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DESIGN OF BRUSHLESS
PERMANENT-MAGNET
MOTORS
j. R. HENDERSHOT J r
and TJE MILLER
MONOGRAPHS IN ELECTRICAL AND ELECTRONIC ENGINEERING
1
Dr. W.L. Soong is now with GE Corporate Research and Development, Schencctady, NY,
USA, and Dr. R. Rabinovici is at Ben-Gurion University of the Negev. Beer-Sheva, Israel.
P refa ce
There are so many independent variables involved in the design process,
that the reiteration method is required. By that we mean making certain
assumptions, assigning trial values to independent variables, and
calculating the dependent variables. The independent or "input"
variables are usually dimensions, winding turns, and magnet material
properties. The dependent or "output" variables are usually perform ance
figures such as torque, current, efficiency, temperature rise, etc. The
ensemble of output data is the "performance". If the performance is not
satisfactory, new estimates are made for the input variables, taking
account of trends observed in successive calculations. The process
continues until the desired performance is achieved.
The individual steps in the design process are essentially simple, but a
comprehensive design exercise may include hundreds of parameters and
thousands of iterations, and is clearly capable of being speeded up and
generally improved with the help o f a computer program such as the
SPEED Laboratorys PC-BDC program. This book follows the conventions
and equations used in PO-BDC, and in fact it can be used as a design
guide in conjunction with PC-BDC or, for that matter, with any equivalent
GAD software or design procedures.
We would like to thank everyone who has helped us, both direcdy and
indirecdy, including all those who provided material in the form of
photographs and diagrams, our customers, and especially our colleagues
and families. We would particularly like to acknowledge R.C. Perrine,
Gene Aha, and Malcolm McGilp on the engineering side, and Susie
Murdoch and Bridget Sweeney for their help with the manuscript.
4. MAGNETIC DESIGN
TJE Miller
4.1 Introduction.........................................................................................4-1
4.2 Permanent magnets and magnetic circuits.................................. 4-3
4.3 Approximate calculation of the flux ...................................... 4-10
4.4 Nonlinear calculation of the magnetic circuit.........................4-16
4.5 Armature reaction and demagnetization ............................... 4-18
4-6 Calculation of rotor leakage perm eance................................. 4-23
4.7 Cogging . .......................................................................................4-26
4.9 Retaining can losses .................................................................... 4-28
5. ELECTRICAL DESIGN
TJE Miller
5.1 Introduction.........................................................................................5-1
5.2 Basic windings ....................................................................................5-1
5.2.1 Squarewave motor............................................................... 5-1
5.2.2 Effect of additional coils..................................................... 5-6
5.2.3 Lap windings and concentric w indings............................ 5-9
5.2.4 MuUiple-pole machines........................................................5-11
5.2.5 ConsequentJ>ole windings and m agnets...........................5-12
5.2.6 Computer-aided design of w indings....................................5-13
5.3 Wye and delta connections................................................ 5-14
5.3.1 Wye connection, with 120? trapezoidal phase EMF . . . . 5-14
5.3.2 Delia connection......................................... ..................... 5-21
5.3.3 Flux/pole and magnet utilization......................................5-31
viii
Contents
5.4 Unipolar 3-phase connection..................................................... 5-32
5.5 Two-phase and single-phase connections............................... 5-32
5.6 The EMF constant fcj. ................................................................. 5-35
5.7 The torque constant fcj................................................................ 5-36
5.7.1 Basi* of torque production coenergy............................. 5-36
5.7.2 Torque linearity..................................................................5-38
5.7.3 Demagnetization....................................... .................. 5-38
5.8 Calculating the number of tu rn s .............................................. 5-38
5.9 Winding inductances and armature reaction .......................5-39
5.9.1 Importance of inductance..................................................5-39
5.9.2 Inductance components .................................................... 5-42
5.9.3 Airgap self-inductance of single coil . ................................5-44
5.9.4 Airgap mutual inductance between two c o ils................... 5-46
5.9.5 Examples of inductance calculations............................... 5-48
5.9.6 General case of airgap inductance......................................5-51
5.9.7 Slot-leakage inductance : self and m utual.........................5-55
5.9.8 End-winding inductance.....................................................5-59
5.10 Slotless windings....................................................... ................... 5-61
5.10.1 General ............................................................................... 5-61
5.10.2 Design theory for slotless windings...................................... 5-63
6. SINEWAVE MOTORS
TJE Miller
6.1 Introduction..........................................................................................6-1
6.1.1 The ideal sinewave m otor.................................................. 6-1
6.1.2 Practical motors designed to approximate the sinewave motor 6-2
6.2 Properties of sine-distributed w indings.......................................... 6-4
6.2.1 Conductor and ampere-conductor distributions................. 6-4
6.2.2 Airgap flux produced by sine-distributed w inding............. 6-4
6.2.3 Selfflux-linkage and inductance of sine-distributed witiding 6-6
6.2.4 Mutual inductance between sine-distributedwindings . . . 6-8
6.2.5 Generated E M F .................................................................. 6-9
6.2.6 Torque.................................................................................6-10
6.2.7 Rotating flux and ampereconductors................................6-10
6.2.8 Vector control or "field-oriented" control............................6-11
6.2.9 Synchronous reactance....................................................... 6-12
6.3 Real w indings............................................................................... 6-13
6.3.1 Full-pitch coil.............................................. .......................6-13
6.3.2 Shortjntch co il...................................................................6-14
ix
Co n ten ts
6.3.3 Distribution or spread ....................................................... 6-17
6.3.4 General case ....................................................................... 6-19
6.3.5 Shew ................................................................................... 6-21
6.3.6 Design formulas for practical windings ............................6-21
6.4 Salient-pole m otors...................................................................... 6-23
6.4.1 Calculation of Xd .............................................................6-23
6.4.2 Calculation of X .............................................................. 6-31
6.4.3 Demagnetizing effect of d-axis flux due to Id .................. 6-33
6.4.4 Cross-magnetizing effect of q-axis flux due to I' ............. 6-33
6.4.5 Significance of rotor leakage ............................................ 6-33
6.5 Phasor diagram ............................ ............................................. 6-35
6.5.1 Non-salient-pole machines...................................................6-35
6.5.2 Salient-pole machines.......................................................... 6-36
6.5.3 Operation as a generator ...................................................6-39
6.6 Circle diagram and speed/torque characteristic.................. 6-42
6.6.1 Non-salient-pole motors with Xd ~ ............................... 6-42
6.6.2 Salient-pole motors with Xd ^ X^ .................................... 6-47
7. Kr AND Kg
TJE Miller
7.1 Introduction ................................................. .................................. 7-1
7.2 Squarewave and sinewave m otors................................................ 7-2
7.3 Definition and measurement of fcj- and k ...................................7-3
7.3.1 DC commutator motors........................................................ 7-3
7.3.2 Three-phase squarewave brushless DC motors..................... 7-4
7.3.3 Two-phase squarewave brushless DC motors....................... 7-7
7.3.4 Two-phase sinewave brushless DC m otors.......................... 7-7
7.3.5 Three-phase sinewave brushless DC motors ....................... 7-8
7.3.6 Summary .............................................................................7-10
7.4 Calculation of k j and ............................................................7-10
7.4.1 Squarewave three-phase brushless DC m otors.....................7-11
7.4.2 Two-phase sinewave brushless DC m otors..........................7-13
7.4.3 Three-phase sinewave brushless DC motors .......................7-15
7.5 Example calculation.................................................................... 7-16
9. CORE LOSSES
TJE Miller and R Rabinovici
9.1 Introduction...................................................................................... 9-1
9.2 Nonsinusoidal Steinmetz equation.................................................9-3
9.3 Core-loss formulas ............................................................................9-3
9.4 Waveform method ............................................................................9-5
9.5 Augmentation of tooth w eight........................................................9-6
9.6 Comparison with test d a ta ............................................................... 9-8
xi
Co ntents
10.5 Unipolar half-bridge controller ............................................. 10-23
10.5.1 Commutation................................................................... 10-23
10.5.2 Period A and period B ......................................................10-24
10.5.3 Chopping (regulation) .................................................... 10-24
10.5.4 State-space averaged values............................................. 10-25
10.5.6 Initial conditions and final DC values ..........................10-26
10.6 O ver-running............................................................................. 10-27
10.7 Practical examples and comparison with test d a ta ............. 10-28
10.7.1 Comparison of measured and computed waveforms . . . . 10-28
10.7.2 Accurate calculation of no-load speed...............................10-30
xiii
Co n t e n t s
14.6.3 Robustness ........................................................................14-30
14.7 PID Controllers ..................................................................... .. 14-31
14.7. J Design of a PID controller.................................................14-31
14.7.2 Tuning a PID controller................................................... 14-32
14.7.3 Auto-tuning.......................................................................14-33
14.8 Digital control ........................................................................... 14-34
14.8.1 Discrete system theory........................................................ 14-34
14.8.2 Z-transforms .....................................................................14-36
14.8.3 Z transforms and difference equations........................... 14-38
14.8.4 Stability of discrete systems.................................................14-38
14.8.5 Digital control system design ............................................14-38
14.8.6 Deadbeat controller...........................................................14-39
14.8.7 Digital P ID ........................................................................14-39
14.8.8 PID control example ........................................................ 14-41
14.9 Advanced control techniques ................................................ 1443
14.9.1 Adaptive control ................................................................ 14-43
14.9.2 Optimal control ................................................................14-46
14.9.3 Observers .......................................................................... 14-46
15. COOLING
TJE Miller
15.1 Introduction............. ...................................................................... 15-1
15.2 Heat rem oval................................................................. .. 15-3
15.2.1 Conduction............................................................................. 15-3
15.2.2 Contact resistance...................................................................15-4
15.2.3 Radiation................................................................................15-6
15.2.4 Convection ............................................................................. 15-6
15.2.5 Natural convection................................................................ 15-7
15.2.6 Forced convection ...................................................................15-7
15.2.7 Some rules of thumb for "calibration" ..................................15-8
15.3 Internal temperature distribution ............................................ 15-9
15.3.1 The diffusion equation........................................................... 15-9
15.3.2 Thermal equivalent circuit ..............................................15-10
15.3.3 Current Density ..................................................... 15-12
15.4 Intermittent operation ............................................................ 15-14
15.4.1 Duty-cycle............................................................................. 15-14
15.4.2 Temperature rise during ON-time....................................15-15
15.4.3 Temperature fall during OFF-time.................................... 15-17
15.4.4 Steady-state............................................................. 15-18
15.4.5 Maximum overload fa c to r................................................. 15-18
xiv
CONTENTS
15.4.6 Maximum overload far a single puke ......... .............. .. 15-19
15.4.7 Required cool-down period...................................... .. 15-19
15*4.8 Maximum, on-time,for a given overbadfactor................ 15-19
15.4.9 Maximum duration of single pulse . ,. ............. 15-20
15.4.10 Graphical transient heating curves ........................15-20
15)5 Thermal modelling by computer ............... ........................... 15-22
15.5.1 Computer model of thermal equivalent ckcu.it. . . . . . . 15-22
15.5.2 Determination of equivalent-circuit parameters bytest. . . 15-23
xv
INDEX
1. GENERAL INTRODUCTION
1-1
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
11-SLOT WOUND
ARMATURE (ROTOR)
Fig. 1.1 Cross-section of DC commutator motor. The cxterior-rotor brushless DC motor has
the same cross-section.
1-3
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
STATOR (LAMINATED)
1.2 Commutation
E U
-ROTOR WITH
c :: id ROTOR WITH
MAGNETS
MAGNETS
STATOR WITH
WINDINGS *1
STATOR WITH
::d WINDINGS------ Px
c : : :d X
UEjd
X
(FROM PM S T A T O R )
Fig. 1.4 Rotor of elementary DC commuUtor motor, rotating in a fixed magnetic field
1-6
1. G e n e r a l I n t r o d u c t io n
Fig. 1.4 shows the rotor of an elementary DC commutator motor,
rotating in a fixed magnetic field. The field is produced by a permanent
magnet, Fig. 1.5. This field is a 2-pole field, because there is only one N
and one S pole in each complete revolution. The axis of the single coil
in Figs. 1.4 and 1.5 is shown at the angle 0 with respect to the reference
axis.
Fig. 1.5 Cross-section of elementary DC commutator motor, showing the position of the
reference axis and the axis of the rotating coil
1-9
D e s ig n o f b r u sh l e ss pe r m a n e n t -m a g n e t m o t o r s
Fig. 1.8 Transistor inverter circuit for use with 3-phase brushless DC motor. The power
transistors perform the switching function of the commutator and brushes, but
they require a separate shaft-position transducer and sensing circuitry (not shown).
1-10
1. G e n er a l I n t r o d u c t io n
Certain important characteristics are the same in both motors. The
current waveform in the phases is a 120 squarewave. Exactly two phases
are conducting at any and every instant. The commutator ensures that
the DC supply current remains constant, as does the torque.
The importance of a constant torque waveform cannot be
overemphasized, especially in servo drives where high precision is
required in both velocity and position control. In machine tools, for
example, the surface finish on machined parts can be adversely affected
by torque variations from the drive motor. Periodic torque variation, or
ripple, is also the cause of vibration which may be extremely troublesome
if it excites a mechanical or structural resonance in the driven equipment
or mountings.
The importance of a constant DC current waveform is that it minimizes
the need for filter capacitors connected across the DC supply, and
generally helps with the levels of harmonics, reducing the filtering
requirements.
At constant speed, the constant torque waveform and the constant DC
supply current waveform represent constant electromechanical energy
conversion according to the equation
E I= T<*m (1.2)
where E is the EMF across 2 phases in series and / is the DC supply
current. The EMF /^connected to the brushes must also remain constant
during each 120 interval, and this can be traced back to the linear rate
of change of flux-linkage of each phase as the magnet rotates. In turn,
this linear rate of change of flux-linkage depends on having a flat-topped
distribution of magnet flux around the stator. More analysis of this is
given in Chapters 5,7,8 and 10.
Equation (1.2) could be said to be the most fundamental equation in
motor theory. It embodies the essential linearity and simplicity of the DC
motor from a control viewpoint, and these are the fundamental features
on which DC servo systems and variable-speed drives have been designed
for many decades. It is very important that the brushless DC motor, in its
ideal form, has exactly the same characteristics.
1-11
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
T= Jct I, (1-4)
i.e., the torque is proportional to the current, 'rhis proportionality is so
important that the constant of proportionality in equation (1.4) is usually
called the torque constant, Ay. It is clear from this ideal case that kE = k^.
