energies
Article
Electromagnetic Design and Analysis of Permanent Magnet
Linear Synchronous Motor
Lijuan Yu 1,2 , Shuyuan Chang 1,2 , Jialong He 1,2, *, Huilu Sun 1,2 , Jie Huang 1,2 and Hailong Tian 1,2
Citation: Yu, L.; Chang, S.; He, J.;
Sun, H.; Huang, J.; Tian, H.
Electromagnetic Design and Analysis
of Permanent Magnet Linear
Synchronous Motor. Energies 2022, 15,
5441. https://doi.org/10.3390/
en15155441
Academic Editors: Ahmed
Abu-Siada and Federico Barrero
Received: 7 June 2022
Accepted: 21 July 2022
Published: 27 July 2022
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Copyright: © 2022 by the authors.
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Energies 2022, 15, 5441. https://doi.org/10.3390/en15155441
1 Key Laboratory of CNC Equipment Reliability, Ministry of Education, Jilin University,
Changchun 130022, China; tallyu@163.com (L.Y.); changsy20@mails.jlu.edu.cn (S.C.);
sunhl20@mails.jlu.edu.cn (H.S.); hj_jlu@163.com (J.H.); tianhl.jlu@foxmail.com (H.T.)
2 College of Mechanical and Aerospace Engineering, Jilin University, Changchun 130022, China
* Correspondence: hjl.star@163.com; Tel.: +86-189-4316-1591
Abstract: Since permanent magnet linear synchronous motors are widely used in fatigue testing,
in this paper, the thrust of a permanent magnet linear synchronous motor (PMLSM) is amplified
more than 10 times by the method of resonance. Firstly, the air gap magnetic field is analyzed by the
equivalent magnetization current method (EMC), the electromagnetic thrust is calculated, and the
expression is given by the Maxwell tensor method. The vibration analysis of the whole machine is
used to obtain the conditions under which the motor resonates. The dynamic and static characteristics
of the motor are analyzed through finite element simulation, the results of the motor design are
judged to be reasonable, and the theoretical calculation results are compared with the simulation
results to verify the accuracy of the theoretical calculation. The accuracy of the simulation results is
verified by static force experiments. Finally, the rated thrust of the motor was enlarged more than
10 times by resonance experiments.
Keywords: permanent magnet linear synchronous motor; electromagnetic design; magnetic field
analysis; resonance; finite element analysis
1. Introductions
In recent years, with the development of permanent magnet materials, the develop-
ment and application of linear motors is very rapid. Compared with rotating motors, linear
motors have the advantages of simple structure, high precision, high speed, and long life,
and are widely used in industrial, civil, military, and other linear motion occasions. The
structure of linear motors is diverse, among which permanent magnet linear synchronous
motors are widely used due to their high thrust and high efficiency [1–5]. Whether there is
an iron core in the permanent magnet synchronous linear motor has a great impact on the
dynamic and static characteristics of the motor, compared with the iron-free linear motor,
the iron core linear motor has a large thrust and high rigidity, suitable for high load, and
the heat dissipation effect is good, the cost is low.
The research on linear motors at home and abroad focuses on magnetic field analysis,
thrust and thrust fluctuation optimization, temperature field simulation, etc. The litera-
ture [6] analyzes the magnetic field distribution of a permanent magnet linear synchronous
motor with a double air gap structure. The literature [7] uses a new method of spatial
harmonic fields to analyze magnetic fields instead of the equivalent magnetization current
method. The literature [7–9] uses the equivalent magnetization current method and the
equivalent magnetization strength method to analyze the magnetic field of the motor. The
magnetic field is calculated using the subdomain method, which takes into account the end
effect of the motor and calculates the thrust in [10,11]. The electromagnetic thrust is calcu-
lated using the Maxwell tensor method in [12,13]. In The literature [14] a 3D finite element
modeling of a unilateral non-ferrous core hybrid magnetized PMLSM and the analysis and
calculation of the magnetic flux density and thrust characteristics of the no-load air gap are
https://www.mdpi.com/journal/energies
 Energies 2022, 15, 5441 2 of 17

calculated. The literature [15] committed to the study of a high-thrust PMLSM, analyzing
the effect of motor size on motor thrust and normal force and verifying it through finite
elements. A new optimization method is proposed to analyze thrust and compare it with
experimental results in [16]. Literature [17] designed a fault-tolerant permanent magnet
linear synchronous motor and designed electromagnetic parameters and analyzed motor
performance. The literature [18] performs electromagnetic design of bilateral permanent
magnet linear synchronous motors and compared with the single-sided linear motor, the
linear motor with the bilateral structure is verified to have better performance. A new
type of high-temperature superconducting flux modulated linear motor is proposed in [19],
compared with the traditional linear motor, the motor has a larger thrust and smaller thrust
fluctuations, and finally, the motor structure parameters are optimized by finite element
analysis and genetic algorithms. The transverse flux linear oscillation motor with a moving
stator is taken as the research object, and the vibration characteristics of the motor are ana-
lyzed and calculated in [20]. The electromagnetic and vibration characteristics of transverse
flux linear oscillatory motors with different magnetization methods are compared and
analyzed in [21].
To obtain the large thrust of the motor, this paper proposes a resonant method to
amplify the thrust, therefore this paper takes the electromagnetic thrust as the design
goal of the unilateral PMLSM electromagnetic design. Through the theoretical analysis of
magnetic field and thrust and the comparison of finite element results and performance,
the rationality of the motor design is verified, as well as static force experiments to verify
the accuracy of simulation results. Through the vibration analysis of the whole machine, it
is concluded that the output thrust can be amplified when the input frequency is consistent
with the vibration frequency of the whole machine. Finally, the output thrust of the motor
is amplified more than 10 times by resonance experiments. This article is divided into
6 sections in total. The structure and parameters of PMLSM are given in Section 2. In
Section 3, magnetic field analysis of the motor is performed using the equivalent magneti-
zation current method and thrust analysis calculations are performed using the Maxwell
tensor method. In Section 4, finite element analysis of motor no-load and load results is
performed by electromagnetic field simulation. In Section 5, the static force experiment
is performed on the motor, and the rationality of the motor design is further verified by
calculating the thrust constant of the motor. Finally, the full text is summarized in Section 6.

