2021 IEEE 2nd International Conference on Electrical Power and Energy Systems (ICEPES)
MANIT, Bhopal, India. Dec 10-11, 2021
Mitigation of Cogging Torque for the Optimal
Design of BLDC Motor
2021 IEEE 2nd International Conference On Electrical Power and Energy Systems (ICEPES) | 978-1-6654-0236-1/21/$31.00 ©2021 IEEE | DOI: 10.1109/ICEPES52894.2021.9699544
Rupam
Electrical and Instrumentation Engineering
Sant Longowal Institute of Engineering and Technology
Longowal, Sangrur
rupamb92@gmail.com
Abstract— Since the previous decade, industries have been
paying close attention to PM Brushless DC (BLDC) motor. In
this paper, a BLDC motor of 1000 Watt is designed by
reducing its cogging torque with varying pole embrace factor,
and FEM tool was used for electromagnetic field analysis of
motor. The cogging torque effect is characterized by RMxprt
parametric analysis and Sequential Non-Linear Programming
optimization technique in ANSYS Maxwell platform.
Consequently, it is observed that the cogging torque at
particular value of pole embrace factor is significantly reduced
and it assists the designers to optimally design the motor. The
motor is designed to have a higher average torque and less
torque ripple. The analytical results are verified by the
simulation results.
Keywords— FEM, BLDC Permanent
Electromagnetic Field and ANSYS Maxwell etc.
I. INTRODUCTION
Permanent magnets (PM) has found plethora of uses in
many electrical machine applications in recent years. In, PM
motors, fundamental active field is created by replacing the
field winding in machines with a permanent magnet (PM),
resulting in reduced and compact size along with increased
efficiency. A BLDC motor is a high-performance motor that
can deliver huge levels of torque across high power density
and a wide speed range. Brushless DC motors are replacing
conventional motors due to their numerous advantages over
the latter. A strong electromagnetic force exists between the
rotor’s permanent magnets and the stator’s coils in a
permanent magnet Brushless DC Motor (BLDC) [1-2].
However, in BLDC motors, pulsating torque is one of the
most significant limitations that have to be factored in while
designing. [3]. Keeping in mind, the role of BLDC motors in
changing the future of motors, this study focuses on design
and analysis of small power-fed applications.
Among the several numerical techniques available for
electromagnetic analysis, FEM based technique is quite
efficient. [5] A finite element-based package is used to
perform an electromagnetic torque analysis. Researchers
mention the use of the technique in the analysis of several
conventional rotating machines, where the electromagnetic
field analysis is performed to compute steady-state flux
leakage distributions [4-6]. Extensive research has been done
in designing of motors. Many models have been proposed
using analytical equations. For analyzing the performance of
the designed BLDC motor, FEM analysis is chosen due to its
numerous applications in conventional rotating machine
analysis.
978-1-6654-0236-1/21/$31.00 ©2021 IEEE
Authorized licensed use limited to: Nirma University Institute of Technology. Downloaded on April 29,2022 at 07:21:50 UTC from IEEE Xplore. Restrictions apply.
Sanjay Marwaha
Electrical and Instrumentation Engineering
Sant Longowal Institute of Engineering and Technology
Longowal, Sangrur
marwaha_sanjay@yahoo.co.in
A review of some of the prominently documented
research related to design and analysis of motors;
conventional as well as brushless, was performed. Cho et al.
[7] presented the vibration features of a brushless direct
current motor (BLDC) using 3-D finite element method. The
electromagnetic force generated by transient analysis was
then performed using the electromagnetic-structural weak
coupled analysis, and frequency response characteristics
were obtained using quick Fourier transformation. Each
analysis result had been practically checked, and the peak
frequency relative errors are fewer than 5%. Popsecu et al.
[8] demonstrated by proposing various adjustments to the
existing winding of the electric motor in use, resulting in
improved performance of the electric motor and evaluation
Magnet, of the outcomes based on losses and material used. Patel and
Suthar [9] with the help of a genetic algorithm, an optimal
design of an Axial Flux type Surface Mounted Permanent
Magnet (AFSPMBLDC) BLDC motor was given. The main
contribution of this research was to provide the best possible
merging of design variables obtained using the genetic
algorithm (GA) optimization technique, as well as the motor
design being dependent on these improved design aspects.
Finally, 3-D finite element analysis was used to validate the
results (FEA). Boztas et al. [10] presented a design of three,
five and seven phase BLDC motor based on the FEM tool.
Then the results was further compared with the experimental
setup which shows with increase of the phases the torque
ripple of the motor gets decreased. Min and Sarlioglu [11]
presented design of factional slot concentrated winding
motor based upon the field weakening region and
analytically determined results compared with the
experimental setup. Liu et al. [12] performed the comparison
of FEM based design of IPMSM motor using experiment
setup to confirm accuracy and validity of the model based on
the parameters backemf, average torque, flux leakage
coefficient, torque harmonics and flux weakening ability.
Dönmezer and Ergene [13] proposed a design of interior
permanent magnet BLDC motor of 24 slot used in general
application in washers, certain cogging torque reduction
approaches bring forwarded, as well as a few simulation
outcomes presented. This combined model (mixed model)
achieves decreased value of cogging torque decrease in the
time keeping back-EMF constant.
After extensive review of documented researches, it is
observed that number of researches on BLDC motor and its
design and analysis is still quite low, mostly because it being
a relatively new technology. To diminish cogging torque, a
wide range of methods can be applied. However, some of the
strategies have various restrictions because of the challenges
in assembling and realizing the design. Thus, BLDC motors
1
open a whole new door into renewed electrical applications pulsation can be reduced when back emf is efficient. As a
and study of effects of BLDC motors in said applications. result, embrace plays a significant part in torque pulsation.
The embrace role will be examined in this part utilizing the
In the present study analysis of 4 pole 24 slot BLDC finite element approach. Analysis will be performed for
motor has been done. At first, analytical equations are various embraces in order to determine their role, and the
represented and later 2D FEM based modeling and embrace with the least torque pulsation will be chosen. The
simulation of 1000 Watt, 4 pole, 24 slot BLDC has been voltage equation for phase A is written using 3-phase BLDC
carried out. Based on FEM, a validation check was equivalent circuit and in the matrix form is stated in equation
performed on the obtained results. Initial Physical parameters number (3) and (4).
of the BLDC motor have been selected on the basis of dia (t)
analytical calculations. Analytical approach builds the Va =ia Ra +La +ea (3)
dt
relation between aligned rotor position and torque generated
by the motor. The major goal of this paper is to study how Va Ra 0 0 ia La 0 0 ia ea
ௗ
changing the rotor pole embrace factor affects the ൥Vb ൩ = ൥ 0 Rb 0 ൩ ൥ia ൩ + ൥ 0 Lb 0 ൩ ൥ib ൩ + ൥eb ൩ (4)
ௗ௧
performance of BLDC motors. Vc 0 0 Rc ia 0 0 Lc ic ec