This equality is often overlooked, especially when English or other non-SI
1-13
D e s ig n o f b r u sh l e ss p e r m a n e n t -m a g n e t m o t o r s
units are being used, because then and kj are not numerically equal,
but differ by a constant multiplying factor. Moreover, different test
methods can be used for measuring and fcp and they usually yield
slighdy different values because the magnetic and clectrical conditions
in the motor may not be the same during both tests. (See Chapter 7).
Referring to the circuit of Fig. 1.7, the applied supply voltage Vs is equal
to the sum of the back-EMF E and the resistive volt-drop in the motor
windings, plus the combined volt-drop from two brush/commutator
interfaces:
V3 = E+ RI+ Vh. (J-5)
J? represents the resistance of two coils (phases) in series, and /is the DC
supply current. This equation also applies to the brushless DC motor, if
represents the volt-drop across two conducting transistors in series. In
well-designed systems, is much smaller than the supply voltage Vt, and
for the remainder of this section we will ignore it.
By substituting for E and I, following a little algebraic manipulation the
speed/torque equation can be derived in the following form:
nl -
(1.7)
E
Vt (1-8)
^LR = ^T^
in Nm. is the locked-rotor current or stall current, limited only by
the winding resistance.
1-14
l . G e n e r a l in t r o d u c t io n
If sufficient load torque is applied, the speed falls to zero and the motor
is then stalled, i.e., in the locked-rotor condition. Then E = 0 and all the
supply voltage is dropped across the motor resistance FL Since R is
usually a very small resistance, the resulting stall current is extremely
large. It is not normally permissible to allow the full locked-rotor current
to flow, even for a short time, because it would either demagnetize the
magnets or destroy the power transistors, or bum the winding
insulation. In fact, normal operation is generally confined to the left-
hand region of Fig. 1.10. Typically, up to 30% of the locked-rotor torque
(and current) may be obtained continuously, and perhaps 50-60% for
very short periods, although these percentages vary widely among
different designs.
RDTDR STATDR
RE
MODULATING FREQUENCY
<SINE 8. COSINE)
400 Hz INPUT
RDTDR ANGLE
Fig. 1.13 Schematic diagram illustrating the operation of a resolver for shaft
position feedback
The resolver rotor mounts on a shaft extension of the brushless DC
motor at the non-drive end, without couplings. All the necessary
electronic circuits are mounted inside the controller. If the brushless
motor can survive the environment, the resolver can also survive since it
is made up of the same materials of copper and iron, without magnets.
1-20
1. G en er a l I n t r o d u c t io n
Like the resolver, the optical encoder is used when more information is
needed than just commutation pulses. It consists of a set of pairs of
phototransistors and collimated light sources, used in conjunction with
a glass or metal encoder disc. The pattern of slits on the disc defines the
frequency and waveform of the pulse trains which are produced by the
phototransistors.
Encoders can be designed to provide commutation pulses directly,
together with a high-frequency pulse train which may be used to generate
a speed signal.
Absolute
Fig. 1.14 Optical encoder disks: absolute (left) and incremental (right).
Fig. 1.14 shows two types of encoder disks. Commercial incremental
encoders usually have two tracks, A and B, which are in quadrature (out
of phase by one-quarter of a slit-pitch). An index pulse (one slit per
revolution) is also provided as a simple absolute position reference. More
complex encoder discs have special patterns (e.g. Gray Scales) which can
be used to provide absolute position information with very fine resolution
and high accuracy. A typical resolution used in motor drives is 1000
lines/rev.
1-21
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
LOGIC
INPUT v POWER
POWER
AC OR OC
POWER
SUPPLY
1-24
1. G e n e r a l I n t r o d u c t io n
1-25
2. MOTOR AND CONTROLLER TYPES
2,1 Introduction
There are several different configurations of brushless motors which use
rotating permanent magnets and stationary phase coils. The main reason
for so many different variations has to do with the utilization of different
magnet grades in addition to the wide range of applications. For
example, if an application requires rapid acceleration and deceleration
of the load (as in servo systems) then the torque/inertia ratio should be
as high as possible. This indicates the use of an interior-rotor motor with
high-energy magnets.
On the other hand, if an application requires constant speed at medium
to high speed it may make more sense to use an exterior-rotor
configuration with the rotating member on the outside of the wound
stator. This type is sometimes used to drive fans and blowers. Perhaps
the most important application for the exterior-rotor motor is the spindle
motor used in computer fixed-disc drives. This application requires a
very uniform and constant speed, and the high inertia of the exterior
rotor is an advantage in achieving this.
There are other applications such as record players, VCR players, CD
players and floppy disc drives for computers which have a different set
of requirements. These motors rotate at relatively low speed. The
packaging envelope is the most important consideration, and it has been
common to design axial-gap or pancake motors for many of these
applications. In most cases they are slotless, meaning that the magnetic
circuit is closed through a smooth backing plate which may not even be
laminated. Slotless motors are sometimes used in the radial-gap
configuration, particularly in applications where the cogging torque due
to slotting must be eliminated. Slodess motors have reduced core losses
and are suitable for application at extremely high speeds, up to at least
100,000 rpm.
2-1
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a c n e t m o t o r s
2 .2 In te rio r-ro to r m o to rs
The interior-rotor motor has the closest configuration to that of the
classical AC synchronous machine or the induction motor, although the
production volumes of exterior-rotor motors are much greater. The
stator is similar to that of the three-phase induction motor. Fig. 2.1
shows an example of the interior-rotor configuration. As stated earlier an
advantage of this design is its high torque/inertia ratio. However, it has
two manufacturing disadvantages:
1. Magnet retention must be carefully implemented so that
the rotor does not fly apart.
2. Although exterior stators are easily cooled, they are
expensive to wind without automatic equipment.
ROTOR '
The rotor shaft must be mounted in bearings. It carries a soft iron yoke
which has a polygonal or circular outside surface on which the magnets
are mounted. The yoke is either machined from low-carbon steel, or
assembled from a stack of laminations (which can be punched from the
2-2
2. M o t o r a n d c o n t r o l l e r types
2-3
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a c n e t m o t o r s
2-4
2. MOTOR AND CONTROLLER TYPES
Fig. 2.2c shows a version of the rotor known as the spoke magnet design or
embedded magnet design. The magnets are magnetized in the
circumferential direction, through their thickness, and their fluxes are
collected and concentrated by soft iron pole-pieces. With 6 or more poles
the flux concentration can be high enough to achieve airgap flux-density
levels, with ferrite magnets, comparable to those which would require a
high-energy magnet in a surface-magnet configuration. The spoke
configuration is becoming more popular because it is a relatively low-cost
fabricated design. The rotor may be larger than that of an equivalent
surface-magnet motor with high-energy magnets, but in many
applications, including many servo systems, a super low inertia is not
necessary. The spoke configuration is especially advantageous in higher-
power machines. Because of the saliency, the most appropriate form of
drive is the sinewave drive (Chapter 6).
The last example shown is Fig* 2.2/which is similar to the first example
except that the magnet arcs are epoxied to a round stack of laminations
so that litde or no grinding is required after assembly unless a retaining
ring is required.
2-5
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
2-6
2. M o t o r a n d c o n t r o l l e r types
A L U M IN U M SQ U IR REL
1 PHASE CAGE D I E - C A S T MOTOR
3 PHASE
WINDINGS
2 4 SLOT
STATOR
PUNCH ING
AC IN D U C T IO N MOTOR
2-7
D e s ig n o f b r u sh l e s s per m a n en t -m a g n e t m o t o r s
2-8
2. M o t o r a n d c o n t r o l l e r types
2-9
D e s ig n o f b r u sh l e s s p e r m a n en t -m a c n e t m o t o r s
ROTOR YOKE
ROTOR MAGNET
STATOR PHASE
COI LS
2-11
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
Fig. 2.8 Axial-gap brushless motor components. (By kind permission or Sony)
PHASE W I N D I N G S
rig. 2.10 Slodcis brujhlcjj pcrmanent-magnet motor
The main feature of this design is the same as that of the axial-gap
slotless motors discussed in the previous section. Without magnetic teeth
and slots, there is no cogging or reluctance torque. The resulting
performance is very smooth. Torque ripple is still possible by virtue of
the discrete locations of the stator conductors, but winding distributions
with low space-harmonic content can be used to minimize this.
Another version of the slotless motor is a completely ironless slotless
configuration, similar to Fig. 2.10 but the laminated steel stator yoke is
either removed altogether or replaced by a magnetically soft ferrite core
of the same shape. The low saturation flux-density of ferrite may not be
a limitation because the flux-density at its large radius is relatively small.
There are no iron losses with this configuration, and extremely high
speed operation is possible without cogging or heating of the stator core.
An apparent disadvantage of the slotless configuration is the loss of the
heat conduction paths from the conductors to the steel teeth. However,
many slodess prototypes have been built for specialty applications with
direct liquid cooling of the conductors. The inductance of slodess
windings is likely to be low, which makes them suitable for high speed.
2-13
DESIGN OF BRUSHLESS PERMANENT-MACNET m o t o r s
2-14
2. M o t o r a n d c o n t r o l l e r types
Fig. 2.12 The phaseleg or half-bridge circuit, shown with a split-level DC supply.
The single phaseleg is rarely used by itself, but its operadon is considered
here in detail because it forms the basic building block from which full-
bridge and three-phase bridge circuits are derived.
The operation of the phaseleg circuit as a power switch is summarized in
Table 2.1. A single phaseleg has only one output terminal, to which one
end of the load impedance is connected. If there is only one phaseleg,
the other end of the load impedance must be connected to a suitable
terminal so that current can flow in closed loops. In Fig. 2-12 the return
terminal is the mid-point of the supply. If transistor Ql is on and Q2 is
off, the output terminal is short-circuited to the positive of the supply
and the voltage across the load is +Vs/2. Conversely, if Q2 is on and Ql
is off, the output voltage is -Fa/2. Ql and Q2 must never be permitted
to switch on simultaneously because they would short-circuit the supply
and very likely suffer a destructive overcurrent. If Ql and Q2 are both
off, the potential of the output terminal can be either positive or
negative, depending on the condition of the diodes. If Ql was formerly
conducting and switches off, the current commutates to diode D2, and
the inductance of the load keeps the current flowing. The voltage across
the load reverses polarity from +Vs/2 to - V$/2 , and it remains at this
value until the current decays to zero, or until Ql switches on again.
2-16
2. M o t o r AND CONTROLLER TYPES
By switching Q1 on and off at appropriate instants, the average current
can be held within a "hysteresis band of a set-point value. This current
is in the positive or forward direction through the load. Similarly, diode
D1 freewheels the load current when Q2 switches off. Q2 and D1
alternately carry reverse load current When Q2 is on, the load voltage
is ~Vt/2 , and when Q2 is off, it is +Vs/2 for as long as the load current
is freewheeling through Dl.
In a single-phase or two-phase motor, Q1 controls the current for 180
electrical degrees when the motor back-EMF has one polarity, and Q2
controls the current for the other 180 in the cycle when the motor back
EMF has the opposite polarity. There is no overlap between the
conduction periods of transistors Q1 and Q2.
Table 2-1 also shows the direction of current and power flow for the
various conditions of the switches. Since all combinations of voltage and
current polarities are available, and the power flow can reverse, the
switch is said to be a four-quadrant switch. However, reverse power flow
cannot be maintained continuously unless the source is capable of
absorbing it. If the source is a battery, reverse current tends to re-charge
the battery (though not necessarily at the optimum rate). If the source
is a rectifier with a smoothing capacitor, reverse power flow tends to over
charge the capacitor because it is blocked by the rectifier, and the
resulting overvoltage can be dangerous unless auxiliary measures are
taken to absorb the energy, such as crowbar circuits, dynamic braking
circuits, or zener diodes.
Q2 Dl D2 4d Power
1 0 0 0 +V./2 + +
0 1 0 0 - V s - +
0 0 0 1 -V./2 + -
0 0 1 0 + V /2 - -
0 0 0 0 Floating 0 0
1 1 0 0 Shoot-through
T a b le 2.1 O p e r a t io n o f s in g l e p h a s e l e g c ir c u it
2-17
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
2-18
2. M o t o r AND CONTROLLER TYPES
diodes. Of course the diodes must have adequate reverse-blocking
capability comparable with the forward-blocking capability of the
transistors, since they are generally connected in anti-parallel with the
transistors.
4. High dv/dt capabilitytransistors should be as near as possible immune
from spurious turn-on caused by the induction of gate current caused by
high dv/dt across the main power terminals. Modern power transistors
are generally MOS-gated, with capacidve input impedance at the gate,
and therefore are inherently suscepdble to spurious turn-on if the gate
is subject to a high dv/dt, which may be coupled via the Miller
capacitance between collector and gate (in an IGBT) or between source
and gate (in a power MOSFET). High dv/dt immunity in the device itself
is obviously desirable, but the safest policy is to drive the gate from a low-
impedance source/sink (such as a pair of driver transistors connected in
totem-pole fashion).
5. High di/dt capabilityM power devices have a maximum rate of change
of current that can be tolerated without current-crowding effects or
second breakdown.
6. High speed of switchingin transistors, the turn-on and turn-off times
need to be as fast as possible to minimize switching losses, although there
is no point in paying a premium for very fast transistors if the switching
losses are insignifcant compared with the conduction losses. In diodes,
the transition from off to on needs to be as fast as possible because the
commutation of inductive current from a transistor branch to a diode
branch is the main means for protecting against destructive transient
voltages. Diodes should also have good reverse-recovery characteristics
(see Chapter 10).
The most startling aspect of the development of brushless motor drives
is the sustained rate of improvement in power electronic switches and in
integrated circuits for digital control. The first brushless motors arrived
on the scene in the early 1960s. They used Alnico magnets, and their
commutation sensors comprised filament lamps with planar silicon photo
transistors. The first power electronic switching device to be developed
and widely applied in motor drives was the SCR in the 1960s. Because
the SCR cannot be turned off by a gate signal, it lent itself to naturally-
commutated converters such as phase-controlled rectifiers used with DC
2-19
D e s ig n o f b r u sh l e ss p e r m a n e n t -m a g n e t m o t o r s
Load current
2-21
D e s ig n o f b r u sh l e s s p e r m a n en t -m a g n e t m o t o r s
\A A A A A A 7 \7 ~ y Hysteresis
band
2-22
2. MOTOR AND CONTROLLER TYPES
The switching of the power transistor is not instantaneous when the
current crosses the threshholds and and therefore the current
waveform can leak outside the hysteresis band. By how much depends on
the response rate of the controlling circuit Moreover, the switching
instants do not occur at a fixed frequency and if it is necessary to filter
the switching frequency to protect neighbouring circuits, the job may be
made more difficult because of the frequency variation.