2. PMLSM Structure and Parameters

According to the actual motor according to a certain proportion of the motor structure
design, the motor model is shown in Figure 1. The motor is composed of a primary and
secondary, and the primary is composed of a mover core and windings, which is the moving
element part, the windings are wound around the mover’s teeth, the potential star diagram
of the tank, and the winding order are shown in Figure 2. The secondary stage is composed
of a stator core and a permanent magnet, which is the stator part, permanent magnets
are arranged at a certain distance on the stator core, the permanent magnet is magnetized
in the direction of radial magnetization and adjacent permanent magnets have opposite
polarity, the slot poles selected by PMLSM are 12 slots and 10 poles. The primary core
Energies 2022, 15, x FOR PEER REVIEW
material is DW465_50, the secondary core material is steel_1010, the permanent magnet 3 of 1
material is NdFe35, and the coil winding material is copper, the parameters of PMLSM are
shown in Table 1.

Figure1.1.PMLSM
Figure PMLSM structure.
structure.
 Energies 2022, 15, 5441 3 of 17

Figure 1. PMLSM structure.

(a) (b)
Figure 2. Winding
Figure arrangement
2. Winding order
arrangement (a) Electrical
order: potential
(a) Electrical star star
potential chart of slot
chart (b) Winding
of slot; (b) Winding arrange-
arrangement order.
ment order.

Table 1. PMLSM
Table parameters.
1. PMLSM parameters.

Parameter
Parameter Symbol Symbol ValueValue Unit
Unit
Slot
Slot width
width bs
𝑏 12
12 mm
mm
Slot depth
Slot depth hs ℎ 40 40 mm
mm
ToothTooth
widthwidth bt 𝑏 8 8 mm
mm
TheThe
length of theofmover
length core core
the mover L L 252 252 mm
mm
The thickness of the mover yoke h2 20 mm
The thickness of the mover yoke ℎ 20 mm
Permanent magnet width τm 21 mm
Permanent magnet
Permanent magnet height width hm 𝜏 4.4 21 mm
mm
Permanent magnet height
Air gap height g ℎ 1 4.4 mm
mm
StatorAir
coregap
length
height L1 g 500 1 mm
mm
Stator iron yoke thickness h1 𝐿 10 mm
Stator core length 500 mm
Polar pitch τ 24 mm
Stator iron
Number yoke
of coil thickness
turns
ℎ 50 10 mm
Polar pitch
Number of permanent magnets 𝜏 20 24 mm
Number
Number of slots
of coil turns 12 50
Number of permanent magnets 20
Number of
3. PMLSM Theoretical slots
Analysis 12
3.1. Magnetic Field Analysis
OR PEER REVIEW 3. PMLSM Theoretical Analysis 4 of 18
In this paper, the equivalent magnetization current method is used to analyze and
3.1.calculate
Magnetic the
Fieldmagnetic
Analysis field of the motor. The PMLSM magnetic field analysis model is
shown
In thisinpaper,
Figurethe
3 and proposesmagnetization
equivalent the following current
assumptions [22]:is used to analyze and
method
calculate the magnetic field of the motor. The PMLSM magnetic field analysis model is
shown in Figure 3 and proposes the following assumptions [22]:
(1) The magnetic field changes in the z-axis direction, ignoring the transverse edge
effect;
(2) The permeability of primary and secondary cores is infinite;
(3) The demagnetization curve of the permanent magnet basically coincides with the
recovery line;
(4) The demagnetization curve of the permanent magnet material is straight, and the
(a) magnet is magnetized relatively uniformly.
permanent (b)
Figure 3. PMLSM magnetic field analysis
Figure 3. PMLSM magneticmodel (a) Permanent
field analysis magnet magnetic
model: (a) Permanent field analysis
magnet magnetic field analysis
model (b) Magnetic field analysis model of armature windings.
model; (b) Magnetic field analysis model of armature windings.

(1) The magnetic field changes in the z-axis direction, ignoring the transverse edge effect;
The model of the magnet magnetization intensity is shown in Figure 4:
(2) The permeability of primary and secondary cores is infinite;
(3) The demagnetization curve of the permanent magnet basically coincides with the
recovery line;
(4) The demagnetization curve of the permanent magnet material is straight, and the
permanent magnet is magnetized relatively uniformly.
The model of the magnet magnetization intensity is shown in Figure 4:
 (a) (b)
Figure 3. PMLSM magnetic field analysis model (a) Permanent magnet magnetic field analysis
Energies 2022, 15, 5441 model (b) Magnetic field analysis model of armature windings. 4 of 17

The model of the magnet magnetization intensity is shown in Figure 4:

