Permanent Magnet

Synchronous Motor (PMSM)

Design
Part 1 General Considerations
Permanent Magnet (PM) Motor
Characterized by permanent
magnets on rotor
Known for its simplicity and
low maintenance
No copper loss on rotor
High efficiency
Exploded View of a PM Motor
J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines
2
nd
Edition, p. 44, Motor Design Books LLC, 2010.
Inner Rotor Possibilities (1)
surface radial
magnet
surface parallel
magnet
breadloaf
magnet
ring
magnet
Inner Rotor Possibilities (2)
(e) IPM in Toyota Prius
Toyota Prius Hybrid Electric Vehicle (HEV)
1. Four cylinder combustion engine;
2. Generator/starter;
3. Electric Motor;
4. Power split device (PSD)
2
3
J. F. Gieras, Permanent Magnet Motor Technology -
Design and Applications, 3
rd
Edition, p. 282, CRC
Press, 2010.
J. R. Hendershot and T. J. E. Miller,
Design of Brushless Permanent Magnet
Machines 2
nd
Edition, p. 34, Motor
Design Books LLC, 2010.
Toyota Prius Power Train
J. F. Gieras, Permanent Magnet Motor
Technology - Design and Applications, 3
rd
Edition, p. 22, CRC Press, 2010.
Segmented Magnets in Large PM Rotor
J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines
2
nd
Edition, p. 94 & 602, Motor Design Books LLC, 2010.
Rotor Skew
stepped magnet
Magnetization Profile
parallel magnetization radial magnetization
radial sine magnetization
sine angle or sine direction
magnetization
most popular
Halbach Array (1)
R. Krishnan, Permanent Magnet Synchronous and Brushless DC Motor Drives, p. 25-30,
CRC press, 2010.
Halbach Array (2)
FEA
Halbach Array (3)
Airgap Flux Density
Rotor is outside
Stator Volume and Size
0
2
V
T
l D
=
The unit for D and L is inch.
3
0
4 ~ 5 in / (ft lb) for 10hp or more (water cooled) V =
Typically
3
0
8 ~ 9 in / (ft lb) for 10hp or less (air cooled) V =
If we design D=L, we have the stator bore (inner)
diameter estimated
3
1
0
) (TV D
estimated
~
We can pick up D close to D
estimated.
m
out
P
T
e
=
Stator Core Design

(1)
,
,
i i c
eff pk g
i i c
core
pk core
l k Pd
l DB
l k d
B =
u
=
(2)
,
i i s
eff pk g s
i i s
tooth
tooth
l k t
l B
l k t
B
t
=
u
=

) (
,
0
eff s pk g ae i ae g eff tooth
l B d r B l t u u

~ = u
}
pk g eff
ae ae pk g eff
P
a is a g eff
ole pitch per half p gap core
B l
P
D
d B
P
l
D
d r B l
,
2 /
0
,
/
0
,

) cos(
2
2

) (
~
=
=
u = u
}
}
t
t
u u
u u
Take
tooth pk core s s
B B t 8 . 0 , 5 . 0
,
~ ~ t
P
D
d
c
6 . 1
~
Effect of Pole Number on Yoke Flux Density
J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines
2
nd
Edition, p. 106, Motor Design Books LLC, 2010.
Finite Element Analysis
with the same d
c
Number of Turns per Coil
pk g a e pk g a e rated
N f N f V
, , ,

44 . 4

2 u ~ u = t
|
P
Dl B
pk g
pk
,
2
= u
1 . 1 /

a w a
N k N =
s d p w
k k k k =
where
Dl B qk f
C V
N
pk g w e
rated
c
,
,
2 2
1 . 1
t
|
=
N
a
is the number of series turns per phase of armature winding
C is the number of parallel circuits of armature winding
C PqN N
c a
/ =
Consider leakage flux
Stator Slot Design
S
D
s
t
t =
3 7
s s s
t d t s s
0.4 0.6
s s s
t t t s s
0
(0.1 ~ 0.5)
s s
b b ~
General Consideration
s
d
s
t
s
t
0 s
b
0 s
d
1 s
d
Define
s s s
b t t =
0
(0.1 ~ 0.5)
s s
d b ~
1
(0.1 ~ 0.5)
s s
d b ~
Stator Conductor Size
Stator current density
a
rated a
copper s
S
C I
J
/
,
,
=
where S
a
is stator (armature) conductor cross section
area and can be determined from the above formula
together with:
2
,
2
A/cm 800 400A/cm : cooled - Air s s
copper s
J
copper s
rated a
a
J
C I
S
,
,
/
=
Permanent Magnets
Samarian Cobalt (SmCo)
Operating temperature of up to 350C
2
nd
strongest rare earth magnet
Neodymium Iron Boron (NdFeB)
Operating temperature of up to 150C
Strongest rare earth magnet
From Yeadon Handbook of Small Electric Motors
Permanent Magnet Properties
Rotor Maximum Diameter
t t rev/min) in ( 2 . 1
) length/min in (
2 . 1
length/s) in (
max
m
r
m
r
r
n
v
f
v
D = =
ft/min 50000 =
r
v
Maximum rotor peripheral speed
Motor Losses (1)
Copper loss
Typical
Stray losses
Electrical phenomenon such as skin and proximity
effect
R I P
Cu
2
=
Motor Losses (2)
Core (Iron) Loss
Hysteresis loss
Eddy Current loss
Mechanical loss
Windage loss
Friction loss
2 / 3 2
) ( ) ( Bf Bf f B P
e c
n
h Iron
k k k
o
+ + =
Finite Element Analysis
Fundamental harmonic
J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines
2
nd
Edition, p. 174-175, Motor Design Books LLC, 2010.
Part 2 Surface Mount Round
Rotor Multi-Pole PM Motor
Design
Magnetic Circuit Analysis
For a multi-pole surface mount rotor
m
d
Poles
a
D
D
0
g m m
gH H d + =
0
0
g m m
gB H d + =
g
0
m m m
m g
d B A
g H A
=
m m g g
B A B A =
Working Point for Permanent Magnetics (1)
B
0
H
0 c
H
r
B
) (
c
c
r
H H
H
B
B + =
H H H
H
B
BH
c
c
r
) ( + =
max
( )
To get (BH) 0 ,
2 2
r c
m m
BH B H
B H
H
c
= = =
c
0 mR
H
mR
B
Maximum Energy Point
Working Point for Permanent Magnetics (2)
Load Line:
( )
( )
0
0