The two switching control strategies, voltage-PWM and "current
regulation", are only the simplest examples of many possibilities. Much
more sophisticated implementations have been developed, using such
techniques as purely digital regulators, pre-programmed switching intants
to minimize the harmonic content in the current waveforms, and
regulators whose switching is defined and implemented in a rotating
reference frame.
conduction period for forward current the transistors Q3 and Q4 and the
diodes D1 and D2 are idle.
The second group of four rows shows the identical control technique
applied to transistors Q3 and Q4 for negative or reverse current. During
the conduction period for reverse current the transistors Q l and Q2 and
the diodes D3 and D4 are idle.
Ql Q2 Q3 Q4 D1 D2 D3 D4 ^load Power
l 1 0 0 + +
0 1 0 1 0 + 0
l 0 0 0 1 0 0 + 0
0 0 1 I + -
1 1 0 0 - +
0 1 0 1 0 - 0
0 1 0 1 0 0 0 - 0
0 0 1 1 +V, -
T able 2.2 O p e r a t io n o f f u l l -b r id g e c ir c u it
Fig. 2.15 shows the waveforms of applied voltage and current for a full-
bridge circuit controlling a single-phase load with 180 conduction for
forward and reverse currents. The diagram shows the on-periods of each
transistor, and the chopping waveforms for forward conduction. The
diagram shows one transistor (Ql) chopping for the whole 180 interval,
while Q2 remains on during the whole of this interval. In this case Ql is
called the chopping transistor and Q2 is called the commutating transistor.
The chopping duty can be assigned to one transistor or it can be shared
between the two. For example, in the next half-cycle of forward current,
Ql could remain on while Q2 chops. The load voltage would be the
same as in the first half-cycle, but the thermal duty experienced by both
transistors would be equalized because their mean and RMS currents
would be equalized.
2-24
2. M o t o r a n d c o n t r o l l e r ty pes
Una Current |
Cl
4
o 90 80 80 120 150 180 210 240 270 300 990 MO Etecdagraaa
Phw* EMF
eph llne
*ph" ^llne
Q1 Q3 Q1
Q4 Q2 Q4
Q1
duty-cycle d JL T U T JU L
Chopping transistor
D4
duty-cycle 1-d n r ^ ir
Chopping c iode
Q2
Commutating transistor
D3
Commutating diode
fig. 2.15 Voltage and current waveform* for fuU-bridge circuit controlling a single
phase load with 180 conduction periods for forward and reverse current
2-25
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
The waveforms in Fig. 2.15 can be used as the basis for calculating the
peak, mean, and RMS currents in the load, in the chopping transistor,
and in the commutating transistor and their respective diodes. Table 2.3
summarizes the result for the case where one transistor does all the
chopping, and Table 2.4 for the case where the chopping is shared
between the two transistors of each phaseleg on alternate cycles. All
these currents are expressed per-unit of the set-point current 7sp which
is the flat-topped value of the line current in Fig. 2.15.
Peak Mean RMS
Line 1 1 1
Chopping transistor 1 d/2
Chopping diode 1 (1 -d)/2 /[ (l- d ) /2 )
Commutating transistor 1 1/2 1 //2
Commutating diode 1 0 0
T a b le 2.4 P eak , m e a n a n d r m s c u r r e n t s s in g l e ph a se f u l l - b r id g e
c ir c u it , th e r m a l l y e q u a l iz e d . S q u a r ew a v e d r iv e .
(d = duty-cycle).
In two-phase drives the operation is similar, but each transistor conducts
for only 90 instead of 180. The waveforms are shown in Fig. 5.17. With
only one transistor chopping in each phaseleg, the peak, mean and RMS
currents are summarized in Table 2.5. If the transistors chop on alternate
cycles, for thermal equalization, the peak, mean, and RMS currents are
as summarized in Table 2.6.
2-26
2. M o t o r a n d c o n t r o l l e r types
T a b le 2.6 P eak , m ea n a n d rm s c u r r e n t s t w o -p h a s e f u l l -b r id g e
CIRCUIT, THERMALLY EQUALIZED. SQUAREWAVE DRIVE.
{d = duty-cycle).
2-27
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Fig. 2.16 Three-phase bridge circuit for sinewave and squarewave drives, (a) wye
connected motor {!>} delta-connected motor
2-28
2. MOTOR AND CONTROLLER TYPES
-30 0 30 60 90 120 150 180 210 240 270 300 330
!SP alec*
1A
*B
*C
I
Q5 Q1 03 Q5
G6 Q2 Q4
ABC A BC A BC A BC ABC ABC
W W Lit LU tu tu
Fig. 2.17 Line current waveforms for three-phase squarewave (upper) and sinewave
(lower) drive*, including the states of the transistors and current paths.
2-29
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Fig. 2.17 shows the states of the power transistors Q1-Q6, and the arrow
diagrams indicate which lines are conducting in which direction. The
angles at the top of Fig. 2.17 represent rotor position in electrical
degrees.
Sinewave operation is shown in the lower part of Fig. 2.17. In sinewave
operation, the line currents are essentially sinusoidal although they have
a ripple component due to the chopping of the transistors. Normally all
three currents are non-zero (except when they pass through zero).
Consequently there are normally three transistors conducting at any time:
either one upper and two lower, or two upper and one lower. Fig. 2.17
shows the states of the power transistors Ql -Q 6, and the arrow diagrams
indicate which lines are conducting in which direction.
In both the squarewave and the sinewave drives it appears from the ideal
waveforms in Fig. 2.17 that there is really only one DC current which is
switched or commutated among the phases. This seems to imply that the
current could be measured with only one current sensor in the DC
supply, and regulated by chopping only one transistor. However, the
operation of the circuit is complicated by the action of the freewheel
diodes and the motor back-EMF. Because of the diodes, the three phase
currents are not necessarily "observable" to a current sensor in the DC
supply. For full control of the current at all times, it is usual to measure
the line currents directly by means of current sensors in the lines.
However, in a three-wire connection iA + ijj + ^ = 0 so that only two
currents need be measured: the third can be determined from the sum
of the other two. This saves one current sensor.
When the control strategy is voltage PWM in the sense described in
connection with Fig. 2.13, it is common practice to use only a single
current sensor in the DC supply, where it can be used not only for
overcurrent protection but also in a torque control loop.
The use of current sensors in the lines does not necessarily guarantee the
detection of overcurrents in all branches of the circuit, since this
depends on the association of the current-feedback signal with the gate
control of the transistor that is chopping at the time.
A full analysis of the transistor and diode currents for 1-, 2- and 3-phase
circuits is given in Chapter 10.
2-30
2. MOTOR AND CONTROLLER TYPES
Fig. 2.18 3-phase bridge circuit showing conducting loops just after Q5 has turned
off and Q1 has turned on. This is the start of the 60 "base interval".
C 120 Q l The "C" means that line current is the regulated parameter.
Ql is the control transistor (chopping transistor). Note that
it is the "incoming" transistor. Throughout the base interval
it is paired with Q6, which is the "old" or "outgoing"
transistor. Q6 remains on for the whole 60, and turns off
at the end (i.e. at the rotor position 90 in Fig. 2.17). In
this strategy, only the upper transistors are used for
chopping. Therefore, Ql continues to chop for 120. Q6
is used only for commutation, and does not do any
chopping. Q3 and Q5 are therefore equivalent to Q l, and
have the same peak, mean, and RMS currents as Q l. Q4
and Q2 are equivalent to Q 6.
2-32
2. MOTOR AND CONTROLLER TYPES
The current sensor controlling Q1 is assumed to be in line
A or in the DC supply line. This ensures that iA will not
exceed the set-point current /sp. However, this sensor does
not detect the current in line B, which is the sum of the
rising current iA and the freewheeling current from line C.
Therefore, i0 can exceed 7sp, and indeed "spikes" of excess
current can be seen in the line current waveforms with this
strategy, as illustrated in the smaller diagram in Fig. 2.18.
Note also that the freewheeling current in Fig. 2.18 is in a
"zero-volt loop", and therefore its decay rate depends on
the total back-EMF in that loop. Under certain condidons
this decay rate may be too slow, so that D 2 never turns off
during the base interval.
The ideal current waveform in Q1 comprises the positive
half-cycles of the current waveform shown at the top of
Fig. 2.17, with chopping continuing for 120. This
waveform is reproduced in Fig. 2.19.
C 60 Q1 This strategy is similar to the previous one, but with Q1
(the incoming transistor) chopping for only 60 to control
the current in line A. The ideal current waveform is shown
in Fig. 2.19, together with the chopping diode current in
D4.
All six transistors do identical duty. Each one conducts for
a total of 120, but it is chopping only for the first 60 of
its conduction period. In the second 60, it remains on,
and the chopping is continued by the "complementary"
transistor, which is always the next one in the commutation
sequence (i.e., Q l,2,3,4,5,6).
V 120 Q1 The "V" means that line-line voltage is the regulated
parameter. Q 1 is the control transistor (chopping
transistor). Note that it is the "incoming" transistor.
Throughout the base segment it is paired with Q 6, which
is the "outgoing" transistor. Q 6 remains on for the whole
60. In this strategy, only the upper transistors are used for
chopping. Therefore, Q1 continues to chop for 120. Q 6
is used only for commutation, and does not do any
2-33
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
2-34
2. M OTOR AND CONTROLLER TVTES
lend to extinguish the freewheeling current quickly.
The ideal current waveform in Q6 is shown in Fig. 2.19,
with chopping continuing for 120. The corresponding
diode current in D3 is also shown.
C 60 Q 6 This strategy is similar to the previous one, but with Q6
(the "outgoing" transistor) chopping for only 60 to
control the current in line A. The ideal current waveform
is shown in Fig. 2.19, together with the chopping diode
current in D3.
All six transistors do identical duty. Each one conducts for
a total of 120, but it is chopping only for the second 60
of its conduction period. In the first 60, it remains on,
and the chopping is continued by the "complementary1
transistor, which is always the previous one in the
commutation sequence (i.e., Q l,2,3,4,5,6).
V 120 Q 6 This is similar to the V 120 Q l strategy, except that the
"outgoing" transistor is used for chopping instead of the
"incoming" transistor.
2-35
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a c n e t m o t o r s
tsga
Current
chopping
m m
Chopping
diode
VA7
Voltage PWM
continuously
iON . i
0 30 60 90 120150 180 210 240 270 300 330 360 elec
------------------------------ Lina
la Currant
^_1
D4 |-
;: ;| C 120 Q1
-01______________________ 1
D4 I C 60Q1
_Q1 V/////Z77777A
D4 r ----. 'i V 120Q1
06 C 120 06
L ..: ' : i 1 D3
06 C 60 06
03
YZZZZZZZZZZZA 06 V 120 06
r D3
05 01 03 05
06 -92. 04
Fig. 2.19 Effect of switch control strategy on mean and RMS transistor and diode
currents in three-phase squarewave drives.
2-36
2. M o t o r and c o n t r o l l e r ty p e s
DELTA
I Peak Mean RMS
Phase 2/3 4/9 4 2 1 /3
2-37
D e s ig n o f b r u s h l e s s p e r m a n en t -m a g n e t m o t o r s
or less than half the mean line current (since each transistor conducts
only on alternate half-cycles). The RMS transistor current is equal to or
less than 1 //2 of the RMS line current, or 1/2 the peak line current.
The mean and RMS diode currents are less than the transistor currents
under most condidons.
2-38
2. MOTOR AND CONTROLLER TYPES
In the single-phase full-bridge inverter (Fig. 5.16) the maximum RMS AC
output voltage is (2^2/n) Vs = 0.90 Vs in squarewave mode. At the limit
of linear modulation in "sine/triangle" PWM, it is V^/V2 = 0.71 Vt.
AC R E C T IF IE R
POWER
IT C H I N G
CONTROLLER
OR M IC R O
EXTERNAI________ 1 SENSORS
COMMANDS
Vs Power electronics
MOTOR
Current
DC M mj} sensors Tacho
Driver
circuits
Shaft'
position
sensor
Current
regulators'^ I 1 j
Commutation
+ Logic
Speed Monitoring
Ref. err r - Motor tem p
speed -Supply voltage
l2 t
-Tacho
PI gain
Speed feedback
Fig. 2.21 Control system block diagram for squarewave brushless motor controller.
2-43
D e s ig n o f b r u sh l e s s pe r m a n en t -m a g n e t m o t o r s
References
[1] Sebastian T, Slcmon GR and Rahman MA [1986] Design considerations for variable
tpnnd permanerd-magnet motorx, International Conference on Electrical Machines, Pt.
3, 1099-1102
[2] Mohan N, Undeland TM and Robbinj WP [1969] Pawn' electronics : converter*,
application* and design, John Wiley & Sons, NY ISBN 0-471-50537-4
[3] Motorola Application Notei MC330H [1990], MC33034 [1989]
[4] Vai P [1990] Vector control of AC. machines. Clarendon Press, Oxford ISBN 0-19-
859370-8
2-47
D e s ig n o f b r u sh l e s s p e r m a n en t -m a g n e t m o t o r s
2-48
2. MOTOR AND CONTROLLER TYPES
Dote Y and Kinoshita S [1990] iJmiUrit servomotor*: fundamental* ami application*
Clarendon Press, Oxford
Leonhard W [1985] Control of electrical drive*, Springer-Verlag, Berlin
Vaj P [1992] Electrical machine* and drive*: a space-vector theory approach. Clarendon
Press, Oxford ISBN 0-19-859378-3
Boldea I and Nasar S [1992] Vector control of AC drive*, CRC Press, ISBN 0-8493-
4408-5
Jouve D and Bui D [1993] Torque ripple compensation inDSP-bavd brushless servo drive.
Intelligent Motion, PCIM Proceedings, Niimberg 28-37
3. BASIC DESIGN CHOICES
3.1 Introduction
Before a brushless motor design can begin, several important decisions
must be made. The reasons for this should be obvious from previous
discussion regarding the features of different types of brushless motors
and the availability of different magnetic materials. The method of
commutation is also an important issue which should be considered in
making the basic decisions about the design. The choice of an
interior rotor, exterior rotor, or an axial-gap motor must be made
first, along with a rough idea of the correct magnet grade. Then the
number of phases, the number of poles, the number of stator slots,
and the winding configuration must be selected. The rotor and
permanent magnet configuration is designed, then the stator and
winding are determined. A step-by-step procedure is provided as a
rough guide for a typical brushless DC motor design.
