Novel Rotor Design with Reduced Rare-Earth

Material for PM Machines

G. Dajaku1), H. Zhou1), X. Dajaku1), and D. Gerling2)
1)
FEAAM GmbH, 85579-Neubiberg, Germany, g.dajaku@feaam.de
2)
Bundeswehr University Munich, 85579-Neubiberg, Germany

Abstract—This paper presents a new rotor topology for
permanent magnet machines aiming to reduce the amount of
rare-earth material by improving the utilization of permanent
magnets on air-gap flux density production. The new rotor
configuration consists of two different rotor topologies which are
combined in one rotor core, where each of them includes
magnetic flux barriers to reduce their rotor MMF sub-harmonics
and simultaneously to amplify the 3rd one which has been used as
an operation wave. This ability has been used to reduce the
required magnets amount for producing the same air-gap flux
density compared with the common PM rotor topologies. The
investigations carried out on a traction motor with the proposed
rotor concept indicate a significant magnet amount reduction in
comparison with the considered reference BMW-i3 motor.
Keywords — permanent magnet machines; new pm rotor
configuration; rare earth material reduction; higher harmonic
rotor.
I. INTRODUCTION
Permanent magnet synchronous machines (PMSMs) with
rare earth permanent magnets (like NdFeB with dysprosium,
Dy) are commonly used for electric vehicle traction
applications. Due to their high torque density, high efficiency,
and their ability to achieve constant power over a wide speed
range this machine type has been used by all hybrids and also
the most of the fully electric vehicles [1]-[4]. However,
unpredictability of the cost of rare-earth materials has driven
different companies to develope alternative machine types
with reduced- or completely without rare-earth magnets.
Recently, interest is rising around synchronous reluctance
machines (SynRM), or assisted by PM, called permanent
magnet assisted reluctance motors (PMASynRM) [5]. Further,
Tesla Motors demonstrates that the copper cage induction
motor (IM) is also a quite acceptable alternative to the rare-
earth PMSMs [6]. Another exemplary rare-earth free traction
motor is the electrically excited synchronous motor (ESM)
used in Renault Zeo EV all-electric car [7]. Considering the
alternatives to PMSMs can be concluded that, in order to
reduce machine costs, the main focus was reducing the use of
rare-earth based materials, however with the drawback of
lower performances.
An alternative solution to reduce the magnet amount by PM
machines without weakening their performances was proposed
in [8]. Different from the common PM rotors the new rotor
design operates with higher rotor magneto motive force
(MMF) harmonics as working wave. In addition to that, some
magnetic flux barriers (FB) have been applied in rotor core to
reduce and meanwhile to transfer the magnetic energy of rotor
MMF sub-harmonics to the working harmonic. As a result, the
operating wave will be enhanced without increasing the
magnet volume.
In this paper, the new PM rotor with highly utilized
magnets is investigated for traction motor applications. Section
II deals with a brief analysis of conventional PM rotors. Then,
section III describes the realization of new rotor design and its
functionality. Further, the analytical functions for the rotor
MMF components also are derived. Afterwards, section IV
studies the new PM rotor for traction applications with the
focus reducting of magnet amount for the same power
compared with the common IPM machines. As exemplary
traction PM motor, the BMW-i3 is considered according to the
specification given in [9, 10]. Finally, different simulations
results based finite elements method (FEM) are presented and
discussed on section V.
II. CONVENTIONAL PM ROTORS
Generally, PMSMs can be grouped into two types.
Depending on the rotor topology they are classified into
interior permanent magnet synchronous motors (IPMSM) and
the surface permanent magnet synchronous motors (SPMSM).
According to Fig. 1, several rotor configurations are available,
hence this machine type offers more optimization potential in
machine design and drive control compared with other
machines.
a) b)
c) d)
Fig. 1. Different common rotor topologies, a). Surface mounted magnets, b).
Tangential magnets, c). V-form magnets, d). Spoke magnets.