II. MATHEMATICAL MODELLING OF BLDC MOTOR The back-EMF values affected with no. of
turns/rotations, the intensity of magnetic field and speed of
The undesired torque produced with interlining of
rotor. If λ is back-EMF constant, then for various phases
permanent magnets on rotor with the machine’s slots and
back-EMF values are shown in Equation (5).
poles in the BLDC motor is known as cogging torque. It is
measured at each place as the rotor rotates from 0 to 360 ea = ω λ (θ)
degrees. The cogging torque diminishes the machine’s 2π
eb =ω λ(θ – )
average torque and introduces undesirable torque ripple in 3
2π
the BLDC motor. It's more evident at slower speeds, with ec =ω λ(θ + ) (5)
jerkiness as a sign. Cogging torque must be eliminated in 3
order to reduce noise and vibration. The cogging torque can The multiplication of back-EMF and phase current
be determined by using equation (1) [14]. produces the instantaneous power supplied by a BLDC
1 dR motor.
Tcog = ‫׎‬2g (1) According to these assumptions, the motor’s input power
2 dƟ
†
and output Power can be stated as in equation (6) & (7);
where ‫ ݃׎‬represents air gap flux and represents taking into account all losses.
†
change in air gap reluctance as a function of rotor angle. As Pi =ia eb +ib eb +ic ec (6)
dR
is directly proportional to cogging torque, and therefore by Po—– =Pi’ -(Pfw† +Pcu +Pt† +Pfe ) (7)
dƟ
dR
reducing , cogging torque will automatically reduce. It where Pi’ is input power Pfw† , Pcu ,Pfe , Pt† , are frictional
dƟ
should be noted that most strategies for lowering cogging and windage losses, stator copper losses, core (iron) losses
torque also lower the effective back EMF, resulting in and diode/transistor losses. Efficiency expression is
mutual torque production. Pole Embrace factor is the represented in equation number (8) it is to calculated input
magnetic arc. According to Figure 1 The Pole Embrace power, output power, and all losses were taken into account.
Factor is the ratio of pole arc to pole pitch, which varies with
Po—–
the degree of electrical rotor rotation. The desired formula is η= (8)
Po—– +Pfw +Pcua +Pt +Pfe
shown in equation (2).
III. DESIGNING AND ANALYSIS OF BLDC MOTOR
The model of inner rotor BLDC has been designed using
ANSYS Maxwell software. The rating of designed motor is
1000 W. The dimensional specifications of the designed
model have been tabulated in Table 1.
Design variables selected for BLDC model modification
is rotor pole embrace factor.