1. Determine application requirements (see Table 3.1)
2. Interior-rotor, exterior-rotor, or axial-gap configuration?
3. Select magnet grade
4. Select number of poles
5. Select number of stator slots and phases
6. Perform rough sizing estimate
7. Select air gap length and determine magnetic loading
8. Design rotor and determine flux/pole
9. Lay out stator lamination dimensions
10. Solve for numbers of conductors and turns/coil
11. Calculate wire size, resistance and inductance/phase
12. Calculate performance
13. Check temperature rise, current density, flux densities,
demagnetization of magnet
14. Modify design and reiterate until objectives are met
In this chapter the first five items are discussed, in terms of the basic
principles of brushless motor theory and practice. Later sections cover
rotor and stator designs, windings, and other practical aspects.
Aside from the motor design there are several other environmental and
performance requirements that must be taken into account. A checklist
of these is given in Table 3.1 for reference.
3-1
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
T a b le 3.1 C h e c k l is t o f a p p l ic a t io n r e q u ir e m e n t s
3-2
3. B a sic d e s ig n c h o ic e s
= / ,' 2 ? s in ( p O ~ c o s
where *is the peak phase current and Nt is the effective number of sine-
distributed turns per phase (Chapter 6). This can be compared with the
equivalent relationship for three-phase motors, equation (6.21). For full
control flexibility and maximum utilization of the available DC voltage,
each phase needs to be fed from a full-bridge inverter circuit (Fig. 5.16),
requiring a total of eight transistors and eight power diodes. This may
seem excessive compared to the six transistors needed in a three-phase
drive, but full-bridge single-phase inverters can be neatly packaged, and
the total Silicon area need be no more than in the equivalent three-
phase drive. With separate full-bridge inverters the two-phase motor also
requires four connecting leads, compared with only three for a three-
phase motor. The number of stator slots in the two-phase motor does not
3-4
3. B a sic d e sig n c h o ic e s
fit naturally into the standards used with three-phase motors, and special
laminations may very well be required.
Three-phase motors are by far the most common choice for all but the
lowest power levels. In common with AC motors generally, they have
extremely good utilization of copper, iron, magnet, insulating materials,
and Silicon, in terms of the quantity of these materials required for a
given output power. Although the utilization can theoretically be argued
to be higher in motors of higher phase number, the gains would be
offset by the increased number of leads and transistors, which increases
cost and may severely compromise reliability. The only practical
application might be for a brushless DC torque motor for direct-drive
applications where backlash from gear reducers is unacceptable.
Three-phase motors have the flexibility afforded by wye- or delta-
connected windings, or even unipolar windings. They can operate with
only three connecting leads with no loss of control flexibility. They have
excellent starting characteristics, with smooth rotation in either direction,
and low torque ripple. They can work with a very wide range of magnet
configurations and an enormous range of winding configurations, and
can take advantage of the coil-winding technology that has been
developed for both AC induction motors and DC brush-type motors.
They can operate with either squarewave drive or sinewave drive, and are
Well adapted to the development of "sensorless" controllers that require
no physical shaft position sensor.
No. of phajcj Conductor utilization No. of power Torque ripple %
% twitches
1 50 2 100
2 SO 4 or 8 30
3 67 fi or 3 IS
4 75 8 10
6 83 12 7
12 92 24 3
3-5
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
8 POLE
SKEWED RING
MAGNET
Two-pole motors not only have the largest diameter, but they also have
the greatest susceptibility to magnetic unbalance which can lead to shaft
flux and induced currents in the bearings.
Another important point regarding the number of poles has to do with
cost. For example, if a bonded ring magnet is used which is molded
from one of the rare-earth materials or a ferrite material, it is easy to
magnetize any number of poles desired on the outside diameter or inside
diameter of the ring. In fact, it does not cost any more to magnetize two
poles than it does a hundred poles once the magnetizing fixture is paid
for. On the other hand, if the motor uses arcs or blocks of samarium
cobalt, the greater the number of poles the greater is the cost in magnets
and labor for fabrication.
It is not surprising then to find that most brushless motors have four, six
or eight poles, with four poles being the most popular choice.
If a rotor is to be designed using embedded slab magnets, there are
several possible configurations. It is easier to configure a design with low
flux leakage from the poles if a high pole number is used. Examples are
shown in Figs. 2.2 e, 3.1a, 3.16 and 3.1 e. It is clear from these examples
that a certain amount of flux can leak from pole to pole inside the rotor,
rather than crossing the airgap and interacting with the stator current to
produce torque. If the magnets are thick enough a six-pole design can
be used with embedded flat magnets, but in most instances an 8-pole
design is required to minimize the flux leakage on the inside o f the
rotor.
As shown in Fig. 3 . 1 skewing of the magnet poles may be used to
reduce cogging torque. This requires specially tooled magnet arcs. If a
ring magnet is used as shown in Fig. 3.1/ the poles can be skewed
magnetically in the magnetizing fixture. The other possibility to reduce
cogging is to radius or chamfer the edges of the magnet poles as shown
in Figs. 3.16, d, and e. This so-called pole-shaping at the edges of the
poles can be more cost-effective because specially tooled skewed pole arcs
are difficult to manufacture. The actual pole arc angle itself will be
covered in the next section.
3-8
3. BASIC DESIGN CHOICES
Slots 8 IS IB 20 24 28 32 36 40 44 48
Poles 2 2 2 2 2 2 2 2 2 2 2
6 10 4 6 4 6 4 6 4 fi 4
fi 14 6 10 fi 10 fi 10 fi
10 10 18 8 14 10 14 8
12 18 22 10 22 12 18 10
14 20 12 26 14 12
14 30 26 14
20 28 18
22 30 20
24 34 SO
26 34
28 36
38
40
42
Until recently, it appears that certain pole and slot numbers are more
popular than others. However, there are many combinations of slot- and
pole-numbers that can be used effectively. Tables 3.33.7 list all the
possible pole-numbers which will operate with stator laminations having
slot-numbers from 3 to 48, for 2, 3, 4, 5, and 6 phases.
Many of the combinations listed are not immediately obvious from a
casual observation, and the tables have been generated with the aid of a
special computer program. It is quite possible that there are useful
applications for some of these slot/pole/phase combinations that have
not been previously used.
3-9
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Slot) 3 6 9 12 15 18 21 24 27 SO 33 Sfi 39 42 45 48
Polci 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
6 a 10 6 8 8 6 8 8 6 8 8 6 8
8 10 8 14 10 8 10 10 8 10 in 8 10
12 18 12 16 16 10 20 14 10 14 14 10 14
14 20 12 22 20 12 16 16 12 16
16 18 26 22 14 26 26 14 20
20 26 16 28 28 16 32
22 28 22 32 32 20 34
24 24 34 34 28 38
26 30 40
28 32
30 34
32 38
40
3-10
3. B a sic d e s ic n c h o ic e s
Slotl 8 16 24 32 441
Polei 2 2 2 2 2 " l
2
4 4 6 4 6 4
6 10 6 10 6
10 18 8 14 10
12 10 26 12
14 12 SO 14
14 34 18
20 20
22 30
24 34
26 36
28 38
40
Slots 5 10 15 20 25 SO 35 40 45 |
Pole. 2 2 2 2 2 2 2 2 2 i
4 4 4 4 4 4 4 4 4
6 6 6 6 6 6 6 6
8 12 8 8 8 8 8 8
12 10 12 12 12 12
14 16 IB 14 14 14
Ifi IB 22 22 16 16
20 24 24 24 IB
22 26 26 26 28
2B 28 32
32 34
34 36
3 -n
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
Slots 12 24 3fi
Poles 2 2 2
10 4 fi
10 10
20 14
22
26
30
For example, if the slots/pole is even, then every edge of every pole lines
up with every slot, causing cogging. If a fracdonal-slot combination is
used, fewer pole-edges line up with the slots. The actual pole arc can
make this situation worse or better. A fractional-slot configuration
minimizes the need for skewing of either the poles or the lamination
stack to reduce cogging. In fact, it is recommended that a integral-slot
winding never be used. Note that this precludes one of the most famous
brushless motorsthe one with 4 poles and 12 slots, as well as all of its
derivatives from the 3 slots/pole series.
A final point to be made about the slot and pole relationship concerns
the winding pitch. Since the coils can be wound only over an integral
number of slots, the winding pitch is determined by dividing the number
of slots by the number of poles and rounding off to the next lower
number, or in the case of the 0.75 slot/pole series, the next larger whole
number. The winding pitch or span is summarised in Table 3.9 for all
the slots/pole ratios in Table 3.8.
It should be obvious that the end turns are shortest when the pitch is
one or two slot-pitches. Anything above 2 requires a considerable
overlapping of end turns from one coil around the preceding coil end
turn. This requires that coils be either hand-inserted or machine wound
with expensive AC induction-motor winding equipment. The single-slot
and 2^slot pitch windings can be automatically wound on needle winders
used for winding stepping motors and series motor stators, and are
economical to make.
3-12
3. B a sic d e s ig n c h o ic e s
3-13
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
3-14
3. B a sic d e s ic n c h o ic e s
'American readers will be interested to know that Joseph Henry, an Albany, N.Y.,
schoolmaster for whom the unit of inductance is named, discovered the law of
electromagnetic induction at about the same time as Faraday, if not before, but Faraday was
narrow!)' first to publish. Ironically, Faraday gave his name (or part of it) to the unit of
capacitance, which is of very liltlc significance in electrical machines! One of the reasons
for Faradays experimental success, after famous scientists had searched in vain for
electromagnetic induction for many years, was that as a chemist he took much trouble to
Obtain and use high-conductivity oxygen-free copper for winding his coils, which at the time
was not generally available. He also owned stock in a Welsh copper mine.
3-15
D e s ig n o f b r u sh l e s s per m a n en t -m a g n e t m o t o r s
i 1
Positive Positive
generator motor i
current current
3-16
3. B a sic d e sig n c h o ic e s
electrons drift to one side of the conductor. The force really appears on
the electrons but since they are, on average, displaced from their
electrically-neutral distribution, there is a force of attraction between
them and the positively-charged ions of the copper lattice, in a direction
across the conductor orthogonal to the direction of current flow. By this
means the force is transmitted as an electrostatic force to the conductor
itself. The Hall coefficient, which relates the electrostatic voltage across the
conductor to the product of the magnetic field and the current, is
extremely small in copper, which is probably why this effect is rarely
discussed or even noticed.
The Lorentz force law is unnecessary in deriving motor design equations
because the desired equation for the torque can usually be derived from
Faraday's Law with the law of conservation of energy, embodied in the
principle of virtual work and the concept of coenergysee Chapter 5. The
widespread use of the Lorentz law is undoubtedly due to its simplicity. In
many cases it gives the correct result, but in slotted motors this is
fortuitous and it is always wise to question its validity.
The force law, however derived and formulated, becomes a torque law
in rotating machines because the rotor is mounted in bearings and the
tangential force "appearing at the rotor surface" moves with the rotor.
The most fundamental laws or equations involved in the design and
performance-analysis of electrical machines are summarized in Table
3.10, along with the basic laws of electromagnetism that go with them.
3-17
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
3-18
3. B a sic d e sig n c h o ic e s
all of the turns link the maximum flux 4> at the same time,
and their contributions to the total winding EMF are
generally not in phase with each other and should be
summed vectorially.
The magnets do not generally produce a perfect
squarewave of flux in the airgap. As a result, the average
EMF calculated by equation (3.2) is not equal to the peak
EMF, even if all the turns are concentrated together.
The back-EMF constant can be modified to take these practical factors
into account by writing
Jc = l? ? p c. (3.3)
3 an
The value of the coefficient C depends on the pole arc and the winding
distribution and connection. The effects of these are discussed at length
in later chapters, particularly Chapter 7. For delta connection, the 2/3
factor is replaced by 1/3.
If $ is measured in SI units (Wb or Webers), and in mechanical
rad/sec, then is in volts. (Z, p, and a are numeric with no dimensions).
If <E> is measured in lines, then equation (3.3) should be multiplied by
10 8 to get E in volts.
As shown in chapters 1 and 5, in squarewave motors the torque is
proportional to the DC current / and the constant of proportionality or
torque constant fcj- is equal to fcE if both are expressed in SI units (Nm/A
and V-s/rad). Other units are frequendy quoted, however, and for
reference the relationships between some common units are summarized
in Table 3.11.
8 Note that the RMS value is different again. Unlike the RMS value of the current,
the RMS value of the back-EMF is of no interest in brushleu motor design. However, care
should be taken while measuring it with electronic instruments (particularly multimeters),
because these arc often set up to measure and indicate RMS values and not average or peak
values. The way to be certain of back-EMF values is to measure them on an oscilloscope,
preferably a digital processing oscilloscope that can calculate the mean value while
displaying the whole waveform. The waveform is of interest for many other reasons, not
least for analyzing torque ripple.
3-19
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
3-20
3. B a sic d e s ig n c h o ic e s
magnet within the magnetic circuit formed by the motor geometry, using
equadon (4.12):
PC = * h* x A (3.4)
f lX G g AU
3-21
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
3-22
3. BASIC DESIGN CHOICES
3.6.3 Basic sizing rules
Magn& overhangIf Ferrite magnets are used as shown in Fig. 2.5, it is
normal practice to increase the magnet area and resulting flux by making
the magnet axial length longer than the stator lamination stack. The
effects of increased flux by using magnet overhang can be quite
significant on a shores tack motor. The amount of overhang should
never exceed the magnet thickness on each end. Surface-magnet rotors
with Rare-earth magnets normally do not use overhang because the
remanence is so high that the stator teeth cannot cany the extra flux,
their width already having been made as small as possible to maximize
winding space.
Qmsequentfole deignsOne of the main advantages of consequent-pole
designs (as shown in Fig. 2.2d) is that operation at the maximum energy-
product is practical because the thicker magnet is used to drive two air
gaps, which decreases the permeance coefficient.
*Spoke* designsIn the case of the "spoke" design, Fig. 2.2e, the magnet
thickness is again based on two airgaps in series, each with one half of
the soft iron pole area. This configuration is cost-effective for both
Ferrite and bonded NdFeB grades because the magnets are flat slabs.
They can be easily magnetized before assembly without concerns about
cleaning after machining. Given the accuracy of the soft iron pole pieces
between the magnets there is no need for machining or grinding on the
finished rotor assembly. Mechanical retention of embedded magnets in
the spoke configuration is more dependable than than any method
which relies solely on adhesive. Other benefits of the embedded-magnet
rotor (spoke and interior-rotor types) include low magnet cost, low
magnet tooling cost, and high airgap flux-density. Also the soft iron pole-
piece can be shaped to reduce cogging.