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A simple PM machine with surface magnets in rotor is parameter should be selected 60 degree, whereas the 1st on for
sketched in Fig. 2a), the rotor magneto motive force (MMF) this case will be only 50%. As a result, different from the
distribution is presented in Fig. 2b), while using Fourier series conventional fundamental machines which usually operate
function the expression for the rotor MMF distribution is with the 1st rotor MMF harmonic as operating wave, under
given in (1). this condition the 3rd rotor MMF harmonic can be used
efficiency also as an operating pole-pair wave. Thus, this rotor
4 H C LM j
Θ PM (α , t ) = ¦
j =1,3,5,... j ⋅π
ξ PM cos ( j ( pα − ωt ) ) (1) type can be called as a “harmonic” wave PM rotor.
A new rotor configuration that operates with the 3rd MMF
rotor harmonic as operating wave was proposed in [8] and is
§ β PM ·
j
ξ PM = sin ¨ j ¸ (2) illustrated in the following Fig. 3. The realization of this rotor
© 2 ¹ type was achieved as a combination of two different rotor
In the above eqs., HC is the coercive field intensity of topologies, i.e. the first rotor with lateral magnets and
permanent magnets, LM is magnet thickness, ȕPM is the additional flux-barriers (FB), and the second configuration
ˆ
magnet pole arc, while j and j Θ with spoke magnets and with lateral magnet-slots as flux-
PM are space harmonics and
barriers (FB). Moreover, the permanent magnets of the first
their corresponding MMF amplitudes. Further, the ȟPM
and the second configuration are magnetized oppositely. In
parameter in eq. (2) notes the pole arc factor of magnets,
addition to that, the both rotor configuration produce a sub-
which influence directly the MMF rotor harmonics according
harmonic component on the rotor MMF, however using flux-
to ȕPM. Hence, depending on the selected ȕPM, some specific
barriers, these component will be reduced and transformed to
harmonics can be improved while other harmonics can be
the operating 3th harmonic.
reduced as proved in Fig. 2c) for the first (fundamental) and
The first FB-rotor configuration is illustrated in Fig. 4a)
the third rotor MMF harmonics.
which includes two FB regions of air between two PM rotor
poles that represents higher magnetic resistances for the sub-
III. NEW PM ROTOR DESIGN harmonics. Thus, the magnetic flux of each permanent magnet
was forced to flow through the two neighbour iron regions of
From the above analysis on the conventional two poles
rotor leading to close to itself. This leads also into
PMSM it is seen that, the magnet pole arc parameter has a
modification of the resulting rotor MMF distribution as
significant effect on the air-gap rotor MMF distribution as
illustrated in Fig. 4b). Compared with conventional rotor, the
well as on the resulting harmonics. E.g. according to Figs. 2c),
MMF produced from one magnet ĬPM,1 is divided equally into
to maximize the 3rd harmonic component the magnet pole arc
two components with theirs magnitudes of Θ*PM ,1 . The air-gap
rotor MMF is presented in (3),

FB FB
rotor-1 rotor-2

a) b)
Fig. 2. a). Simple PM machine with surface magnets in the rotor; b). Rotor
MMF distribution.
+
100
Pole arc factor [ % ]

80

60
New
40 rotor
j=1
20
j=3
0
0 50 100 150
Beta [degree]
PM
Fig. 3. New rotor design as combination of FB rotor-1 and FB rotor-2.
Fig. 2. c). Pole arc factor for the 1st and 3th MMF harmincs vs. ȕPM.

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 250
j = 1, conv. rotor1

Pole arc factor [ % ]

200
with FB j = 3, conv. rotor1
without FB j = 1, FB rotor1
150
j = 3, FB rotor1
100

50

0
0 50 100 150
Beta [degree]
PM
a) b) c)
Fig. 4. a). First PM rotor with FBs; b). Rotor MMF distribution, c). Pole arc factor for the 1st and 3th MMF harmincs vs ȕPM.

250
j = 1, conv. rotor2

Pole arc factor [ % ]

200
j = 3, conv. rotor2
150 j = 1, FB rotor2
j = 3, FB rotor2
100

50
with FB
without FB 0
0 50 100 150
Beta [degree]
PM
a) b) c)
Fig. 5. a). Second PM rotor with FBs; b). Rotor MMF distribution, c). Pole arc factor for the 1st and 3th MMF harmincs vs. ȕPM.