Figure 4.4.Distribution
Figure Distributionmapmap
of magnetization intensity
of magnetization of permanent
intensity magnets. magnets.
of permanent
According
According to to
thethe
above assumptions,
above the magnetization
assumptions, intensity isintensity
the magnetization expanded is
into
expanded into
each harmonic according to the Fourier series:
each harmonic according to the Fourier series:
∞
4𝐵
4Br (−1) 1 1 (2𝑛 − 1)𝜋𝜏 1)(2𝑛
(2n −cos πτm− 1)𝜋𝑥(2n − 1)πx
MM(𝑥)
(x) =
=𝜋𝜇 ∑
πµ0 n=1
n+1 sin
(−1)2𝑛 − 1
2n − 1
sin
2𝜏 2τ 𝜏 cos τ
(1) (1)

where 𝜇µ0 is
where isthe
thevacuum
vacuum permeability,
permeability, 𝐵 isBthe
r ispermanent
the permanent
magnetmagnet magnet, 𝜏magnet,
residual residual is τ is the
the polar
polar distance, andτ𝜏m isisthe
distance,and the permanent
permanent magnet
magnet width.
width.
The
Theequivalent
equivalentmagnetization
magnetization current densitydensity
current of the permanent magnet is: magnet is:
of the permanent
4𝐵4B ∞ (2𝑛 − 1)𝜋𝜏 1)(2𝑛
(2n −sin πτm− 1)𝜋𝑥(2n − 1)πx (2)
J𝐽m (𝑥)
r (−1)
( x )==−−
𝜏𝜇 ∑ (−1)sin
n +1
sin2𝜏 𝜏sin (2)
τµ0 n=1 2τ τ
When
Whenpermanent
permanent magnets act alone,
magnets the following
act alone, magnetic magnetic
the following field equations
fieldcan be
equations can be
established according
established to Maxwell’s
according equations:
to Maxwell’s equations:
In the air gap area:
In the air gap area:
𝜕 𝐴 ∂2 Am1
𝜕 𝐴 ∂2 Am1
+ =0 (3)
𝜕𝑥 ∂x2 𝜕𝑦+ ∂y2 = 0 (3)
Inthe
In thepermanent
permanent magnet
magnet area: area:
𝜕 𝐴 ∂2 Am2
𝜕 𝐴∂2 Am2
+ + = −𝜇 𝐽= −µ0 Jm (4) (4)
𝜕𝑥 ∂x2 𝜕𝑦 ∂y2
The
Theseparation
separationvariable method
variable is usedistoused
method obtain
toaobtain
generalasolution:
general solution:
𝐴 = 𝐴 𝑐ℎ𝑘 𝑦 + 𝐵 𝑠ℎ𝑘 𝑦 ∙ 𝑀 cos 𝑘 𝑥 + 𝑁 sin 𝑘 𝑥
⎧ Am1 = [ A1 chk n y + B1 shk n y]·[ M1 cos k n x + N1 sin k n x ]
⎪𝐴 = 𝐴 𝑐ℎ𝑘 𝑦 + 𝐵 𝑠ℎ𝑘 𝑦 ∙ 𝑀 cos 𝑘 𝑥 + 𝑁 sin 𝑘 𝑥

Am2 = [ A2 chk n y1+ B2 shk(2𝑛
n y ]·[ M2 cos k(2𝑛 nx +−N 2 sin k n x ] (5)
⎨ − 4𝐵 𝜏 (−1)
∞ sin
− 1)𝜋𝜏
sin
1)𝜋𝑥 (5)
⎪
⎩  𝜋− 4Br τ (−(2𝑛
1)n+−11) 1 sin2𝜏 sin2𝜏
( 2n − 1 ) πτ ( 2n −1)πx
∑ m

 π2 (2n−1)2 2τ 2τ
n =1
Equation (6) can be obtained according to the boundary condition:


 B1 = Fn ·shk n hm
 A1 = − Fn · chk nH

·shk n hm


h shkn H i (6)
chk n H


 A 2 = F n chk n h m − shk n H · shk n h m

= shkFnn H ·shk n ( H − hm )


∞
(2n−1)π 4Br τ n +1 1 (2n−1)πτm
In the above equation: k n = , Fn = π2 ∑ (−1) sin .
τ
n =1 (2n−1)2 2τ
The vector magnetic potential and magnetic induction intensity of the air gap magnetic
field region can be obtained, respectively:

shk ( H −h )


 Am1 = Fn nshkn H m · sin k n x ·chk n y − Fn sin k n x

shk n ( H −hm )
Bm1x = ∂A 1
∂y = Fn k n shk n H · sin k n x ·shk n y (7)

−

 ∂A1 shk n( H h m)
m1y = − ∂x = − Fn k n · cos k n x ·chk n y + Fn k n cos k n x
 B
shk n H
The vector magnetic potential and magnetic induction intensity of the permanent
magnet region are, respectively:
Energies 2022, 15, 5441 5 of 17

Am2 = − Fn shk n hm



 shk n H · sin k n x · chk n ( H − y )
shk n hm
Bm2x = ∂A
∂y = Fn k n shk n H · sin k n x · shk n ( H − y )
2
(8)

shk n hm

Bm2y = − ∂A
∂x = Fn k n shk n H · cos k n x · chk n ( H − y )
2


The equivalent magnetization current of the armature winding is:

∞ h i
2 nπ (3+k ) nπ (3−k )
Js ( x ) = nπ ∑ cos 6 − cos 6 ·
n h n =1 i h i h io (9)
nπ nπ nπ
Ja sin 3τ s
( x + τs ) + Jb sin 3τs x + J c sin 3τs ( x − τs )
In the above equation: Ja , Jb, Jc is the current density of the windings, the expression
is as follows: 


 Ja = N 1 ia
bs h s

Jb = N 1 ib
bs h s (10)