3-25
D e s ic n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
3-26
3. B a sic d e s ig n c h o ic e s
3. Welding
4. Self-cleating
5. Slot liners
The bonding method is usually used only for prototypes or small
quantities. It is obvious by its name that epoxy in the form of a thin spray
coating is applied to at least one side of every lamination before they are
stacked in a fixture, clamped, and heated to cure the epoxy. Another
form of this is to align, clamp, preheat and apply Loctite which
penetrates between the laminations and bonds them together. Another
method is to provide holes in the stamping die to accept through-rivets
which are staked in place. The holes must be located at points in the
magnetic circuit such that the electrical circuits formed by shorting the
laminations to the rivets will not have significant induced currents in
them. The rivet holes are usually near the outside diameter of the
lamination. Rivets or overboils can be fitted outside the lamination stack.
In some cases they also help to hold the end-bells in position.
Another common procedure is automatic TIG (tungsten/inert gas)
welding. This can be used on an automatic assembly line for low-cost,
high-volume production.
A popular method of stacking and retaining laminations into packs that
do not require welding is to use a progressive punching die with a station
at the end of the stamping process which makes a small indentation in
each lamination. The indentations protrude on the other side of each
lamination, providing a self-cleating action when they are nested together
under pressure. The indentations are usually located in the
neighborhood of the teeth.
A common way to hold stacks together until they are wound during the
production of AC induction motors is easily used for brushless DC
motors because of the similarity of the stator laminations. This method
uses cuffs on each end of the slot liners which are automatically inserted
into the stator slot openings. The cuffs on either end of the lamination
stack are folded back automatically and hold the stack together quite
snugly until it is wound and varnished. This is an excellent method for
high speed automatic brushless motor manufacturing which can be
borrowed or adapted from induction motor production lines. Skewed
packs can be made after winding using this system.
3-28
3. Basic d e s ig n c h o ic e s
Insulating the slots1O nce the lamination stack is in a pack form, it must
be insulated before winding so that the magnet wire does not short out
to the pack. There are several ways that this is accomplished. For
prototypes either hand-cut slot-liners and end insulators are used, or if
the equipment is available a 3-M fluidized-bed epoxy coating system can
be used. For high-volume production motors a molded plastic insulator
is commonly used for small brushless machines, usually one on each side
of the pack. Frequently, in the molding process of the insulators various
connection methods are molded as part of the insulator so that
automatic connections of lead wires, Hall switches or printed circuit
boards can be incorporated with the attachment of the magnet wire from
(he coil windings. This high-volume insulating and connecting technique
is seldom used in large motors. The most common method for larger
motors is the cuffed slot liner as used in AC induction motors.
Automatic equipment is available for this sort of insulating.
fig. 3.3 Lamination packs with slot liners (courtesy of Industra Automation)
3-29
D esig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
3-31
D e s ig n o f b r u sh l e ss p e r m a n en t -m a g n e t m o t o r s
3-32
3. B a sic d e s ig n c h o ic e s
3-33
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
3-34
3. B a sic d e sig n c h o ic e s
6 SLOT 12 SLOT
4 POLE 4 POLE
1 COIL/POLE/PHASE 2 CO IL/POLE/PHASE
24 SLOT 36 SLOT
4 POLE 4 POLE
3-36
3. B a sic d e s ig n c h o ic e s
With the 24-slot stator in Fig. 3.4, the coil span could be 6 slots, but with
1 coil per pole and three phases, half the slots would be empty while the
other half would contain two coil-sides each. Fig. 3.4 shows a more
practical arrangement with a coil span of 5 slots and one coil per pole.
With the 36-slot stator the coil span could be 9 slots but 8,7,6 or even 5
could be used. The winding shown has 2 coils/pole with spans of 9 and
8 each. Alternatively the spans could be 8 and 7 slots. This is a concentric
winding. In an electrically equivalent lap winding, all coils would have the
same span, either 8 or 7, and there would still be two coils per pole.
The windings in Fig. 3.4 are all relatively concentrated, as would be
suitable for squarewave motors. For sinewave motors it is more
appropriate to use short-pitched coils and a more distributed winding.
The windings in Fig. 3.4 fill exactly 1/3 of the available space in the slots,
leaving the same amount of space for the other two windings.
4 POLE ROTOR 6 COILS/POLE
ST ARTS FINISHES
3-37
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
A B C A B C
I I
I
T
1
4
A B C A B C
START S FI NI SHES
Fig. 3.5b Concentric winding
An example of a lap winding is shown in Fig. 3.5a, and an example of a
concentric winding in Fig. 3.5b.
3.8.3 Winding configurationsfractional and integral slot
An integral-slot stator is one with an integral number of slots per pole, so
that the pole-pitch is an integral number of slot-pitches. The windings of
integral-slot stators are naturally regular and symmetrical: the coils fall
naturally into groups, each group usually being associated with one pole
as in the 36-slot stator in Fig. 3.4.
A fiactional-slot stator has a non-integral number of slots per pole: for
example, a 4-pole motor with 15 slots has 3.75 slots/pole and there is no
perfectly symmetrical winding arrangement with identical groups of coils
3-38
3. B a sic d e sig n c h o ic e s
The first step is to calculate the slots/pole and the maximum coil span
ffraax us*ng equation (3.9). 0max is an integral number of slot-pitches,
and the remainder e is a fractional number of slot-pitches between 0 and
1 : thus
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
For the 15/4 motor, <Jmax = 3 and e = 0.75. The actual coil span used
can be less than 3 slots, and in the example shown in Fig. 3.6 the coil
span is a = 2 slots.
The first coil in Fig. 3.6 is wound in slots 1 & 3, so the position of the
axis of this coil can be charactemed as (1 + 3)/2 = 2, i.e. 2 slot-pitches
from the origin (the w-axis), or aligned with the centreline of slot 2.
The rule for locating subsequent coils is expressed in terms of Sp, the
number of slots forward from the "return" coilside of the previous coil to
the "go" coilside of the coil next to be inserted. The value of is given
by
=
f CTm a x + 1 if e S 0 .5
(3-11)
I ^ s s -t7max> f > 0-5
where Na is the number of slots per section. The winding is divided into
sections if the number of coils per phase Cph is divisible by the number
of pole-pairs p. In fact, the number of sections S is equal to the highest
common factor of and pole-pairs p, so that
N = -----^ 2 * -----. (3.12)
H C F [^h^ ]
The rule expressed in equations (3.11) and (3.12) tends to minimize the
build-up of phase displacement or phase error between subsequent coils.
Note that when Sp = cj nax + 1 the winding is progressive, in the sense that
successive coils follow one another in the positive (CCW) direction.
When Sp = Na - omax, the winding is retrogressive in the sense that
successive coils follow one another in the negative (CW) direction.
The winding in Fig. 3.6 has only one section: the number of coils per
phase is 15/3 = 5, and this has no common factor with p, which
is 2. Therefore Nss = Njloti = 15, and with CTmax = 3 and e = 0.75 > 0.5, .Sp
= 3 + 1 = 4 slots. Since the "return" coilside of coil 1 is in slot 3, the "go"
coilside of coil 2 will be in slot 3 + 4 = 7 . The polarity of successive coils
is alternated so that coil 2 has a span of -2 rather than +2, and its
"return" coilside is therefore in slot 7 - 2 = 5 . Note that the axis of coil
2 is at (7 + 5)/2 = 6, and this is 4 slots further on than the axis of coil 1.
Since the pole-pitch is 3.75 slots, the axis of coil 2 is displaced 1/4 of a
3-40
3. B a sic d e s ic n c h o ic e s
slot clockwise from the position it would need to have in order for the
EMF's in coils 1 and 2 to be in phase. It can be said that the phase
displacement between coil 2 and coil 1 is + 1 /4 slot. This does not sound
much, but in clectrical degrees 1 slot is equivalent to 1 /1 5 x 2 x 360 =
48, so the phase displacement of coil 2 is 12 relative to coil 1 .
Proceeding with the winding, coil 3 is in slots (5 + 4) = 9 and (9 + 2) =
11. Its axis is at (9 + l l ) / 2 = 10, that is, 8 slot-pitches further on than the
axis of coil 1. The nearest integral number of pole-pitches from the axis
of phase 1 is at 7.5 slot-pitches from the axis of phase 1, and therefore
coil 3 has a phase displacement of 1 /2 slot or 24 relative to coil 1.
The winding can be completed by continuing in the same fashion: coil
4 is in slots 15 & 13 with a phase displacement of 36, and coil 5 is in
slots 2 & 4 with a phase displacement of 48 or one complete slot. The
resulting coil list is summarized in Table 3.13.
Coil No. Turn* Go slot Retn dot Span
1 12 1 3 2
2 12 7 5 -2
3 12 9 11 2
4 12 15 13 -2
5 12 2 4 2
3-41
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
The three-phase motor in Fig. 3.7 has 18 slots and 8 poles, and C. , =
18/3 = 6 coils per phase. With p = 4, the highest common factor o f fph
and p is 2, and therefore there will be two sections and two sequences,
each containing 3 coils. Each section will have 4 poles and = 9 slots.
The number of slots/pole is 18/8 = 2.25, so oraax = 2 and e = 0.25.
Therefore, from equation (3.11), 5^ = 9 - 2 * 7. These parameters
define the winding pattern shown in Fig. 3.7 for the first three coils only,
forming the first sequence. The second sequence is obtained by copying
the first sequence coilside-for-coilside, Na slots further on. Thus coil 1 in
slots 1 Sc 3 is followed by coil 2 in slots (3 + 7) = 10 and (10 - 2) = 8,
then the first sequence is completed by coil 3 in slots (8 + 7) = 15 and
15 + 2 = 17. The second sequence is obtained by copying coil 1 to coil
342
3. B a sic d e sic n c h o ic e s
3-43
D e s ig n o f b r u sh l e s s pe r m a n en t -m a g n e t m o t o r s
Fig. 3,8 Back-EMF waveform for three-phase 15/4 motor of Fig, 3.6.
a EMF waveform of one coil
b line-line EMF waveform of entire winding {wye connection)
c Electromagnetic torque waveform with squarewave drive
Also shown in Fig. 3.8 is the electromagnetic torque waveform obtained
with perfect squarewave drive. Similarly, Fig. 3.9a shows the back-EMF
waveform from a single coil of the winding in Fig. 3.7, and Fig. 3.9b
shows the line-line back-EMF waveform from the whole winding.
3-44
3. B a sic d e s ig n c h o ic e s
Fig. 3.9 Back-EMF waveform for three-phase 18/8 motor of Fig. 3.7.
a EMF waveform of one coil
b line-line EMF waveform of entire winding (wye connection)
c Electromagnetic torque waveform with squarewave drive
The winding is connected in wye. Fig. 3.9 c shows the torque waveform for
squarewave drive. In both cases the magnet pole arc is 140 electrical,
and the single-coil waveforms were calculated w i t h 5 x ! 2 = 60 turns in
3-45
D e s ig n o f b r u sh l e s s pe r m a n en t -m a g n e t m o t o r s
Offset = 1 x + k= i i2 3 (3.13)
3 2p p
With integer values of k, the second term merely advances the start of
phase 2 by 360A electrical degrees. Some examples of windings are given
in Figs. 3.113.19, and the Offset parameter is tabled in these figures.
For example, in Fig. 3.11, with 6 slots and 2 poles {p = 1), equation
(3.13) gives Offset = 2 with no need for the second term, i.e. k = 0. In Fig.
3.12, with 9 slots and 8 poles, 2/3 x 9/8 = 3/4, which is not an integer.
Trying k = 1 gives 3/4 + 9/4 = 12/4 = 3, which is the correct value of
Offset for this winding. If no integral value of Offset can be found from
equation (3.13), it is impossible to wind a balanced three-phase winding
in the given number of slots and poles. For example, with 15 slots and
6 poles Offset is nonintegral for all integer values of k. On the other
hand, the 15/4 motor works with k= 1 to give Offset = 10, as in Fig. 3.16.
Cheeking the windingA simple check on the validity of a winding
configuration generated by equations (3.11-13) is to test whether all the
slots contain equal numbers of coilsides. Generally this will be the case,
provided that valid slot/pole combinations are used (Tables 3.3-9).
3-46
3. B a sic d e s ig n c h o ic e s
348
3. B a sic d e s ig n c h o ic e s
same for every motor configuration within the same group, so the
examples shown can be applied to other motors in the same group.
The back-EMF waveforms in Figs. 3.11-3.19 were calculated without any
fringing effects, i.e. assuming no airgap .5 When actual back-EMF
waveshapes are measured on motors of these examples, fringing causes
the comers to be rounded: see Chapter 8. This does not significandy
affect the usefulness of this data in making comparisons between the
different configurations.
Some combinations of the windings and pole-arcs give rise to excessive
third-harmonic EMFs in the phases, making them unsuitable for delta
connection. This is discussed in more detail in Chapter 5.
All the plots in Figs. 3.11-3.19 extend over 180 electrical degrees. The
data with each curve includes the average value of the back-EMF
throughout the 60 commutation zone, expressed as a percentage of the
peak value of the ideal squarewave back-EMF that would be achieved with
a concentrated full-pitch coil (see Chapters 5,7 and 8). This percentage
expresses the effect of the coil span, skew, and method of connection on
the torque constant. The ideal commutation zone average would be
100%, but the actual value is reduced by short-pitching the windings, by
fringing at the edges of the magnet, and by skew. The reduction in
average EMF caused by skewing is noticeable and is the price paid for
low cogging torque. Other techniques for reducing cogging (radii or
chamfers on the magnets) have similar effects on the back-EMF wave.
The number of slots can be determined using the examples as a general
guide, along with the rotor pole arc angle to achieve the desired output
considering cogging torque and winding designs. In general, the smallest
number of slots gives the lowest labor cost in winding, and a coil span of
1 or 2 slots yields the lowest phase resistance. The phase inductance is
decreased if the same number of turns is distributed among a greater
number of slots, so the electrical time constant can be lower with a
greater number of slots per pole.
c The computer program, which is the work of G. Aha and R.C. Perrinc, constructs
the waveforms from a 35-term Fourier series. The truncation is the cause of the high-
frequency ripple visible on some of the waveforms (Cihb phrrwmrrwn).
