 4.7 mm distant from borders 0.72 mm
Am = L m × e (13) C 2.4 mm distant from borders 0.55 mm
D Borders (steel rotor surface) 0.25 mm

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 D. Inclination angles θinclination = inclination angle of the magnet blocks
Cm = total length of the magnets or rotor
The rotors were manufactured in two geometrical forms for giron = air gap between the stator and the rotor iron border
comparison, one with aligned magnets and the other with L m = magnet width – 0.1 Yp ˂ L m ˂ 0.9 Yp
axially skewed magnets.
According to [16], three factors contribute to reduce ripple
torque for a machine working as a motor, namely, distribution TABLE VII
COMPARISON OF THE MAGNETS INCLINATION ANGLES
of the stator windings, the type of the waveforms feeding the
Magnet
machine, and the machine geometry. inclination Design Angle
One important characteristic is the cogging torque that can be angle 3.7º 5º 7º
understood as an oscillatory torque caused by the rotor Neodymium
tendency to align with the stator on a determined position where magnet
specs Measures in milimeters
the magnet magnetic flux is maximized [16]. The cogging Magnet
torque occurs even when there is no current in the stator and length (Cm) 20 19 20
can be reduced with a high value in the relation between slots Magnet
and poles [5], besides all the other factors for the ripple torque width (Lm) 16 14 9
Magnet
reduction. thickness (e) 8 5 5
That inclination should meet the following criterion: the Maximum
extremity of the last magnet block should be in the same initial calculated
gap (g) 0.96 0.81 1.2
direction of the opposite extremity of the next magnet block, as
refers to the other pole, as seen by the intersection between % pitch pole 67 58 37
poles, as sketched in fig. 5. The inclination angle is a Measures in Wb/m²
consequence of the established criterion and not a Mean magnetic
determination. The selection of a new inclination angle would remanence (B) 0.33 0.33 0.5
require a new specification of the magnet width and, Measures in Volts
consequently, proper remanence values and thickness of the Tension
new magnet which, in turn, would cause a new air gap value. probable 230 198 195

Technical and economical considerations

Tendency to Tendency to
highest THD Acquisition lowest THD
and torque for a and torque
fluctuations in reasonable fluctuations in
Favorable relation to magnet relation to
aspects other angles cost other angles

High acquisition
cost due to its High acquisition
Unfavorable high dimension Low generated cost due to its
aspects values tension high remanence
Fig. 5 – Magnet inclination angle

Table VII presents two new inclination angles for III. EVALUATIONS AND RESULTS
comparison with that determined by the design, which shows
the disadvantage of the magnets high acquisition costs. The The scope was to analyze comparatively the two geometrical
maximum inclination angle calculated per (16) is approximately forms of the synchronous machine of permanent magnets
11º. inserted in the rotor using aligned and skewed magnets,
respectively, as shown in Figs. 6 and 7. The prototype was
   180   evaluated either as a generator and a motor.
 (D int est − 2 ⋅ giron) ⋅ sin  − Lm 
  p   
θinclination = arctg   (16)
 Cm 
 
 

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 capacity at 195 V and 205 V without charge. Figure 9 shows
the three-phase waveforms spectrum of the skewed magnet
rotor without charge and the coils closed in triangle. The three-
phase waveforms configuration of the skewed magnets with the
coils closed in star is shown in Fig. 10.

Fig. 6 – Rotor prototype with aligned magnets

Fig. 7 – Rotor prototype with skewed magnets

Fig. 9 – Three-phase waveforms without charge for coils connected in triangle
- skewed magnet rotor
A. Machine Operating as a Generator

1) Generator with Aligned Magnets

The rehearsals were performed at the nominal frequency of

60 Hz at 600 rpm and the results obtained were 238 V without
charge with 16% of total harmonic distortion (THD). The
spectrum voltage of the three-phase waveform with charge is
shown in Fig. 8, obtained by a Yokogawa CW 240 and WT
1600 energy analyzers. At the nominal frequency, there were no
variations in the waveforms with or without charge. However,
the essay in charge, with a unitary power factor, the capacity of
generation was 475 W (three-phase) at 221 V. Fig. 10 – Three-phase waveforms without charge for coils connected in star -
skewed magnet rotor

3) Discussion about the Generator

Favorable aspects of the skewed magnet rotor configuration

Fig. 8 – Three-phase waveforms with charge for coils connected in triangle –
aligned magnet rotor
2) Generator with Skewed Magnets
Following the same methodologies of the previous topic, at
the nominal frequency of 60 Hz and 600 rpm the generator with
skewed magnets presented a THD of 8 % and 7 % respectively
for the coils closed in triangle and in star, 236 W three-phase
are the reduced harmonic distortion (in the context of
decentralized generation). The main negative aspect was the
low generating capacity in relation to the other configuration,
thus ratifying the design theory of a generated voltage capacity
near 200V in view of the application of the inferior magnetic
remanence of N35 neodymium magnets.
Otherwise, the favorable aspects of the aligned magnet rotor
configuration are the high generating capacity and low drop of
voltage in relation to the application of charges. However, a
detrimental factor for the application of this configuration is the
need for a high starting torque (cogging torque) of around ± 9.8
N.m, which limits its application in aeolical sites and small
hydroelectrical plants.