to Fig. 5a), these slot regions will influence the magnetic flux
4 ⋅ Θ PM ,1 path for the spoke magnets and with this also the resulting
Θ FB ,1 (α , t ) = ¦
j =1,3,5,... j ⋅π
⋅ ξ FB ,1 ⋅ cos ( j ( pα − ωt ) )
j
(3)
MMF distribution on the rotor surface, as illustrated in Fig.
5b). The corresponding air-gap rotor MMF distribution can be
where described with Fourier series given in (6)
β PM
Θ PM ,1 = H C ⋅ LM , Θ*PM ,1 = Θ PM ,1 (4) 4 ⋅ Θ PM ,2
π − β PM Θ FB ,2 (α , t ) = ¦
j =1,3,5,... j ⋅π
⋅ jξ FB ,2 ⋅ cos ( j ( pα − ωt ) ) (6)

π β PM § π· where
j
ξ FB ,1 = j
ξ PM − sin ¨ j ¸ (5)
π − β PM π − β PM © 2¹ 2Wmag,2
Θ PM ,2 = H C ⋅ LM 2 (7)
π ⋅ ror
In above equations with jξ FB ,1 is noted the resulting pole arc
factor, and index 1 was used for the FB rotor-1 parameters. § β ·
The first term in eq. (5) indicates that, the FB effect influence g 0 + ¨ 1 + PM ¸ LM
© π ¹
positively all space harmonics by the factor ʌ/(ʌ-ȕPM), Θ*PM ,2 = Θ PM ,2 (8)
g0 + LM
however, depending on the harmonic order, the second
component will reduce or improve them by factor ȕPM/(ʌ-ȕPM). g0
The variation of ȟFB,1 with the magnet pol-arc angle ȕPM for the Θ**
PM ,2 = Θ PM ,2 (9)
1st and 3rd harmonics are depicted in Fig. 5c). For comparison, g 0 + LM
also the results for the conventional rotor are given. For the
conventional rotor the results are similar with in Fig. 2, while LM ­° π jξ PM § g 0 + LM β PM · § π · ½°
ξ FB ,2 =
j
® −¨ + ¸ sin ¨ j ¸ ¾
for the FB rotor-1, we can see the significant positive effect of g 0 + LM °¯ π − β PM © LM π − β PM ¹ © 2 ¹ ¿°
FBs for the 3rd harmonic, as well as on the reduction of the 1st (10)
or the sub-harmonic. E. g., considering the case when
ȕPM=60°, with the FBs rotor design the 1st harmonic is reduced In the above eqs., with LM2 is noted the magnet length in
for factor two, while the 3rd one was increased for factor two. magnetization direction, Wmag,2 is the magnet width, ror is the
Next, following with the second spoke magnets design rotor radius, while ȟPM,2 is the pole arc factor. Index 2 was
with that includes also the magnet-slots of rotor-1. According used for the second FB rotor parameters.

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Eq. (10) shows that, the both geometry parameters of rotor-1
conv. rotor2
magnet slot, e.g. the LM and ȕPM influences the pole arc factor 1
conv. rotor1
1
FB rotor1 FB rotor2
for the second rotor configuration. In addition to that,

Brad [ p.u. ]
Brad [ p.u. ]
0.8 0.8
depending on harmonic order j the second term on the pole arc
factor serves to improve (j=3,7,...) or to reduce (j=1,5,...) it. 0.6 0.6