3-49
D e sig n o f bru sh less perm a nent -m a g n et m o t o r s
Slots/pole 0.75
Slots 6
Poles 8
Phases 3
Pole arc 30 (120e)
Offset 2
Coil span 1
Hg. 3.11a
WYE DELTA
Skew
3-50
3. B a sic d e sig n c h o ic e s
Slots/pole 0.75
Slots 6
Poles 8
Phases 3
Pole arc 45 (180e)
Offset 2
Coil span 1
Fig. 3.11 fr
WYE DELTA
Skew
3-51
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
Slots/pole 1.125
Slots 9
Poles 8
Phases 3
Pole arc 30 (120 e)
Offset 3
Coil span 1
Fig. 3.12a
WYE DELTA
Skew
Skew = 1
3-52
3. B a sic d e s ig n c h o ic e s
Slots/pole 1.125
Slots 9
Poles 8
Phases 3
Pole arc 45 (180 e)
Offset 3
Coil span 1
Fig. 3.124
WYE DELTA
Excessive
third-harmonic
Skew
Excessive
Skew = 1
third-harmonic
3-53
D esig n o f bru sh less perm anent -m a g n et m o t o r s
Slots/pole 1.5
Slots 6
Poles 4
Phases 3
Pole arc 60 (120e)
Offset 1
Coil span 1
Fig. 3.13a
WYE DELTA
Skew
3-54
3. B a sic d e s ig n c h o ic e s
Slots/pole 1.5
Slots 6
Poles 4
Phases 3
Pole arc 90 (180e)
Offset 1
Coil span 1
Fig. 3. ISA
WYE DELTA
Skew
3-55
D e sic n o f bru sh less perm a nent -m a gnet m o t o r s
Slots/pole 2.25
Slots 18
Poles 8
Phases 3
Pole arc 30 (120e)
Offset 6
Coil span 2
Fig. 3.14a
WYE DELTA
Skew
Skew = 1
3-56
3. B a sic d e s ig n c h o ic e s
Slots/pole 2.25
Slots 18
Poles 8
Phases 3
Pole arc 45 (180e)
Offset 6
Coil span 2
Fig. 3.14ft
WYE DELTA
o Excessive
ii
third-harmonic
Skew
Skew = 1
Excessive
third-harmonic
3-57
D esig n o f bru sh less perm anent -m a gnet m o t o r s
Slots/pole 3.0
Slots 12
Poles
Phases 3
Pole arc 60 ( 120 e)
Offset
Coil span
Fig. 3.15a
WYE DELTA
-58
3. B a sic d e sig n c h o ic e s
Slots/pole 3.0
Slots 12
Poles 4
Phases 3
Pole arc 90 (180e)
Offset 2
Coil span 3
Fig. 3.15*
WYE DELTA
o Excessive
li third-harmonic
Skew
Excessive
Skew = 1
third-harmonic
3-59
D esig n o f brushless perm anent -m a g n et m o t o r s
Slots/pole 3.75
Slots 15
Poles 4
Phases 3
Pole arc 60 ( 120e)
Offset 10
Coil span 3
Kg. S.lfia
WYE DELTA
J
/ \
Skew
3-60
3. B asic CHOICES
Slots/pole 3.75
Slots 15
Poles 4
Phases 3
Pole arc 90 (180e)
Offset 10
Coil span 3
fig.
WYE DELTA
Excessive
third-harmonic
Excessive
third-harmonic
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
Slots/pole 4.5
Slots 18
Poles 4
Phases 3
Pole arc 60 ( 120e)
Offset 3
Coil span 4
Fig. 3.17o
WYE DELTA
Skew
Skew = 1
3-62
3. BASIC DESIGN CHOICES
Slots/pole 4.5
Slots 18
Poles 4
Phases 3
Pole arc 90 (180 e)
Offset 3
Coil span 4
Fig. 3.17*
WYE DELTA
Skew
Excessive
Skew = 1
third-harmonic
SS3
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
Slots/pole 5.25
Slots 21
Poles 4
Phases 3
Pole arc 60 (120 e)
Offset 14
Coil span 5
Fig. 3.18a
WYE DELTA
Skew
Skew = 1
3-64
3. B a sic d e s ig n c h o ic e s
Slots/pole 5.25
Slots 21
Poles 4
Phases 3
Pole arc 90 (180e)
Offset 14
Coil span 5
Fig. 3.1 BA
WYE DELTA
n Excessive
third-harmonic
Skew
Excessive
Skew = 1
third-harmonic
S-65
D esig n o f bru sh less perm anent -m a g n et m o t o r s
Slots/pole 6.0
Slots 24
Poles 4
Phases 3
Pole arc 60 ( 120e)
Offset 4
Coil span 6
Fig. 3.19a
DELTA
h
Skew
/
/ \
\'
Skew = 1
'
Slots/pole 6.0
Slots 24
Poles 4
Phases 3
Pole arc 90 (180 e)
Offset 4
Coil span 6
Fig. 3.19ft
WYE DELTA
Excessive
third-harmonic
Excessive
third-harmonic
3-67
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
Aw ~ \ ^slot^slot
N
(3.14)
The next smaller wire gage is selected from a wire table, after selecting
the type of varnish insulation required for the required temperature
rating.
[NOTE: The definition of slot fill used here is not the same as the ratio
of conductor area to total slot area, which is considerably lower.]
3.8.6 Basic winding calculations
ResistanceThe actual "bare copper" wire diameter is used to calculate the
phase resistance. This requires the determination of the mean length of
one turn (MLT). The M LT includes twice the stack length, plus twice
the end-tum crossover length, plus twice the coil "bundle" thickness. A
full scale drawing or CAD print is useful for determining the MLT. For
concentric or concentrated windings, each coil in a pole group has a
different turn length, and this must be taken into account.
The resistance per coil Rc is a simple calculation using Q, the value of
resistance per 1000 ft. for the particular wire gage selected. Divide this
3-68
3. B a sic d e s ig n c h o ic e s
3-69
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
Fig. 3.21 Brushlew DC disc motor (Infranor). Drawing mpplitd by Uhw.-Pnf. Dr-
Ing. 0. Hmntbrrgrr of Institut fur Ehtktritchr. Maschmen, RWl'H-Aachm, [2]
3-70
D e sig n o f bru sh less perm a nent -m a g n et m o t o r s
Fig. 3-21 shows a disc motor with two stator halves each carrying a set of
pole windings. The magnets are held in the rotating disc between the
$tator halves. The stator core is made from a wound-up strip of steel
bolted to the housing for good heat transfer. This motor has low inertia.
Fig. 3,22 Exterior-rotor 40mm brushleu DC motor for computer disc drive. Phots
kindly supplied by Syruktron Corp., Portland, Ongpn
Figs. 3.22 and 3.23 show typical exterior-rotor motors of the type used in
computer disc drives and laser scanners.
3-71
D e sig n o f bru sh less perm a nent -m a g n et m o t o r s
Fig. 3.23 Exterior-rotor half-height brushless DC motor for computer disc drive.
Photo kindly supplied by Synfktron Corp., Portland, Ortgon
3-72
3. B a sic d e s ig n c h o ic e s
Fig. 3.24 Small bruihleu DC actuator motor. Photo kindt) supplied by Lucas Aeroipacr
Fig. 3.25 8-pole spoke-typc rotor (Pacific Scicntific F40 Series). Photo kindly supplied
by Pacific Scientific, Rockford, lUinoii
3-73
D e sig n o f b r u sh l e ss pe r m a n e n t - m a g n e t m o t o r s
Fig. 3.26 Pacific Scientific brushless servomotors. The largest of these motors (7,5')
produce up to 50 Nm continuous stall torque and 200 Nm peak torque.
Photo kindly supplied by Pacific Scientific, Radford, Illinois
3-74
4. MAGNETIC DESIGN
4.1 Introduction
The flux in a brushless permanent-magnet motor is established by the
magnets. We have seen in Chapter 1 that the torque is proportional to
the current and the flux, while the no-load speed is proportional to the
voltage and inversely proportional to the flux. The flux is clearly a most
important parameter in the design. This chaptcr describes the simplest
methods of calculating it, for later use in the calculation of the EMF and
torque equations and the speed/torque characteristic.
The simplest motor is the 2-pole motor, Fig. 4.1. The flux is intended to
link the coils of the phase windings on the stator, and these coils are
located as close as possible to the magnet to minimize the amount of
magnet flux that "leaks" from the N pole to the S pole without linking
any turns of the windings. The laminated steel core of the stator acts as
4 rl
D e sig n o f bru sh less perm anent -m a g n et m o t o r s
a flux guide. The high permeability steel teeth draw the flux radially
across the narrow airgap and the yoke (back-iron) returns it from the N
pole to the S pole with very little expenditure of MMF (magnetomotive
force or magnetic potential drop). The rotor hub performs a similar
function inside the rotor. Because the steel stator and rotor absorb very
little MMF, most of the magnets MMF is available to drive flux across the
airgap.
The slotting is an ingenious way to achieve a narrow airgap length while
keeping the winding conductors close to the magnet. Other benefits of
slotting are subtle but extremely important. The slotted structure
provides a rigid housing for the windings and their relatively fragile
insulation. It greatly increases the surface contact area between the
windings and the steel, providing a path of low thermal resistance which
is important in keeping the windings (and hence also the magnets) cool.
The steel does not have unlimited capacity for carrying flux. If the flux-
density exceeds approximately 1.6-1.7 Tesla [TJ, the permeability
decreases rapidly. At a flux-density of about 2.1 T, the incremental
permeability of steel is practically the same as that of air. The magnetic
design should ensure that the flux-densities in the steel are kept below
these levels, otherwise the magnet MMF will be wasted in driving flux
through the steel. The end result would be that the flux linking the
windings would be restricted; or, what amounts to the same thing, the
amount of magnet material required to establish a given flux would be
greatly increased.
Another reason for limiting the flux-density in the steel, especially in the
stator, is that the core losses increase rapidly at high flux-density. Core
losses are caused by hysteresis and by eddy-currents (see Chapter 9). The
eddy-current component can be reduced by stamping the laminations
from thinner-gauge sheet, or by using high-Silicon steels, but both of
these measures increase cost.
Clearly there is a concentration of flux in the teeth. The flux crossing the
airgap funnels into the teeth, which occupy approximately half of the
periphery at a radius taken half-way down the slots. This means that the
airgap flux-density will be of the order of one-half the maximum flux-
density in the teeth, i.e., at most, 0.8 T if the steel is kept below 1.6 T.
The flux-density in the magnets in a surface-magnet motor of the type
shown in Fig. 4.1 will be comparable to the airgap flux-density, or slightly
4-2
4. M a g n e t ic D e s ig n
higher. In motors of this type, only the so-called high-energy magnets
(Cobalt-Samarium; Neodymium-Iron-Boron) are capable of operating at
this high level of flux-density. Motors with ferrite magnets operate with
lower flux-densities, and of course they are less expensive,
T able 4.1 M a g n e t ic / e l e c t r ic c ir c u it a n a lo c y
Electric circuit analysis employs ideal current and voltage sources, and
real sources of current and voltage can be represented by their Thevenin
or Norton equivalent circuits, i.e. a voltage source in series with an
internal resistance, or a current source in parallel with an internal
conductance. (Conductance = 1/resistance). Similarly, in magnetic
circuits a permanent magnet can be represented by a Thevenin
equivalent circuit comprising an MMF source in series with an internal
reluctance; or by a Norton equivalent circuit comprising a flux source in
parallel with an internal permeance, Fig. 4.2. (Permeance =
1/reluctance). This internal permeance is sometimed called the magnet
leakage permeance.
The Thevenin and Norton equivalent circuits are exactly equivalent and
cannot be distinguished from each other by measurements at the
"terminals", since they both represent the same thing. Which one to use
is a matter of convenience. For example in the Norton equivalent circuit,
the internal leakage permeance represents flux that circulates inside the
magnet and does not emerge from the pole faces.
4-3
D e sig n o f bru sh less perm anent -m agnet m o t o r s
T H E V E N IN NORTON
MO
FLUX
4-4
4. M a g n e t ic D e sig n
The "open-circuit" condition, on the other hand, requires that the flux
leaving the magnet poles is zero. In order to achieve this, an external
demagnetizing MMF must be applied to suppress the flux. The external
MMF must exactly balance the internal MMF of the magnet when the
flux emerging from the poles is zero. It is only possible to do this in a
magnetizing fixture with a separate DC coil which provides the external
MMF. The terminal MMF is negative because it opposes the internal MMF
Fc of the magnet, and is exactly equal to it. Fc is called the coercive MMF
because it is the MMF required to coerce the magnet to produce zero
flux. It directly expresses the resistance of the magnet to
demagnetization.
The amount of flux <I>r that can be produced into an infinitely
permeable keeper expresses the maximum available flux from the
magnet. >r is called the remanent flux. This is an historical term
describing how much flux "remains" in the magnet after it has been
magnetized. It should be interpreted carefully, because the ability of a
magnet to retain flux in a magnetic circuit depends on Fc as much as it
does on 4*r. It is better to think of 4>r as the flux "retained by a keeper
in the magnetic short-circuit condition.
In normal operation there is no keeper, and the magnet operates at a
flux below <&r- This is because the MMF drop across the airgap appears
as a negative, demagnetizing MMF as seen from the magnet "terminals".
In addition, the phase currents produce an additional demagnetizing
MMF which drives the operating point still further down the
characteristic.
It is clear from this that magnets require two parameters Fc and <t>r to
characterize them properly. Moreover, the slope of the magnet
characteristic relates Fc and For a given remanent flux <l>r, it is
desirable to have the flattest possible slope since this is associated with a
high value of Fc and a high resistance to demagnetization.
The most suitable magnets for brushless motors are the ferrites or ceramic
magnets, and the high-energy rare-earth and Neodymium-Iron-Boron
magnets. All these magnets have straight characteristics whose slope is
close to the theoretical maximum, and they are classified as hard magnets
because of their high resistance to demagnetization. Other magnets,
particularly Alnico magnets, have a high remanent flux but very low
4-5
D esig n o f brushless perm a nent -m a gnet m o t o r s
O P E N -C IR C U IT -
O P E R A T IN G P O IN T
NORMAL LOAD
DEMAG LOAD LINE
C H A R A C T E R IS T IC
/-P .C .
KN EE
H ca j Hc M ' ' m
PROJECTED
CURVE ACTUAL curve DEMAG EFFECT
OF PHASE CURRENT
Fig, 4.4 B /H characteristic of a hard permanent magnet material. This is the second
quadrant part of the full hysteresis loop. Note the krut. Also shown is the normal
operating point, the load line, and the effect of demagnetizing phase current.