TABLE I. INITIAL DIMENSION SPECIFICATIONS OF BLDC

MOTOR

Parameter Value Units

Stator Outer Dia (Dso) 120 mm
Stator Inner Dia (Dio) 75 mm
Fig. 1. Diagram of the Pole Embrace Factor of BLDC Motor
Steel Type M19_24G
β
Pn = Pole arcൗpole pitch = (2) Rotor Outer Dia (Dro) 74 mm
γ
Rotor Inner Dia (Dri) 26 mm
Where β is pole arc and γ is pole pitch and pn represents
as Rotor Pole embrace factor. The stator induction back emf Length (L) 65 mm
is directly affected by flux density of air gap. Torque Magnet Type NdFe35

Authorized licensed use limited to: Nirma University Institute of Technology. Downloaded on April 29,2022 at 07:21:50 UTC from IEEE Xplore. Restrictions apply.
 A 4 pole, 24 slot design of BLDC motor is represented in The cogging torque value is undesirable; it would be
figure 2. In this model, Design variables selected for advisable to select design variable where there is lowest
modification is rotor pole embrace factor. cogging torque. In this part to further reduce the cogging
torque, Sequential Non-Linear Programming (SNLP)
optimizer is selected under optimization analysis to achieve
best optimal value of the variable. The variables can take any
value within the simulator's permissible constraints and
numerical precision restrictions.
In the figure 5 is given the calculated cogging torque
value corresponding to the SNLP under the twenty numbers
of iterations. It is observed cogging torque value reduced to
0.0001 which approximately equals to 0 at calculated rotor
pole embrace factor equal to the 0.6666661513.
1.20
Curve Info
CoggingTorqueParameter
Setup2 : Performance

1.00

CoggingTorqueParameter [NewtonMeter]
Fig 2. 4 pole 24 slot design of BLDC motor
0.80

IV. RESULTS AND DISCUSSION

The rotor position vs. cogging torque waveform for the 0.60

initial design parameter is shown in figure 3. The waveform

shown for the initial design parameter is 0.55; at this point 0.40

high cogging torque is observed 1.07039 Newton-meter

(Nm). 0.20

1.25
Curve Info
CoggingTorque 0.00
Setup2 : Performance 0.55 0.58 0.60 0.63 0.65 0.68 0.70 0.72 0.75
pn='0.55' pn
Fig 5. Lowest Cogging Torque value via Optimization Analysis
0.63
CoggingTorque [NewtonMeter]

The comparison of cogging torque values can be

0.00
observed in figure 6 at various rotor pole embrace factor
values. And from the diminishing size of the waveform of
cogging torque it can be seen 0.6666661513 is the best
-0.63 optimal value for the lowest cogging torque comparatively to
the other rotor pole embrace factor values.
1.25
Curve Info
-1.25 CoggingTorque
0.00 125.00 250.00 375.00 Setup2 : Performance
ElectricalDegree [deg] pn='0.55'
CoggingTorque_1
Fig 3. Cogging torque vs. Electrical Degree of BLDC motor Setup2 : Performance
0.63 pn='0.65'