N i

 J = 1b

c bs h s

 a i = I sin ( ωt + ϕ)
i = I sin ωt + ϕ − 2π


(11)
 b 3

ic = I sin ωt + ϕ + 2π 3
In the above equation: N1 is the number of coil turns; I is the amplitude of the current;
ω is the motor angular frequency; ϕ is the phase angle.
For armature windings acting alone, the following magnetic field equations can be
established according to Maxwell’s equations:
In the air gap area:
∂2 As1 ∂2 As1
2
+ =0 (12)
∂x ∂y2
In the armature winding area:
∂2 As2 ∂2 As2
+ = −µ0 Js (13)
∂x2 ∂y2
By using the method of separating variables, a general solution can be obtained:

 As1 = [ a1 chpn y + b1 shpn y]·[m1 cos pn x + n1 sin pn x ]


 As2 = [ a2 chphn y + b2 shpn y]·[m2 cos pn xi+ n2 sin pn x ]



2 ∞
+ 18τ s µ0 nπ (3−k )
− cos nπ (36+k) (14)
 n 3 π3 ∑ cos 6
n = 1



 n h i   h io
 · J cos nπ ( x + τ ) + J cos nπ x + J cos nπ ( x − τ )

a 3τs s b 3τs c 3τs s

Equation (15) can be obtained according to the boundary condition as:

 shp h 2
 a1 = Gn shp (hn +s H ) e( pn H )

 n s

chpn (hs + H )shpn H ( pn H )2
a2 = − Gn shp e (15)
 n (hs + H )

 2
b2 = Gn shpn He( pn H )


18τs 2 µ0 ∞
h i
nπ (3+k ) nπ (3−k )
nπ
In the above equation: pn = 3τ s
, Gn = 3
n π 3 ∑ cos 6 − cos 6 , k = bτss .
n =1
The vector magnetic potential and magnetic flux density in the air gap region are,
respectively, as follows:
G shpn hs ( pn H )2

As1 = shpn (h + e chpn y·{ Ja sin[ pn ( x + τs )] + Jb sin( pn x ) + Jc sin[ pn ( x − τs )]}
n s H)




Gn pn shpn hs ( pn H )2
Bs1x = shp e shpn y·{ Ja sin[ pn ( x + τs )] + Jb sin( pn x ) + Jc sin[ pn ( x − τs )]} (16)
 n (hs + H )
Gn pn shpn hs ( pn H )2


Bs1y = − shp e chpn y·{ Ja cos[ pn ( x + τs )] + Jb cos( pn x ) + Jc cos[ pn ( x − τs )]}

(h + H )
n s
 Energies 2022, 15, 5441 6 of 17

The vector magnetic potentials and magnetic flux densities of the armature winding
region are as follows:
2
  
shpn He( pn H )


 A s2 = − G n shpn (hs + H ) chp (
n sh + H − y ) − 1



·{ Ja sin[ pn ( x + τs )] + Jb sin( pn x ) + Jc sin[ pn ( x − τs )]}





2
  
 B = G shpn He( pn H ) shp (h + H − y) − 1


s2x n shpn (hs + H ) n s
(17)
·{ −




 J a sin [ p n ( x + τs )] + Jb sin ( p n x ) + Jc sin [ p n ( x τs )]}
2
  
shpn He( pn H )

 Bs2y = Gn shpn (hs + H ) shpn (hs + H − y) − 1







·{ Ja cos[ pn ( x + τs )] + Jb cos( pn x ) + Jc cos[ pn ( x − τs )]}

3.2. Electromagnetic Thrust Calculation

Based on the analysis of the magnetic field, the Maxwell tensor method is used to
analyze and calculate the horizontal electromagnetic thrust of PMLSM. The method is to
equate the volumetric electromagnetic force received by any region of the stressed object
to the tension on the surface outside the area of the object, and then obtain the sum of
the electromagnetic forces by integrating the equal density of the magnetic field tension
tensor. The integral path for calculating the electromagnetic thrust by this method only
contains a primary iron core, and the integral path selected in this paper is A-B-C-D, the
PMLSM integration path is shown in Figure 5. Using Maxwell’s method to calculate the
electromagnetic force in the two-dimensional magnetic field, the total electromagnetic
thrust of the surface can be obtained as follows:
I →→  
D → 1 →
F= B B · n − B2 n ds (18)
µ0 2
s →
→
D Is the length of the motor in the z-axis direction, µ0 = 4π × 10−7 the n and B
expressions are as follows:
Energies 2022, 15, x FOR PEER REVIEW ( → → → 7 of 18
n = n x a x + ny ay
→ → → (19)
B = Bx a x + By ay
→ →
a x and ay are unit vectors in the x and y directions, respectively. n x and ny are projec-
ations
primary iron core,
of the normal and the
vectors integral
of the surfacepath selected
in the x and yin this paper
directions, is A-B-C-D, the PMLSM
respectively.
integration path is
The horizontal andshown
normal in Figure 5. Using
electromagnetic Maxwell’s
force magnitude method
of the to be
motor can calculate
found the
electromagnetic
as follows: force in the two-dimensional magnetic field, the total electromagnetic

D
H h 2 
2 n + 2B B n ds
i
thrust of the surface can  be
 Fx =obtained
2µ0
as
B x follows:
− B y x x y y

D
Hs h
𝐷B2 − B2 ny + 2Bx By nx ds
 i (20)
 Fy = 2µ

F=
0 y ⃗x ⃗
𝐵 𝐵 ∙ 𝑛⃗ 𝐵 𝑛⃗ 𝑑𝑠 (18)
s 𝜇
where Bx and By are tangential and normal magnetic flux density, respectively, and s is the
integral path, this article focuses on the horizontal electromagnetic thrust.