g
m
m m
m
c m
A
d
B H
g A
P H

=
=
1 1.2
rm
s s
P
c
is called permeance coefficient
/
/
g g g
m m
c
m m m g m
A A g
d
P
g A A d
= = ~ =
R
R
P
P
Define: (1 )
m m r m m c
B B H H o o = =
0.5 0.8
m
o ~
Typically pick up:
0
r
rm
c
B
H

=
0
1
m m
c rm
m m
B
P
H
o

o
= =

Airgap Magnetic Field from PM Rotor

/2 /2
/2 /2
2
cos( ) ( ) cos( )
2
sin
4
2

PM PM
PM PM
rh m ae ae m ae ae
PM
m
B B h d B h d
h
B
h
t
t
u u u u
t

t
+

(
= +
(

| |
|
\ .
=
} }
,
1,3,5...
cos( ) cos( )
2
g rotor Rh
h
Rh rh de rh d
B B
P
B B h B h u u
=
=
= =

sin
2
PM
ph
k h

| |
=
|
\ .
pitch factor for the
h
th
harmonic
, g rotor
B
m
B
m
B
t 2
2
P M

PM
t
2
PM

t +
2
2
PM

t
t
de
u
2
PM

2
de d
P
u u =
2
PM

t
PM embrace:
PM

t
electrical angle
Phasor Diagram
|
V
A
E
A S
jX I
o
full-load pull out
Typically, design cos 1 at full-load for PMSM.
sin 1/3 ( =19.47 ) so that T (1 / 3)T
u
o o
~
~ ~

, , ,
, , ,
cos 0.94
sin 0.33
g pk r pk r pk
a pk r pk r pk
B B B
B B B
o
o
= ~
= ~
net
B
R
B
S
B
o
,
4
sin
2
PM
r pk m
B B

t
| |
~
|
\ .
Air Gap Size and PM Thickness
Initial total effective air gap size:
0
, ,

4
1.5 2

a
a pk A rated
total
N
B I
g P

t
=
' ' /
c
total total total m rm
g k g g g d = = +
0
,
,

4
1.5 2
a
total A rated
a pk
N
g I
B P

t
=
From:
From:
m
c
d
P
g
~
(1 ) '
'
m total
m m total rm
g g
d g
o
o
=
=
( )
g m
A A ~
1
m
c rm
m
P
o

o
=

Carters coefficient
total
g
s
d
s
t
s
t
0 s
b
0 s
d
1 s
d
Effective Air Gap

'
total c total
g k g =
where the Carters coefficient
2
0 0 0
0
2 '
atan ln 1
2 ' 2 '
s
c
s s total s
s
total s total
k
b b g b
g b g
t
t
t
=

(
| |

+ (
`
|
( \ .


)
2
0
0
5 '
s
c
s
s
total s
k
b
g b
t
t
~

+
approximately
Rotor Sizing
Total rotor diameter, including magnet
Rotor inner diameter
g D D
r
2 =
2
i r m
D D d =
Example - Specifications
Output power: 10 kW
Terminal voltage: 270 V
Mechanical speed: 10,000 rpm
Input voltage configuration: Y-connected
Number of poles: 4
Fractional stator pitch: 5/6
Number of slots in stator: 24
Permanent magnet: NdFeB-48
Efficiency: 95%
Part 3 Two Pole Super High
Speed PM Motor with Magnet
Inserted in Rotor Shaft
Prototype
Rotor is assembled by
heating and cooling.
Rotor is welded and
well balanced after
assembly.
Air Gap Size
For a 2-pole PM rotor
2 0
eff g m r
g H H D + =
0
2 0
eff m m r
g B H D + =
0
/ 2
r m
c
e f f m
D B
P
g H
= =
N
S
r
D
eff
g
2 2
r
D D
g + =
( )
g m
A A ~
1 1 1
( ) (1 )
2 2 2
r r
c c
c r m r m
D D D
k k
P
+ =
Define: (1 )
m m r m m c
B B H H o o = =
0.5 0.8
m
o ~
Typically pick up:
0
1
m m
c rm
m m
B
P
H
o

o
= =

1 1
c
r
c
c
c r m
k
D D
k
k
P
=

+ +
( )
2 2
r r
eff c
rm rm
D D
g k g

+ = +
2
r
D D
g

=
Carters coefficient
total
g
s
d
s
t
s
t
0 s
b
0 s
d
1 s
d
Effective Air Gap

'
total c total
g k g =
where the Carters coefficient
2
0 0 0
0
2 '
atan ln 1
2 ' 2 '
s
c
s s total s
s
total s total
k
b b g b
g b g
t
t
t
=

(
| |

+ (
`
|
( \ .


)
2
0
0
5 '
s
c
s
s
total s
k
b
g b
t
t
~

+
approximately
, '
2 2
r r
total eff total
rm rm
D D
g g g g

= + = +
Example - Specifications
Design a 2kW, 100krpm, NdFeB-38 PMSM, 2 pole
36 V terminal voltage, Y connected, 90% efficiency.