To reduce the cogging torque value, rotor pole embrace CoggingTorque_2

Setup2 : Performance
pn='0.6666661513'
Y1 [NewtonMeter]

factor is varied from 0.55 to 0.75 gradually taking the step

size 0.05 under parametric method. From total of five values, 0.00

including intermediate values, with a step size of 0.05

starting from 0.55 to 0.75, best optimal value(s) has to be
found out using ANSYS Maxwell RMxprt. Figure 5 shows -0.63

the variance in cogging torque versus embrace values as a

function of conducted parametric solutions. The lowest
cogging torque component can be attained when the embrace -1.25
0.00 125.00 250.00 375.00
is extremely close to 0.65, as shown in figure 4 which is ElectricalDegree [deg]

0.759333 Newton-meter (Nm). Fig 6. Comparison of Cogging Torque values

The magnetic analysis combined with the electrical

CoggingTorqueParameter [NewtonMeter]

1.15
analysis is vital for the examination of electromagnetic
problems. ANSYS Maxwell, a computational
1.05 electromagnetic tool is used to create the motor model,
which is based on the periodic boundary condition of the
0.95 motor's inner magnetic field distribution.
To speed up the calculation, one fourth of the motor
0.85 model is employed in the simulation calculation. In Figure 7,
a Magnetic Field model of Inner Rotor BLDC Motor at the
0.75
optimal value of the design variable is shown.
0.55 0.58 0.60 0.63 0.65 0.68 0.70 0.72 0.75
pn

Fig 4. Cogging Torque value via Parametric Analysis

Authorized licensed use limited to: Nirma University Institute of Technology. Downloaded on April 29,2022 at 07:21:50 UTC from IEEE Xplore. Restrictions apply.
Fig 7. FEM based 2D Model of Inner Rotor BLDC Motor
Fig 10. 2D FEM Magnetic Field Density (B) Distribution

For moving torque response, winding current response of

respective phases at any moment of time, transient field
analysis of the 2D FEM based BLDC model is performed.
The setup has been tuned for discrete time simulation starting
from 0 to 60 ms with time step of 2 ms.
The model has been designed for rotor pole embrace
factor 0.6666661513. Waveform of Moving torque with
respect to the time is shown in figure 8.
Torque Maxwell2DDesign1 ANSOFT
15.00
Curve Info
Moving1.Torque
Setup1 : Transient

12.50
Moving1.Torque [NewtonMeter]

10.00

7.50
Fig 11. 2D FEM Magnetic Field Intensity (H) Distribution
5.00

In the figure 12 the mesh plot of the 2D magnetic

2.50
analysis with the values of magnetic flux lines distribution is
0.00
shown. It shows the magnetic flux lines are non-uniform
0.00 10.00 20.00 30.00
Time [ms]
40.00 50.00 60.00
across the region.
Fig 8. Waveform of Moving Torque vs. Time

Waveform shown in figure 9 is the winding currents of

Phase A, B and C with respect to different time intervals.
Winding Currents Maxwell2DDesign1 ANSOFT
15.00
Curve Info
Current(PhaseA)
Setup1 : Transient
Current(PhaseB)
10.00 Setup1 : Transient
Current(PhaseC)
Setup1 : Transient

5.00
Y1 [A]

0.00

-5.00

Fig 12. Mesh Plot of BLDC motor with Magnetic Flux lines distribution
-10.00

-15.00
0.00 10.00 20.00
Time [ms]
Fig 9. Waveform of Winding Currents vs. Time
To further estimate magnetic field density on the edges
and surfaces of the respective motor, 2D model must be
created under Finite Element Analysis. It examines the
magnetic field distribution at any instant of time and
position.
Figure 10 and Figure 11 shows the magnetic flux density
distribution profile at t = 60 ms, rotor position θ = 25.287º.
The motor was running constantly at 1049.41 rpm. It is seen
that the maximum magnetic field density has the value 1.8T
in the stator and the H_vector is distributed simultaneously
across the vector boundary.
V. CONCLUSION
30.00
40.00 50.00 60.00
The purpose of the research described in this paper is to
show how of rotor pole embrace factors affect BLDC
performance. Analytically, a link between rotor pole embrace
factor and the full electrical cycle has been established. It is
concluded that with help of parametric analysis and
optimization technique cogging torque is reduced by varying
pole embrace factor. Electromagnetic field analysis with
FEM tool is carried out based on the optimal value of pole
embrace factor. The optimal calculated value of cogging
torque results is 0.001 Nm at 0.6666661514 rotor pole
embrace factor from the 1.07039 Nm at 0.55 initial value of
rotor pole embrace. Further 3D FEM analysis can consider at
various other dependable geometric factors to determine
other factors for this model such as core and eddy current
losses.