Figure 5.
Figure PMLSM integration
5. PMLSM integrationpath.
path.

𝐷 Is the length of the motor in the z-axis direction, 𝜇 = 4𝜋 × 10 the 𝑛⃗ and 𝐵⃗

expressions are as follows:

𝑛⃗ = 𝑛 𝑎 ⃗ + 𝑛 𝑎 ⃗
(19)
𝐵⃗ = 𝐵 𝑎 ⃗ + 𝐵 𝑎 ⃗
 ⎪ 2𝜇0 𝑦
𝑠
(20)
⎨𝐹 = 𝐷 𝐵2𝑦 −𝐵
2
𝑛𝑦 + 2𝐵𝑥 𝐵𝑦 𝑛 𝑑𝑠
⎪ 𝑦 2𝜇 𝑥 𝑥
⎩ 0
𝑠

Energies 2022, 15, 5441 where 𝐵 and 𝐵 are tangential and normal magnetic flux density, respectively, 7 of and
17 𝑠
is the integral path, this article focuses on the horizontal electromagnetic thrust.

3.3.
3.3. Vibration Analysis
Vibration Analysis
The linear
The linearmotor
motormechanical
mechanicalloading
loading model
model is shown
is shown in Figure
in Figure 6. 6.

Figure 6.
6. Linear
Linearmotor
motormechanical
mechanicalloading
loading model.
model.

Replace the mass of the mover part with mass block m, replace the elastic element
and related components and dampers with springs with a stiffness k and damping c,
respectively, and use F (t) to represent the electromagnetic force generated by the motor.
This dynamic model can be regarded as a single-degree-of-freedom forced vibration system
according to vibration theory, so the alternating load test applied to the specimen by this
actuator is fully in line with its vibration theory method. The external excitation of the
motor is as follows:
F (t) = A0 cos ωt = kA cos ω (21)
where A0 is the incentive amplitude, A is an order with displacement, and ω is the
frequency of excitation. For this mechanical loading model, according to the vibration
analysis theory, the equation of motion of the second-order system is:
.. .
mx (t) + c x (t) + kx (t) = F (t) (22)
k
m= ωn 2 , mc
= 2ξ. ωn is the natural frequency of the system, and ξ is the viscous
damping factor. Bring the above expression into the above formula:
.. .
x (t) + 2ξωn x (t) + ωn 2 x (t) = Aωn 2 cos ωt (23)
Solving Equation (25) can be obtained:
x (t) = X cos(ωt − φ) (24)
A
X = s (25)
 2 2  2
1− ω
ωn + 2ξ ωωn

2ξ ωωn
φ = tan−1  2 (26)
1 − ωωn
The derivative of Equation (28) is zero, and its pole position can be derived, that is,
the peak point position of the amplitude of the response force with respect to the driving
frequency ω: q
ω = ωn 1 − 2ξ2 (27)
Let β be the magnification factor, the value of which is:
1
β = s (28)
 2 2  2
1 − ωωn + 2ξ ωωn

When driving frequency ω is associated with the natural frequency of the system ωn ,
the output thrust of the linear motor actuator will be infinitely amplified.
 cogging groove due to the effect of the cogging effect. As a result of the EMC solution, the
waveform is smoother and has the characteristics of a flat top wave. From the figure, it
can be obtained that the maximum value of EMC to solve the air gap magnetic density is
1T, and the finite element method to solve the maximum value of the air gap magnetic
Energies 2022, 15, 5441
density is 1.11T, and the solution results of the two are basically the same. EMC simplifies8 of 17
the motor model to two dimensions and idealizes some boundary conditions, this method
of solving the magnetic flux density of the air gap is relatively simple and is the basis for
other solution methods. Furthermore, the finite element analysis solution takes into
4. Finitethe
account Element
coggingAnalysis
effect, so the solution result is relatively more accurate.
4.1. Analysis
Figure 10ofshows
No-Load theSimulation Resultsof the air gap magnetic flux density, the result
Fourier analysis
includes the first 10 harmonic components,
No-load is the state in which the coil the air gap magnetic
windings of thedensity
motorfundamental wave The
are not current.
amplitude
PMLSM flux is 0.9647T,
waveformaccounting
diagram for 86.5%
and theof the
backmaximum air gap magnetic
EMF waveform diagram fluxare
density,
shown in
indicates
Figure 7.that the fundamental
It can be seen from wave
the is consistent
Figure thatwith the total waveform.
the sinusoidal Among
rate of the fluxthem, the is
waveform
third and fifth
relatively harmonious
good, reflectingcomponents are relativelyof
the high performance large. Through
the motor, thealso
and above analysis,that
confirms it can
the air
be concluded that the air gap magnetic density waveform is good, all of which
gap magnetic flux density is also sinusoidal distribution, and the amplitude of the flux is are sinusoidal
distributions,
0.34 Wb. Thewhichback not
EMF only verifies the
waveform accuracy ofpoorly
is relatively theoretical calculations
sinusoidal, but also
and there areverifies
mutations
the design results of the motor are reasonable. In addition, the air gap
in the peaks and troughs, this is not only closely related to the magnetic flux density magnetic densityof the
fundamental
no-load air gapwavebutamplitude
also hasis arelatively large, which
certain impact canthrust
on the provide a large enough
fluctuations thrust
of the to In
motor.
the motor to meet the design goal of the motor’s electromagnetic thrust.
addition, the amplitude of the back EMF is 47 V.