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 B. Machine Operating as a Motor

1) Aligned Magnet Motor

Initially, the start tests without charge presented pronounced

trepidations in frequencies below 15 Hz and totally unfavorable
in starts without charge. This result indicated an unacceptable
behavior. In this configuration the rotor presented its shaft as
too clogged, and its instability at the start raised difficulties in
proceeding with the tests.
Fig. 12 – Performance versus torque
2) Skewed Magnet Motor

The first test was to check the start current (without charge),
relating the prototype with both the skewed permanent magnet
(PM) rotor and squirrel cage rotor respectively. The results
were 2 A and 7 A, which meant that the start current by means
of the converter (in 60 Hz) was less than the nominal current
itself for the prototype.
Figures 11, 12, and 13 demonstrate the compared graphics
and confirm the optimum performance of the prototype in
relation to induction motor. At nominal current, it can be
verified (see Fig. 11) that the 15.3 N.m and 6.5 N.m
Fig. 13 – Power factor versus torque
respectively refer to machine with skewed PM rotor – and the
squirrel cage rotor. Figure 12 presents the skewed PM rotor
best operating point, which is at 86% efficiency, corresponding
to a torque of 6.5 N.m, an equivalent value to the nominal
induction motor torque.

Fig. 14 – Extrapolated curve with constant torque (skewed PM rotor)

3) Discussions about the Machine Operating as a Motor

The motor with skewed PM rotor presents various favorable

Fig. 11 – Torque versus current
As can be observed, Fig. 13 shows the power factor behavior
with charge, the squirrel cage rotor curve is linear while for
skewed PM rotor the power factor values do not practically
change in torque value above 3 N.m (20% of skewed PM rotor
nominal torque).
Finally, the last test was accomplished, as shown in Fig. 14,
aiming to check the skewed PM rotor behavior with charge and
frequency above nominal, and a constant charge of 6 N.m
(squirrel cage rotor nominal torque) was applied.
characteristics, namely: start (with or without charge) with no
significant anomalies, low starting current, low energetic
consumption, high torque/volume relation, operating at 240%
torque, power factor of 166% and efficiency of 148% higher in
relation to squirrel cage rotor and was also verified the machine
full operation without charge up to 120 Hz (it could even be
higher!). The detrimental factor, though, is the impossibility of
its start and direct operation from the power line. On the other
hand, frequency converters can be used to compensate for that.
The aligned permanent magnet rotor has the drawback of its
shaft being clogged and great trepidations to start. A clogged
shaft means that in this configuration of concentrated windings

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there is a pronounced cogging torque which was minimized
with the skewed permanent magnets.
IV. CONCLUSION
The synchronous multi-pole machine equipped with skewed
magnet rotor is a great option for electrical machines. Some of
its benefits are low maintenance, no energy consumption in the
rotor (in relation to a conventional synchronous generator), high
torque and low energy consumption. As a multi-pole generator,
it will certainly eliminate reductors or speed multipliers. All
that would certainly cause an increase of global performance in
hydroelectrical plants, aeolic sites, and combustion engines.
This study will certainly contribute to the revision of the
analytical method and to the establishment of a safe reference
aiming at a renewed design of standard motors considering the
reduction of time and costs of manufacture. In other words, the
modular construction of the skewed magnet rotor distributes the
magnetic flux along the pitch pole, thus simplifying and
reducing the manufacturing costs in comparison with a standard
motor, which uses the process of laser cutting of the silicon
steel plates and subsequent aluminum casting to form the
skewed bars.
The rotor, manufactured with 1006 steel, presents another
economic advantage: 1006 steel is cheap, and turning and
milling tools are easily encountered and operated. However,
laser cutting machines and technology process are expensive.
Magnets made of rectangular neodymium are easily produced at
a reasonable price in relation to the magnets made in the form
of arc, besides being of simple assembly.
The results found by the motor skewed permanent magnets
design operating as a motor tend to show this type of
configuration as a favorable option for substituting the three-
phase induction motors, once the tests presented a torque over
15 N.m, two and half times greater than a induction motor
nominal torque at the same current.
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