Authorized licensed use limited to: Nirma University Institute of Technology. Downloaded on April 29,2022 at 07:21:50 UTC from IEEE Xplore. Restrictions apply.
 REFERENCES
[1] D.C. Hanselman, “Brushless permanent magnet motor design” The
Writers' Collective, 2003.
[2] J. Santiago De, J., H. Bernhoff, B. Ekergård, S. Eriksson, S.
Ferhatovic, R. Waters, & M. Leijon, “Electrical motor drivelines in
commercial all-electric vehicles: A review” IEEE Trans. on veh.
Technol., vol. 61, no. 2, 2011, pp-475-484.
[3] S. Jain, & L. Kumar, “Fundamentals of power electronics controlled
electric propulsion”, In Power Electronics Handbook, Butterworth-
Heinemann Publishers 2018, pp. 1023-1065.
[4] A. Kumar, S. Marwaha, A. Singh, & A. Marwaha, “Comparative
leakage field analysis of electromagnetic devices using finite element
and fuzzy methods”, Expert Syst. Appl., vol. 37, no.5, 2010, pp.
3827-3834.
[5] A. Kumar, S. Marwaha, A. Marwaha, & A. Marwaha, “Comparative
Mechanical Dynamic Analysis of Permanent Magnet Generator Using
Finite Element and Fuzzy Methods”, Open Autom. Control. Syst. J.,
vol. 2, no. 1, 2009.
[6] A. Kumar, S. Marwaha, A. Singh, & A. Marwaha, “Performance
investigation of a permanent magnet generator” Simul Model Pract
Theory, vol. 17, no. 10, (2009), pp. 1548-1554.
[7] S. Cho, J. Hwang, & C. W. Kim, “A study on vibration characteristics
of brushless DC motor by electromagnetic-structural coupled analysis
using entire finite element model” IEEE Trans. Energy Convers., vol.
33, no. 4, 2018, pp. 1712-1718.
Authorized licensed use limited to: Nirma University Institute of Technology. Downloaded on April 29,2022 at 07:21:50 UTC from IEEE Xplore. Restrictions apply.
[8] M. Popescu, J. Goss, D. A. Staton, D. Hawkins, Y. C. Chong, &
Boglietti, “A. Electrical vehicles—Practical solutions for power
traction motor systems” IEEE Trans. Ind. Appl., vol. 54 no. 3, 2018,
pp. 2751-2762.
[9] A. N. Patel, & B. N. Suthar, “Design optimization of axial flux
surface mounted permanent magnet brushless dc motor for electrical
vehicle based on genetic algorithm”, Int. J. of Engg., vol. 31 no. 7,
2018, pp.1050-1056.
[10] G. Boztas, M. Yildirim, & O. Aydogmus, “Design and Analysis of
Multi-Phase BLDC Motors for Electric Vehicles”, ETASR, vol. 8
no.2, 2018, pp. 2646-2650.
[11] S. G. Min, & B. Sarlioglu, “Analysis and comparative study of flux
weakening capability in fractional-slot concentrated windings” IEEE
Trans. Energy Convers., vol. 33, no. 3, 2017, pp. 1025-1035.
[12] X. Liu, H. Chen, J. Zhao,, & A. Belahcen, “Research on the
performances and parameters of interior PMSM used for electric
vehicles”, IEEE Trans. Ind. Electron., vol. 63, no. 6, 2016, pp. 3533-
3545.
[13] Y. Donmezer, & L. T. Ergene, “Cogging torque analysis of interior-
type permanent-magnet brushless DC motor used in washers”. In
2009 8th International Symposium on Advanced Electromechanical
Motion Systems & Electric Drives Joint Symposium, IEEE, 2009 July
pp. 1-6.
[14] T. J. Miller, “Brushless permanent-magnet and reluctance motor
drivers.” 1989