Energies 2022, 15, x FOR PEER REVIEW 10 of 18

(a)

(b)
Figure
Figure7.7.PMLSM
PMLSMflux andand
flux back−EMF waveform
back–EMF diagram
waveform (a) Motor
diagram: flux waveform
(a) Motor diagramdiagram;
flux waveform (b)
Motor back EMF waveform diagram.
(b) Motor back EMF waveform diagram.
Energies 2022, 15, 5441 9 of 17

Due to the structural characteristics such as the disconnection and slotting of the pri-
mary core, horizontal detent force and normal detent force are generated during operation,
and the detent force produces thrust fluctuations during operation, which greatly reduces
the performance of the motor. In this paper, the detent force is reduced by optimizing the
primary length to suppress the longitudinal(b)
end effect. PMLSM horizontal detent force and
normal detent force are shown in Figure 8, the horizontal detent force amplitude fluctuates
Figure 7. PMLSM flux and back−EMF waveform diagram (a) Motor flux waveform diagram (b)
between −74 N and 105 N, the detent force fluctuation amplitude is 179 N, and the average
Motor back EMF waveform diagram.
normal detent force is 6.6 KN.

Energies 2022, 15, x FOR PEER REVIEW 11 of 18

(a)

(b)
Figure
Figure 8.
8. PMLSM
PMLSM horizontal
horizontaldetent
detentforce
forceand
and normal
normal detent
detent force
force:(a)
(a)PMLSM
PMLSMhorizontal
horizontaldetent
detent
force (b) PMLSM normal detent force.
force; (b) PMLSM normal detent force.

1.5

1
Energies 2022, 15, 5441 10 of 17

Figure 9 is the result of solving the air gap normal magnetic flux density by the
equivalent magnetization current method and finite element method. It can be seen from
the figure that both waveforms are positively linear and have a period of twice the polarity
of 48 mm. As a result of the finite element solution, the wave has a depression at the
cogging groove due to the effect of the cogging effect. As a result of the EMC solution, the
waveform is smoother and has the characteristics of a flat top wave. From the figure, it can
be obtained that the maximum value of EMC to solve the air gap magnetic density is 1 T,
and the finite element method to solve the maximum value of the air gap magnetic density
is 1.11 T, and the solution results of the two are basically the same. EMC simplifies the
motor model to two dimensions(b)and idealizes some boundary conditions, this method of
Figuresolving thehorizontal
8. PMLSM magnetic fluxforce
detent density of thedetent
and normal air gap
forceis(a)relatively simpledetent
PMLSM horizontal and is the basis for other
solution
force (b) PMLSM methods.
normal detentFurthermore,
force. the finite element analysis solution takes into account the
cogging effect, so the solution result is relatively more accurate.
1.5

0.5

-0.5

-1

-1.5
Energies 2022, 15, x FOR PEER REVIEW 0.035 0.04 0.045 0.05 0.055 0.06 0.065 0.07 0.075 0.08 0.085 12 of 18
X/m
(a)

(b)
Figure 9. No−load air gap magnetic flux density distribution curve (a) No-load method calculates
Figure 9. No-load air gap magnetic flux density distribution curve: (a) No-load method calculates
the solution results for magnetic flux density theory (b) The result of the no-load method is to solve
thefinite
the solution results
element for magnetic
of magnetic flux density theory; (b) The result of the no-load method is to solve
flux density.
the finite element of magnetic flux density.
Energies 2022, 15, 5441 11 of 17

Figure 10 shows the Fourier analysis of the air gap magnetic flux density, the result
includes the first 10 harmonic components, the air gap magnetic density fundamental wave
amplitude is 0.9647 T, accounting for 86.5% of the maximum air gap magnetic flux density,
indicates that the fundamental wave is consistent with the total waveform. Among them,
the third and fifth harmonious components are relatively large. Through the above analysis,
(b)
it can be concluded that the air gap magnetic density waveform is good, all of which are
Figure 9. No−load air sinusoidal distributions,
gap magnetic which
flux density not only verifies
distribution curve the
(a) accuracy
No-load of theoretical
method calculations but
calculates
also verifies the design results of the motor are reasonable. In addition, the
the solution results for magnetic flux density theory (b) The result of the no-load method is to solve air gap magnetic
density fundamental
the finite element of magnetic flux density. wave amplitude is relatively large, which can provide a large enough
thrust to the motor to meet the design goal of the motor’s electromagnetic thrust.

Figure 10. Air gap magnetic density

Figure 10. Fourier
Air gap analysis.
magnetic density Fourier analysis.

4.2. Analysis of Load Simulation Results

4.2. Analysis of Load Simulation Results
The magnetic field line and magnetic flux density distribution cloud diagram of
The magnetic field
PMLSM line and magnetic
running fluxofdensity
0.01 s at a speed 0.96 m/sdistribution cloud11.diagram
are shown in Figure This can beofseen in the
PMLSM running 0.01 s at a speed
magnetic of distribution
field line 0.96 m/s are shown
cloud map,in Figure
most 11. This
magnetic can be
field lines seen
travel in a loop
through
of permanent
the magnetic field line distributionmagnets,
cloudair gaps,most
map, and amateur windings,
magnetic a small
field lines number
travel of magnetic
through a field
lines are the components of the permanent magnet in the horizontal
loop of permanent magnets, air gaps, and amateur windings, a small number of magnetic direction. Furthermore,
it can be seen from the magnetic flux density distribution cloud diagram that the maximum
magnetic flux density of the tooth part is 2.3 T, and the maximum magnetic flux density of
the primary yoke is 1.6 T, there is some magnetic saturation.
Figure 12 is the result of solving the horizontal electromagnetic thrust of the motor by
finite element analysis (FEA) and Maxwell tensor method, respectively. It can be seen from
the figure that the average electromagnetic thrust of Maxwell’s tensor solution is 987 N,
and the average electromagnetic thrust of the finite element solution is 948 N, the results of
the two are basically the same, and the accuracy of the theoretical analysis was verified.
 field lines are the components of the permanent magnet in the horizontal direction.
Furthermore, it can be seen from the magnetic flux density distribution cloud diagram
Energies 2022, 15, 5441 12 of 17
that the maximum magnetic flux density of the tooth part is 2.3 T, and the maximum
magnetic flux density of the primary yoke is 1.6T, there is some magnetic saturation.