This represents the geometry FB effect on the pole arc 0.4 0.4
parameter. Fig. 5c) investigate the ȕPM effect (magnet pole arc 0.2 0.2
of rotor-1) on the 1st and the 3rd harmonic. For comparison, the 0 0
0 5 10 0 5 10
conventional spoke magnet rotor is also considered. From the Harmonic Order Harmonic Order
results, it can be seen that also for the second spoke magnets a) b)
FB rotor design the FBs have a significant effect on the MMF Fig. 7. Comparison of air-gap flux density harmonics due to rotor field,
harmonics. Selecting ȕPM=60°, the 1st harmonics is reduced a). Rotor-1, b). Rotor-2.
for 20%, while the 3rd one was increased more than factor two.
components will be added. As a result, the 3rd or the working
harmonic will be improved. Fig. 8 compares the air-gap flux
IV. AIR-GAP FLUX DENSITY ANALYSIS density of a conventional six-pole surface magnets rotor with
Finite elements analysis (FEA) is used in following to the proposed new six-pole rotor. The conventional PMSM
prove the rotor FB effect on the air-gap flux density harmonics requires six-magnets to produce an uniform six-poles
of rotor. The investigations are performed on the simple magnetic field distribution, while with the new rotor design
machine geometries given in Figs. 4a) and 5a). For only four-magnets. Moreover, concerning the magnet amount,
comparison, also the analogous conventional rotor designs the new rotor design produce the same air-gap flux density
without FBs are considered. Figs. 6 presents the field with about 39% lower PM Mass. In the view of machine costs,
distribution of studied machines, while Fig. 7 compares the based on that the magnet material represents the dominant
air-gap flux density harmonics. As can be seen here, the rotor machine costs, the proposed new rotor design will reduce
FB depicts the same effect also on the resulting air-gap flux them significantly.
density. Due to rotor FBs, the 1st flux density harmonic is
reduced, while the 3rd one significantly has been increased.
By combination of FB rotor-1 and 2 as illustrated in Fig. 3,
their sub-harmonic components are shifted to each other for
180 degree, so this component completely will be cancelled.
On the other side, while the 3rd harmonics are in phase, these

a) b)
Fig. 8. Flux lines distribution for the six-poles PMSMs, a) Conventional rotor,
b). New rotor.

1
B [T]

0
a) b)
-1
0 2 4 6
alfa [degree]

1
B [T]

0.5

0
0 5 10 15 20
Harmonic Order
c) d) Fig. 9. Comparison of air gab flux density characteristic due to rotor field;
Results in red for the conventional rotor, in blue for new rotor.
Fig. 6. Flux lines distribution, a). Conventional rotor-1, b). FB rotor-1, c).
Conventional rotor-2, b). FB rotor-2.

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 V. NEW PM ROTOR DESIGN FOR TRACTION MACHINES PMUFconv-rotor = 300Nm/1,90kg =158 Nm/kg
The performances of the new PM machine design are PMUFnew-rotor = 300Nm/1,25kg =240 Nm/kg
compared against that of the BMW-i3 traction motor in this
As expected, the above results indicate that the effectiveness
section. The both machines are investigated under the same of PMs on the torque production with the new rotor design
electrical and geometrical constraints. For the BMW-i3 the significantly will be improved. Hence, considering that the
data are taken from [9, 10], while for the new machine only
rare-earth magnets dominate the machine costs, the future
the rotor was changed by holding the other stator and winding
traction motors with the new rotor design will be considerably
data the same. Fig. 10 show the geometries and flux density
cheaper.
distributions of studied PMSMs, while the key dimensions are
given in Table-I. The aim is to compare their performances A. Machine parameters
concerning utilization of magnets for torque production. Table-II resumes the machine parameters. The phase
For the new rotor design the magnet size parameters are resistance is determined considering the stator winding
derived from the condition that both machines should provide temperature of 80°C and slot fill factor of 42%. While the flux
the same electromagnetic torque under the maximal current
excitation. This has been shown on the simulation results TABLE I. MOTOR SPECIFICATIONS
presented in Fig.11 for the electromagnetic torque when I=400
Arms. Beside the similar results, however concerning the
BMW-i3 rotor New PM rotor
magnet weight the new design is more cost-effective Pole pairs [--] 6 6
compared with reference design. According to Table-I, the
new design required only 1,25 kg magnet material instead of Stator slots [--] 72 72
1,9 kg used by the reference motor. In order to compare the Rotor poles [--] 12
12
efficiency of the new rotor for torque production, a PM
utilization factor similar to [11] is used below. According to Stator diameter [mm] 242 242
magnet specifications, e.g. geometry data and density, as well
as, the obtained results for the maximal torque the following Rotor diameter [mm] 178,6 178,6
was obtained:
Gap length [mm] 0,76 0,8

Stack length [mm] 132,3 132,3

Stator winding Single layer distributed winding with q=2

25 *) 36
Magnet-1 [mm] 12-magnets 4-magnets
a) *)
5 5
13 *) 24
Magnet-2 [mm] 12-magnets 4-magnets
2,2 *) 5,4
Magnet weight [ kg ] 1,9 1,25

*) estimated

b)

Fig. 10. Studied traction PM machines; a). New PM rotor, b). bmw-i3 rotor. Fig. 11. Electromagnetic torque v.s rotor position for 400Arms.