This scales the units on the horizontal axis from A/m to Tesla, so that
the slope of the demagnetization characteristic becomes equal to the
relative recoil permeability, Hrec- Hard permanent magnets have a relative
recoil permeability in the range 1.01.1, close to that of air. With the
horizontal axis plotted as instead of H, a relative recoil permeability
of 1 has a slope of 45. When c.g.s. units (Gauss and Oersteds) are used
for B and H, there is no need to scale the horizontal axis because the
permeability of free space is unity in the c.g.s. system.
We have already seen that the airgap applies a static demagnetizing field
to the magnet, causing it to operate below its remanent flux-density. With
no current in the phase windings, the operating point is typically at the
point labelled OPEN-CIRCUIT in Fig. 4.4, with BM of the order of 0.7-0.95
* Bt. The line from the origin through the open-circuit operating point
is called the load line.
4-7
D e s ic n o f b r u sh l e s s p e r m a n en t -m a g n e t m o t o r s
S.I. c.g.s.
1 Tesla 10^ gauss or 10 kG
I A/m 471/1000 Oe
1 kj/m3 n/25 MGOe
The slope of the load line is the penneance coefficient, (P.C.). With the
horizontal axis plotted as instead of H, or in c.g.s. units, the
permeance coefficient is typically in the range 5-15.
When current flows in the phase windings, the additional field may drive
the operating point still further down the demagnetization characteristic,
depressing the airgap-flux-density as well as the magnet flux-density below
the open-circuit or no-load value. When the phase current is removed,
the operating point recovers to the open-circuit point, and the recovery
is complete and reversible provided that the excursion of the operating
point has not left the straight part of the demagnetization characteristic.
The straight part, over which the magnet normally operates, is called the
recoil line.
In Fig. 4.4 the intersection of the recoil line with the negadve-//M axis is
labelled //ca, the apparent coercivity. This is used later in the magnetic
circuit calculation. The actual coercivity is labelled Hc.
The best grades of hard permanent magnets have demagnetization curves
that remain straight throughout the second quadrant and in some cases
well into the third quadrant (negative BM as well as negative //M). These
magnets can withstand a demagnetizing field that is sufficient actually to
reverse the flux in the magnet, and still recover with no permanent loss
of magnetism.
Other materials have a knee in the second quadrant, as in Fig. 4.4. If the
operating point is forced below the knee, then when the demagnetizing
field is removed the magnet recovers along a lower recoil line. Fig. 4.4
shows an example in which the demagnetizing field is just sufficient to
reduce to zero. The magnet "recoils" along the depressed recoil line,
but it has lost almost 20% of its remanent flux. This loss is irreversible.
4-8
4. M a g n e t ic D esig n
A material which has a straight demagnetization characteristic at room
temperature may develop a knee in the second quadrant at higher
temperatures (this is characteristic of Cobalt-Samarium and Neodymium-
Iron-Boron magnets); or at lower temperatures (this is characteristic of
Ferrite magnets).
Generally, the remanent flux-density Bf decreases with temperature. This
effect is usually specified in terms of the reversible temperature coefficient of
Bt, quoted in % per degree C. If this coefficient is given the symbol a fir,
then the remanent flux-density at temperature 7"C is given by
B im = Brm M l + Br * I ? - 20)/100] (4.4)
4-9
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Bm t
1.2
1.0
0.8
0.6
0.4
0.2
0
^ 0 HM T 1.2 1.0 0.8 0.6 0.4 0.2
4-10
4. M a g n e t ic D esig n
LEAKAGE FLUX
A IN FLUX
*9
4-11
D esig n o f bru sh less perm anent -m a g n et m o t o r s
PL is in parallel with the magnet internal permeance The armature
MM F Fa due to phase current is shown as an MMF in series with the
airgap reluctance R^, but it will be assumed initially that = 0 (open-
circuit conditions).
In Fig. 4.7, permeances P and reluctances R are mixed freely, reflecting
the point of view in which a leakage permeance diverts magnet flux away
from the windings, while a reluctance (principally of the airgap) presents
a magnetic "resistance" to the flux. The reluctances of the steel stator
and rotor are omitted from Fig. 4.7 for simplicity, i.e., it is assumed that
the steel is infinitely permeable. The magnet permeance is given by
hi P
(4.7)
4-12
4. M a g n e t ic D esig n
M a g n e t (1 pole)
Note that having^ KG < 1 means that the airgap flux density is reduced
compared to the value it would have if there were no leakage. The
corresponding flux-density in the magnet is determined as
' B 7LKG
~ * 7 Ms r LKQV (410)
Since ^lkG < 1, for a given airgap flux the magnet flux and flux-density
are greater than they would be if there were no leakage. This is
intuitively correct, since the magnet must provide the leakage flux over
and above the airgap flux.
The operating point of the magnet can now be determined either
graphically, from Fig. 4.4; or by calculating //M from the equation which
describes the demagnetization characteristic:
Bh = + Bt ; > B^. (4.11)
The inequality B ^ > By, expresses the need to check that the operating
point is above the knee point.
With the foregoing equations it is not difficult to determine the value of
the permeance coefficient, and a convenient formula is
PC = - J - * h i * jli.. (4.12)
^UCG g'
In surface-magnet motors and the permeance coefficient is
roughly equal to / ^ / g . In order to achieve a high permeance
coefficient, desirable for operating as close as possible to the remanent
flux-density, the magnet length needs to be much greater than the airgap
length.
4-14
4. M a g n e t ic D e sig n
Another useful relationship involving the permeance coefficient [2] is
* * = tPC*
f T ;Mrec
,- x (413)
Since nrec is close to unity for most hard magnets used in brushless
motors, a high permeance coefficient ensures that the magnet operates
close to its remanent point. A value of 5 would be typical, giving ^ =
0.83flr with |ircc = 1. If the permeance coefficient is as low as 1, then
with prec = 1 5 ^ = Br/2, which corresponds to the maximum BH product
or energy product.
It can be seen from these design equations that, with a given magnet
material, the need for a high flux density is satisfied by making the
magnet as thick as possible in relation to the airgap length, while the
need for a large flux per pole is satisfied by increasing the magnet pole
area. For the open-circuit condition the magnet volume per pole can be
shown to satisfy the equation
2 W . ..
K, = -------I _, (4.14)
M I ^ mI
where is the magnetic energy per pole stored in the airgap, equal to
BgH^/2 x A x g. This energy is determined by the volume of the airgap
and the flux-density B , so in order to minimize the volume of magnet
material required, it appears that the magnet should be operated with
the maximum energy product If the demagnetization
characteristic is straight, then the maximum energy product occurs when
= Br/ 2, with a permeance coefficient approximately equal to 1 , i.e.,
the operating point is half-way down the demagnetization characteristic.
This theoretical result is never applied in practical motor design, however, because
of the allowances needed for the demagnetizing MMF of the phase currents and
temperature effects.
Nevertheless, it is still meaningful to talk about a magnet material as
having a high maximum energy product | b e c a u s e this is a single
number representing the fact that both the remanent flux-density and
the coercivity are high. In common parlance, the BIImax figure is widely
used to express the "strength" of various magnet grades, and the units
are usually MGOe (megaGauss-Oersteds) or kj/m .
4-15
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
^ca (4.15)
where Hca is the apparent coerchrity of the magnet. This is defined in Fig.
4.4, and is usually greater than the actual coercivity because of the knee
that may exist in the demagnetization curve in the second quadrant.
Like the linear calculation in the previous section, the nonlinear
calculation begins by assuming that the solution for will not fall below
the knee-point value 1^, and this must be checked independently.
Proceeding with the individual MMF drops, and starting with the airgap,
the airgap flux-density is initially assumed to be equal to the value
calculated in equation (4.9). Then
(4.16)
Assume that the stator yoke flux is equal to the gap flux crossing the
airgap over half the pole area. Then
(4.17)
4-16
4. M a g n e t ic D e sig n
where Asy is the yoke cross-section area, and
U sy - X s y (V
The functional notation represents a linear (or cubic-spline)
interpolation along the B/H curve of the steel. In other words, once the
yoke flux-density is calculated from equation (4.17), the magnetic field
strength H^ is determined from the B /H curve. Then
^ ^ * A* <419)
where L^. is the length of the flux-path through the stator yoke over
one-half of a pole-pitch. Similar equations are written for the stator teeth
and for the rotor yoke,giving MMF components Fst and respectively.
The magnet flux is taken to be
- -5 s- (4.20)
LKG
^ = MT 1 = M L K G (421)
Fu *V (4-22>
Now all the MMF drops are added together
F - 4 + + F* + Fv> + (4-23)
The principle of the iteration is that if F > Fca, is decreased and the
calculation is repeated; if F< Fa , B is increased and the calculation is
repeated, and this continues until r is within 0.1% of F^. An under
relaxation factor can be used, multiplying the right-hand side of equation
(4.23) to assist convergence, or Newtons method can be used.
4-17
D esig n o f brushless perm a nent -m a gnet m o t o r s
M. (4 2 5 )
1 + LKG MO g
4-21
D e sig n o f bru sh less perm a nent -m agnet m o t o r s
4r22
4. M a c n e t ic D e sig n
q -axis
elemental strip bounded by two arcs, centre H, radii rand r+ dr, between
the equipotential surfaces AD and CD. The flux through this strip is
(4.30)
where /"is the MMF or magnetic potential drop between faces AD and
CD. The total flux between faces AD and CD is given by
(4.31)
The permeance ratio for this shape is the coefficient of (1/H qI^) fy/F, i.e.
(1/0) In (r2/ r j ) . In the case of the shape ADCB, rj = HA and r2 = HD.
Permeance DEJCThis permeance has an irregular shape that is not easy
to formulate analytically. The following technique is an amalgamation of
Roters technique [29] and the dual-energy method described by Prof.
Hammond [30]. Consider a brick-shaped volume carrying flux as shown
in Fig. 4.126. If the length of the brick (into the paper) is the
permeance is ^ nLs[k w/h, and w/h is the permeance coefficient. If this
is written as w h /$ , the product wh can be replaced by the transverse area
At and the permeance coefficient can be written At/ A2. The method
attributed to Roters involves applying this expression to any arbitrary
shape, such as the shape DEJC in Fig. 4.12a. The area At can be
calculated without difficulty if the shape is bounded by arcs and straight-
line segments, but it is not obvious what value should be given to /*a.
The crudest approach is to make h equal to the average of the two sides
that "channel the flux: in Fig. 4.12a, this would mean making k equal
to the average of the arc length DC and the straight-line segment EJ.
Other formulations of mean squares, or mean squares of reciprocals of
these sides, are possible, but if the shape is "reasonably square, or more
precisely, if it is close to a curvilinear square, then all these estimates give
more or less the same result.
In principle the estimated permeance coefficient can be improved by
means of the dual-energy method. In Fig. 4.126, the reluctance across the
area At (i.e., orthogonal to the original flux direction) is ( l A l 0Z.stk) h/w,
and the reluctance coefficient h/w can be written At /w~. The. same
uncertainty applies to the assignment of a suitable value to w2, but a
crude approximation is to use the average such as (DE+ arc CJ)/2. The
dual-energy principle states that the actual permeance coefficient
4
4. M a g n e t ic D e s ig n
estimate can be improved by replacing it with
4 (4.32)
A2 \
The closer the original shape is to a curvilinear square, the more
accurate this formula will be.
The two leakage permeance coefficients can be added to the permeance
coefficient for the segment of magnet that lies within the boundary of
the half-pole section, i.e. v>M/(L ^ /2 ). Equivalently, the per-unit rotor
leakage permeance can be written
Al = P\dcb + Pdejc + / ends (4.33)
whore s permeance coefficient for the shape ADCB, p ^ jC is
the permeance coefficient for the shape DEJC,and pendi is the per-unit
end-flux leakage permeance.
Permeance due to end-Jlux between pole-piecesFringing also occurs between
polc-pieces outside the active length. A very rough guide to the
contribution pcnAi is to assume that the flux flows in semicircular arcs
spanning the magnet, and use equation (4.31) with r-y = Lj^/2 and r2 =
2fj. Then
/ends * In . (4.34)
^ s tk rt
This formula includes both ends of the machine.
Permeance egad- 1This permeance can be calculated by equation (4.31) with
0 = ft/2, rj = he (airgap length), and r2 = hg. The resulting permeance
ratio can then be added to the permeance ratio for the half-pole section
of the airgap, which is anD /pg. It is common to augment the pole-arc
in this type of rotor by 2 x g / [gvD/Tj radians to account for fringing flux
that flows within the area hed at each edge of the pole-piece.
"Lumped" permeance calculations of this type have been used for a long
time and occasionally refined into complex nonlinear magnetic
ccjuivalent-circuit calculations. The method is less accurate and less
reliable than the modem finite-element method: its main virtues are
simplicity and ease of programming, and its use can be justified only
4-25
D e sic n o f bru sh less perm anent -m agnet m o t o r s
4.7 Cogging
Cogging is the oscillatory torque caused by the tendency of the rotor to
line up with the stator in a particular direction where the permeance of
the magnetic circuit "seen" by the magnets is maximized. Cogging
torque exists even when there is no stator current. When visitors to a
trade exhibition rotate the shafts of brushless motors on the display
stands, they are feeling the cogging torque. When the motor is running,
additional oscillatory torque components can result from the interaction
of the magnet with space-harmonics of the winding layout and with
current harmonics in the drive current. These additional oscillatory
torque components are electromagnetic and are generally referred to as
torque ripple, while the term cogging is often reserved for the zero-current
condition. In a well designed motor the torque ripple and the cogging
should both be negligible, but it is possible for the torque ripple to
exceed the cogging torque by a large amount if the motor has an
inappropriate combination of winding layout, drive current, and internal
geometry. Manual rotation of a disconnected motor gives no indication
whatsoever about torque ripple.
One of the characteristics of a servomotor is low torque ripple, and "low"
generally means less than 1-2% of rated torque. This figure applies to the
combined effects of cogging and electromagnetic torque ripple, and is
met by the best quality sinewave-drive servomotors.