(a)

(b)
Figure11.
Figure 11. PMLSM magnetic field
PMLSM magnetic field lines
lines and
and magnetic
magnetic flux
flux density
density distribution
distribution cloud
cloud map:
map (a)
Magnetic field line distribution (b) Magnetic flux density distribution.
(a) Magnetic field line distribution; (b) Magnetic flux density distribution.
 Figure 12 is the result of solving the horizontal electromagnetic thrust of the motor
by finite element analysis (FEA) and Maxwell tensor method, respectively. It can be seen
from the figure that the average electromagnetic thrust of Maxwell’s tensor solution is 987
N, and the average electromagnetic thrust of the finite element solution is 948 N, the
Energies 2022, 15, 5441 13 of 17
results of the two are basically the same, and the accuracy of the theoretical analysis was
verified.

(a)

(b)
Figure
Figure 12.
12. Maxwell
Maxwell stress
stress tensor
tensor method
method and
and finite
finite element
element method
method solution
solution for
for the
the horizontal
horizontal
electromagnetic thrust of the motor (a) Finite element solves for the horizontal electromagnetic
electromagnetic thrust of the motor: (a) Finite element solves for the horizontal electromagnetic thrust
thrust of the motor (b) Maxwell stress tensor method solves for the horizontal electromagnetic thrust
of the motor; (b) Maxwell stress tensor method solves for the horizontal electromagnetic thrust of
of the motor.
the motor.

5. Experimental Analysis
5.1. Thrust Constant Test
The PMLSM experimental platform is shown in Figure 13, which is composed of a
whole machine part and a servo drive, of which the whole machine part is composed of a
motor body, a pressure sensor, and a force measuring ring.
 5. Experimental Analysis
5.1. Thrust Constant Test

Energies 2022, 15, 5441

The PMLSM experimental platform is shown in Figure 13, which is composed 14 ofofa17
whole machine part and a servo drive, of which the whole machine part is composed of a
motor body, a pressure sensor, and a force measuring ring.

(a) (b)
Figure 13.13.
Figure PMLSM experimental
PMLSM platform
experimental (a)(a)
platform: Motor overall
Motor and
overall force
and measuring
force device
measuring (b)(b)
device; drive.
drive.

InInthis
thispaper,
paper,thethestatic
staticforce
forceloading
loadingtesttestofofthe
theunilateral
unilateralPMLSM
PMLSMisiscarried
carriedout,
out,and
and
theperformance
the performance ofof
thethemotor
motor is ischecked
checked bybytesting
testing the
the thrust
thrust constant
constant ofof
the the motor,and
motor, and
theexpression
the expressionofofthe thethrust
thrustconstant
constantisisasasfollows:
follows:
F
CF = 𝐹 (29)
𝐶 = I (29)
𝐼
Simulation and experimental output thrust and thrust constants under different cur-
rents are shown in Table 2, in the case of the motor-rated thrust constant of 93 N/A, the
Simulation
simulated thrust and experimental
constant output thrust
can be calculated as 97.29 and thrust
N/A, constants
the error under
is 4.6%, and different
the experi-
currents are shown in Table 2, in the case of the motor-rated thrust
mental thrust constant is 96.53 N/A, the error is 3.79%, and the error is less than constant of 93 N/A, the
5%, which
simulated thrust
verifies that constant
the motor can be calculated
performance is good. The as data
97.29of N/A,
motorthe error isand
simulation 4.6%, and the
experimental
experimental thrust constant is 96.53 N/A, the error is 3.79%, and
output thrust are fitted by the least-squares method as shown in Figure 14, and it can the error is less than 5%,be
which verifies that the motor performance is good. The data of
seen from the figure that the simulation and experimental output thrust curves meet the motor simulation and
experimental
linear regressionoutput thrust are
equation, and fitted
the by the design
motor least-squares
resultsmethod
are more as reasonable.
shown in Figure 14,
However,
and it can be seen from the figure that the simulation and experimental
as the current increases, the motor is affected by the amateur reaction and temperature, output thrust
curves
causing meet the linear
the thrust regression
constant decreases equation,
gradually. and the motor design results are more
reasonable. However, as the current increases, the motor is affected by the amateur
Comparison
Table 2.and
reaction of simulation
temperature, causingand theexperimental
thrust constantoutput thrust at gradually.
decreases different currents.

Simulate Simulation Experimental Experimental

Current RMS
Output Thrust Thrust Constant Output Thrust Thrust Constant
A
N N/A N N/A
1 99 99 89 89
2 205 102.5 196 98
3 295 98.3 291 97
4 390 97.5 392 98
5 485 97 489 97.8
6 579 96.5 589 98.1
7 674 96.2 676 96.5
8 765 95.6 772 96.5
9 860 95.5 881 97.8
10 948 94.8 966 96.6
 4 390 97.5 392 98
5 485 97 489 97.8
6 579 96.5 589 98.1
7 674 96.2 676 96.5
8 765 95.6 772 96.5
Energies 2022, 15, 5441 9 860 95.5 881 97.8 15 of 17
10 948 94.8 966 96.6

1000
Simulation result
900
Experimental result

800

700

F/N 600

500

400

300

200

100

0
1 2 3 4 5 6 7 8 9 10
I/A

Figure 14. 14.