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 a) b) c)
Fig. 12. . Electromagnetic torque v.s load angle, a). for 50Arms; b). for 200 Arms, c). for 400Arms.

a) b) c)
Fig. 13 . Electromagnetic torque characteristics, a). Torque difference between new and the reference design; b). PM torque, c). Reluctance torque.

linkage and inductance parameters are determined for rated
load current 200A. The results for phase resistances show
similar values since the both designs have the same stator and
winding specifications. Whereas, the main differences appear
on the ȥPM and Ldq parameters that are generated from the
rotor geometry effects. According to inductance values for the
reference motor can be concluded that this machine was
designed to produce a high reluctance ratio, while the
proposed motor is developed to produce a high PM flux
amount with minimized magnet volume. Comparing the PM
flux-linkage results and also the magnet weights given in
Table-I can be concluded that, the proposed design is able to
produce about 36% more PM flux with approximately 34%
less magnet amount as the reference motor. Therefore, if we
calculate here the utilization factor of permanent magnet for
flux production, can be concluded that this factor has been
increase from 23,2 mVs/kg to 48mVs/kg.
TABLE II. MACHINE PARAMETERS
BMW-i3 rotor New PM rotor
Phase resistance [mɏ] 5,6
PM flux-linkage [mVs] 44
Ld inductance [mH] 0,090
Lq inductance [mH] 0,255
B. Analysis of torque components
The electromagnetic torque in IPM machines at the steady
state is the sum of reluctance torque and PM torque
components [12, 13]
m
T = p ( ( Ld − Lq )id iq + ψ PM iq ) (11)
2
where p is the number of pole pairs, ȥPM is the PM flux
linkage due to magnets, Ld, and Lq are the d- and q-axis
inductances, while id and iq are the dq-current in dq-rotor
frame.
From (11), the torque components can be presented as
m
Tpm = p ⋅ ψ PM ⋅ i ⋅ cos(δ) (12)
2
m
Trel = p( Ld − Lq ) ⋅ i 2 ⋅ cos(δ) ⋅ sin(δ) (13)
2
The above equations show that, both torque components are
dependent on the load angle į, further the PM torque increase
linearly with load current ( ࡱ i), whereas the reluctance torque
increase quadratically with load current ( ࡱ i2). Therefore,
5,6 according to the torque characteristics, and also the machine
parameters will be expected the new machine design will
60 produce even more torque with decreased load current
compared with the reference motor. The reason is that the new
0,247 rotor is designed/dimensioned to provide the same torque at
0,332 maximal current, and this is the case where the reference
motor produces the maximal reluctance torque. However,

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when the excitation current is reduced, according to (13) the
reluctance torque decrease rapidly compared with PM torque
component. This behavior is demonstrated with various
simulation results depicted in Fig. 12. Further to torque
analysis, Fig. 13a) give the torque difference between the new
and reference design as function of load current. From here
can be deduced that for lower excitation currents the proposed
design can produce up to 37% more torque than the reference
motor.
VI. CONCLUSIONS
This paper presents an alternative rotor design concept for
PM machines. The purpose of the new design was to reduce
the amount of rare-earth material using a high efficient rotor
configuration which consists of a combination of lateral- and
spoke magnets in one rotor core. With this combination the
utilization of permanent magnets for flux density production is
increased by more than 30% in comparison with common PM
rotor topologies.
To prove the effectiveness of the new rotor on reduction of
magnet amount, the investigations are carried out on traction
motor applications, where the BMW-i3 PMSM was used as
reference motor. For comparison the both machines are
investigated under the same electrical and geometrical
constraints. Further, the stator geometry with winding
specifications are held the same, while for the new machine
only the rotor was changed. The magnet size parameters for
the new rotor are derived from the condition that both
machines should provide the same electromagnetic torque
under the maximal excitation current. The investigations on
the proposed rotor concept indicate significant magnet amount
reduction in comparison with the reference motor. For the
given requirements concerning the torque capability the new
design required only 1,25 kg magnet material instead of 1,9 kg
used by the reference motor. Therefore, the ability to save a
huge amount of rare earth magnets with the new rotor design
makes the future traction PM motors considerably cheaper
than before.
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