Figure Simulation and experimental
Simulation output thrust
and experimental curves.
output thrust curves.

5.2.
5.2. Resonance
Resonance Experiments
Experiments
In In
thisthis
paper, the resonance
paper, amplification
the resonance experiment
amplification of PMLSM isofcarried
experiment PMLSM out isto carried out to
achieve thrust amplification at the condition of the motor movement speed is 5mm/s, the
achieve thrust amplification at the condition of the motor movement speed is 5mm/s, the
amplitude of the current is 15A, the voltage is 230V, and the running time is 1s at each
amplitude of the current is 15 A, the voltage is 230 V, and the running time is 1s at each
frequency. First of all, by finding the frequency range when the system is in approximate
frequency.
resonance First of all,
to determine theby findingpoint
resonance the frequency
of the system, rangethe when the system
input waveform of is
thein approximate
resonance
actuator toadetermine
is set to sine wave, thethe resonance
input frequencypoint of the
is within therange
system, theHz,
of 1–200 input waveform of the
and the
actuatorcorresponding
frequency is set to a sine to wave, the thrust
the output input isfrequency
the resonanceis within the
point of therange of The
system. 1–200 Hz, and the
fitting curve is
frequency shown in Figure
corresponding 15, the
to the frequency
output thrustrange
is thewhen the system
resonance pointreaches
of the system. The
resonance is about
fitting curve 128 Hz toin132
is shown Hz. By
Figure comparing
15, the thrust
the frequency output
range at these
when the frequencies,
system reaches resonance
it can be concluded that the resonant frequency of the linear motor actuator is 130 Hz, and
is about 128 Hz to 132 Hz. By comparing the thrust output at these
Energies 2022, 15, x FOR PEER REVIEW the 17 of frequencies, it can
actuator output load is 11.5 KN. The output of the maximum continuous thrust of18950
be concluded that the resonant frequency of the linear motor actuator
N relative to the linear motor is approximately 12.1 times the output thrust in the resonant is 130 Hz, and the
actuator output load is 11.5 KN. The output of the maximum continuous thrust of 950 N
relative
state. Usually,tothe
the linearfrequency
natural motor isofapproximately
the component is12.1 times
several the output
thousand thrust
HZ, which is in the resonant
muchstate. Usually,
bigger than thethe natural
system’s frequency
natural ofso
frequency, the
thecomponent is be
motor will not several thousand HZ, which is
destroyed.
much bigger than the system’s natural frequency, so the motor will not be destroyed.

12

10

8
F/KN

0
0 20 40 60 80 100 120 140 160 180 200
f/Hz

Figure 15. Thrust-frequency

Figure fitting curve.
15. Thrust-frequency fitting curve.

6. Conclusions
In this paper, the electromagnetic design of the unilateral PMLSM is carried out and
the structural parameters are given. Furthermore, the magnetic field and electromagnetic
thrust of the motor are theoretically analyzed, and mathematical expressions are given by
EMC and Maxwell tensor method. Through the vibration analysis of the whole machine,
the conditions for the resonance of the motor are obtained. In the case of no-load, the
Energies 2022, 15, 5441 16 of 17

6. Conclusions
In this paper, the electromagnetic design of the unilateral PMLSM is carried out and
the structural parameters are given. Furthermore, the magnetic field and electromagnetic
thrust of the motor are theoretically analyzed, and mathematical expressions are given by
EMC and Maxwell tensor method. Through the vibration analysis of the whole machine,
the conditions for the resonance of the motor are obtained. In the case of no-load, the
magnetic chain and back EMF are positive linear, the detent force is reasonable, the air
gap magnetic flux density waveforms positive linearity, and the theory is consistent with
the simulation solution results. In the case of load, most of the magnetic field lines form a
closed loop, but there is a certain magnetic saturation in the core part, and the theoretical
analysis of electromagnetic thrust is consistent with the simulation results. Through the
PMLSM static force test, the thrust constant under the experiment is basically consistent
with the simulation solution results, and the errors of both are less than 5%. Through
the above analysis, it can be concluded that the motor design results are more reasonable.
Finally, through resonance experiments, the thrust was amplified by 12.1 times under the
condition that the rated thrust of the motor was 950 N.

Author Contributions: Conceptualization, L.Y., S.C. and J.H. (Jialong He); Data curation, S.C.; Formal
analysis, S.C.; Funding acquisition, L.Y.; Investigation, S.C. and H.S.; Methodology, S.C. and J.H.
(Jialong He); Project administration, L.Y., J.H. (Jialong He), H.S., J.H. (Jie Huang) and H.T.; Resources,
L.Y.; Software, S.C.; Supervision, L.Y.; Validation, S.C., J.H. (Jialong He), H.S. and H.T.; Visualization,
S.C.; Writing—original draft, S.C., H.S. and J.H. (Jie Huang); Writing—review & editing, S.C. All
authors have read and agreed to the published version of the manuscript.
Funding: This work was supported by the Science and Technology Development Program of Jilin
Province (20210201040GX): Research on Electronic High-Frequency Linear Actuator for Accelerated
Fatigue Test of Automobile Parts.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Conflicts of Interest: The authors declare no conflict of interest.

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