With a large number of slots/pole the cogging torque is inherently
reduced by the fact that the relative permeance variation seen by the
magnet is reduced as it successively covers and uncovers the slots one at
a time: indeed the permeance variation can be thought of as being
4-26
4. M a g n e t ic D e s ig n
concentrated at the edges of the magnet. A small amount of skew is then
usually sufficient to eliminate most of the cogging. When the number of
.dots/pole is closer to 1 , the slot geometry becomes more important, and
the widths of the teeth in particular can be adjusted to minimize the
cogging effect. An analysis of this approach was given by Ackermann et
al [1]. They developed an equation for the cogging torque:
^cog = j D L * E * K Jn ^ ( j g )
4 n n a L sk
where n = hS, k = 1,2,..., and S is the lowest common multiple of the
number of slots iVsloU and the number of poles 2p. The
s i n n o i stk^ function represents the effect of skewing, where o
is the skew angle, and An is the nth space-harmonic of the permeance
of the magnetic circuit "seen by the magnet as the rotor rotates.^, is the
nth space-harmonic of the magnet flux-distribution, and is the angle
of rotation of the rotor. This somewhat complex equation is derived from
the rate of change of coenergy as the magnet rotates. It clearly shows the
interaction between the space-harmonics of the magnetic circuit
permeance and the distribution of magnet flux, and can be used to
identify torque harmonics of a particular order.
The calculation of cogging torque from the rate of change of coenergy
can be applied with calculated values of coenergy obtained with the
fin ite -c le m e n t method. Because of the differentiation of the coenergy,
the finite-element solution needs to be very accurate, requiring a fine
mesh at the very least.
Cogging torque can also be compensated electromagnetically by adapting
the drive current waveforms to produce an electromagnetic torque ripple
component that cancels the cogging [2].
Other methods for reducing cogging include the use of birfurcated teeth
(as in Fig. 8.9), or punching holes in the tooth overhangs to modulate
the permeance variation [3 ]. Bifurcated teeth or "dummy slots" have a
similar effect to that of doubling the number of slots: the cogging torque
frequency is doubled and the amount of skew required to eliminate the
cogging is halved. Also, the permeance variation caused by uncovering
one half-tooth is of the order of half the variation caused by uncovering
a whole tooth, so the magnitude of the cogging torque decreases as well.
Tlie cogging torque can be adversely affected by partial demagnetization
4-27
D esig n o f bru sh less perm a n en t -m a g n et m o t o r s
of the magnets through over temperature or overcurrent, particularly in
surface-magnet motors because the degree of demagnetization is liable
to vary over the face of the magnet, producing a distortion in the back-
EMF waveform. This distortion tends to aggravate the torque ripple as
well as the cogging. Interior-magnet motors do not suffer from this
problem to the same extent
A summary of methods for reducing cogging torque is given in Table 4.3.
Increase airgap length
Use fractional slots/pole
Use larger number of slots/pole
Use thick tooth tipi to prevent saturation
Keep slot openings to a minimum
Use magnetic slot wcdges
Skew stator stack or magnets
Radius or chamfer magnet poles
Radius or chamfer stator tooth tips, or punch holes in tooth tips
Vary the magnetization of the magnet poles
Use bifurcated teeth
Use lower magnet flux-density
Compensate cogging by modulating drive current weaveform
T a b le 4.3 Methods f o r r e d u c in g c o g c in c t o r q u e
4-28
4. M a g n e t ic D esig n
r.( . i .12
(BOD-
Magnet retaining can. (a) Geometry of induced current, (b) Short can haa
higher rcjistance to induced current, (c) Can divided into insulated rings
to reduce losses.
Fig. 4.13 (a) Dip in flux-density caused by stator slot opening as it moves relative
to the rotor at velocity v. (b) Construction of RMS value of the flux-
density variation in the can.
As the rotor passes a slot opening, the dip in the airgap flux-density
moves along the B-waveform which is otherwise moving synchronously
with the rotor. The variation in B is separated out in Fig. 4.136 and each
dip is represented as a half-sinewave of width 0 radians. The dips repeat
at intervals of A.s radians, where Xi = 2 n/jVs|otJ is the slot-pitch.
It is assumed that the eddy-currents are resistance-limited i.e., that they do
not modify the B-field. This assumption is appropriate bccause in cases
where retaining can losses are a problem, the eddy-currents need to be
resistance-limited in order to keep them low. (Bolton [6] presents a
method of analysis that does not make this assumption and allows the
eddy-currents to be resistance-limited or inductance-limited. His analysis
also includes a useful and relatively simple criterion for determining
when the eddy-currents are resistance-limited. This criterion is expressed
in terms of dimensions and can therefore be used as a design rule).
4-30
4. M a g n e t ic D e sig n
The rotation of the rotor causes an Afield in the can, given by v x B
where v is the surface speed in m /s. The corresponding current-density
in the axial direction is /= E/p. I f / 2p is integrated over the volume of
the can, the losses P can be calculated as well as the average loss per unit
area w. The result is
w = - * L ( B N P ft w / m 2 ( 4 .3 6 )
3600 p
The B value in equation (4.36) is the effective or RMS value of the flux-
density variation over the surface of the can. Referring to Fig. 4.136, this
can be estimated as
B = * iL (4.37)
V2 N
in IT). This result is intuitively derived as the RMS value of the half-
sinewave, modified by the effective "duty-cycle" implicit in the fact that
the dips repeat after rather than after p.
For example, if P/A^ = 1/4 and = 0.2 T, D = 100 mm, t = 0.5 mm, and
JV= 3000 rev/min, the surface loss is w = 3.6 W /cm 2 for copper, or 0.088
W/cm 2 for stainless steel (i.e., 0.57 W /in2).
The above analysis is "two-dimensional" and only considers current
flowing in the axial direction. Of course the current must flow in
complete loops as illustrated in Fig. 4.12. There is a circumferential
component as well as an axial component. Russell and Norsworthy
derived a simple formula for modifying the total can losses by a factor
to take account of the end-effects. Assuming that the can has the same
axial length as the rotor, i.e. LJ[k, the total can losses are given by
P = J^w A W (4.38)
where A = nDL^ is the surface area and
'PL*
Ks * 1 -
tanh
D (4.39)
P^&k
D
4-31
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
References
1 Ackemiann B et al [1992] Afeui technique for reducing cogging torque in a class of
bushiest DC. mot/m, IEE Proceedings 139, No. 4, 315-820.
2. Jouvc D and Bui D [ 1993] Torque ripple compensation inDSP-bavrihrushle.tt m o drive.
Intelligent Motion, PC1M Proceedings, Numberg 28-37
3 Gizaw D [1993] Permanent magnet bmxhtf.it DC. motor having reduced cogging, United
States Patent No. 5,250,867
4- Takahashi I, Koganezawa T, Su G and Oyama K [ 1993] A super high-speed PM motor
driven hy a quasi-current source inverter, IEEE Industry Applications Society Annual
Meeting, Toronto R57-W52
5- Russell RL and Norsworthy KH [ 1958] Eddy-currents and wall losvs in icreened-rotor
induction motors, IEE Proceedings 105A, 1B3-175
h Bolton H [19fi9] Transverse edge-effect in sheet-rolor induction motors, IEE Proceedings
116, No. 5, 725-731
4-33
I
5. ELECTRICAL DESIGN
j .l Introduction
Now that we have reviewed the configuration of the motor and
determined how to calculate the magnetic flux, we are in a good position
to study the basic electrical operation. This chapter considers the
windings in more detail: in particular, the factors affecting the layout of
the windings and the calculation of the correct number of turns. This
requires a simple explanation of the operation of the ideal brushless DC
motor, describing how a squarewave EMF is generated and how this
relates to the operation of the power electronic controller. Motors with
1,2, and 3 phases are considered, and there is a discussion of the use of
wye and delta connections in three-phase motors. Although this chapter
is mainly about squarewave motors, it deals with many fundamental
points which are important for sinewave motors also (see Chapter 6).
The chapter includes a treatment of winding inductances and the analysis
of slodess windings.
*-axis). In Fig. 5.1 the rotor is shown at the position \ = 0: i.e., the d-axis
coincides with the x-axis. The *-axis is the stator reference axis and for
this reason the slot-numbering scheme begins with the axis of slot 0 on
this axis. Slot 0, of course, is the same as slot 12 in this machine.
d-AXIS
Fig. 5.1 12-slot, 2-pole brushless DC motor showing the winding of phase 1 with 1
coil/pole, 5/6-pitch, and 2 slots/pole/phase
When the rotor moves, the whole flux-distribution moves. Thus, for
example, Fig. 5-26 shows the distribution B(9) when the rotor is at the
position =105.
5-2
5. E le c t r ic a l D esig n
The stator has 12 slots and a three-phase wye-conected winding. Only
phase 1 is shown. There are 6 slots per pole and 2 slots per pole per
phase. This is not necessarily a desirable combination in practice (see
Chapter 3) but it is useful for illustrating the winding principles
developed in this chapter for both squarewave and sinewave motors.
Each phase winding consists of two coils 1 and 2 of jVj turns each. Coil
1 is wound in slots 1&6 and thus has a span of 5 slot-pitches. The span
is also called the pitch or throw of the coil. Since one pole-pitch is 6 slot-
pitches in this machine, the coil pitch is said to be 5/6. The "start" of
coil 1 is in slot 1 , and its axis is located at half the span further round
the stator, i.e. at 5/2 = 2-5 slot-pitches from the start. Since slot 1 is
located at 30 (one slot-pitch) from the *-axis, the axis of coil 1 is at 30
+ (5/2) x 30 = 105 from the #-axis.
The flux-linkage of a stationary coil is represen ted by th e function i|>c (),
because it varies as the rotor rotates. Fig. 5.2c shows the waveform of
the flux-linkage i|/cl() and Fig. 5.2d shows the back-EMF ci() in coil
1 as the rotor rotates. These waveforms are plotted vs. rotor position
The origin is at 5 = 0t corresponding to the particular rotor position
shown in Fig. 5.1. Thus the negative peak of the flux-linkage i|rc] occurs
when the rotor is at the position = 105, where the S-pole rf-axis is
aligned with the axis of phase 1.
The back-EMF is derived directly from the flux-linkage waveform by
Faradays Law:
* 5) . (5.1)
df oc
The notation e() simply means the EMF plotted as a function of rotor
position rather than plotting it as a time waveform e{t). The waveshape
is unaffected because E, = and Ci>ra = d^/dt. This equation applies
not only to individual coils but also to the complete phase winding.
The corresponding waveforms for coil 2 are identical but opposite in
sign, because coil 2 is displaced by 180 and therefore links magnet flux
of exactly the same magnitude but of opposite polarity to that linked by
coil 1. When the coils are connected in series, coil 2 must be effectively
reverse-connected so that the total back-EMF is doubled to 2ecl, otherwise
the total EMF would be zero.
5-3
D esig n o f bru sh less perm anent -m a c n et m o t o r s
6(5=0)
a
B (? = 105)
CONDUCTION INTERVAL
ec2<5>
e
Wi 2//( /lM) W ///A
ec3< S>
's(5>
180 360
Fig. 5.2 (a,b) Magnet flux distribution (c) flux-linkage waveform and (d,e,f) EMF and
current waveform* corresponding to the motor of Fig. 5.1.
5-4
5. E l e c t r ic a l D e sig n
In Fig. 5.1 the conductors of phase 1 occupy 4 of the 12 slots, leaving 4
slots for each of the other two phases without requiring any slot to
contain conductors from more than one phase. A single-layer winding is
therefore built up with phase 2 in slots 5&10, 4&11; and phase 3 in 3&8,
2&9. This ensures that the winding axis of phase 2 is 120 ahead of the
phase 1 axis (i.e., at 105 + 120 = 225) and the winding axis of phase 3
is 240 ahead at 105 + 2 x 120 = 345. The phase 2 axis is along the
centre-line of tooth 7/8 and the phase 3 axis is along the centre-line of
tooth 11/12. Thus the phase winding axes are displaced from each other
by 4 slot-pitches ( 120).
With a magnet pole-arc of PM = 180 and a coil-pitch of 5/6, the back-
EMF is ideally flat-topped over 5/6 of a pole-pitch or 150. However,
fringing effects at the edges of the magnet poles cause the EMF
waveform to be rounded and the effective flat-top may extend over no
more than 120 in practice. This is 1/3 of a revolution. Now phase 1 can
produce constant torque if it is fed with constant current of the correct
polarity during the 120 interval. If phases 2 and 3 are fed with the same
current during the other two 120 intervals, constant torque can be
produced through one complete revolution, as shown in Fig. 1.6.
The necessary phase current waveforms are shown as blocks in Fig.
5.2d,e,f It is important to note that the conduction intervals are 120
wide, and alternate in polarity. The resulting current waveform in each
phase is described as a "120 squarewave1', and the three phase currents
form a balanced set with equal phase displacements of 120. Becausc of
the phase displacement between phases, there is a commutation
(transistor switching) every 60, and therefore there are 6 commutations
per cycle of the fundamental frequency. There are two phases
conducting at any and every instant, and this is often called 2'phaseon
operation. A commutation always switches one phase off at the same time
as another one is switched on. The sequence of switching the six power
transistors in Fig. 1.8 is shown in Fig. 10.3 together with the three phase
current waveforms for a wye-connected stator. For a delta-connected
stator, the phase and line current waveforms are shown in Fig. 10.4; the
transistor switching sequence is identical for wye and delta conections,
and in fact the controller does not "know" the difference between them.
Note that in Figs. 10.3 and 10.4, the origin is taken as the axis of phase
1, i.e. at the 105 point in Fig. 5.2.
5-5
D esig n o f brushless perm a nent -m a g n et m o t o r s
PH A SE 1 A XIS
d-AXIS
Fig. 5.3 12'ilot, 2-pole brujhleu DC motor showing the winding of phase I with 2
coils/pole, having pitches of 5/fi and 1/2 respectively.
5.2.2 Effect of additional coils
Fig. 5.3 shows the phase 1 winding with two additional coils 3 and 4, each
of which has a pitch of 3 slots. This is 1/2 of a pole-pitch, or 90 electrical
degrees. The axes of coils 3 and 4 are coincident with those of coils 1
and 2 respectively, so their flux-linkages and EMFs will be in phase with
i|cl and ec]. The additional coils are assumed to have the same numbers
of turns as coils 1 and 2. Fig. 5.4 shows the flux-linkage i|jc3 and EMF
of coil 3 together with t|rcl and ecl, as well as the total flux-linkage and
5-6
5. E l e c t r ic a l D e s ig n
COIL e 150
EMF c3
e
FUNDAMENTAL
ACTUAL 90
e c 1 + e c3
/
/ s.
s
\
s
J ^ __
30 deg
180 360
Eft- 5.4 (a,b,c) flux-linkage waveforms and (d,e,f) EMF waveforms corresponding to the
motor of Fig. 5.3.
5-7
d e s ig n o f bru sh less perm a nent -m a gnet m o t o r s
FUNDAMENTAL
Fig. 5.4g Expanded view of Fig. 5.4/ showing the actual EMF waveform and the
fundamental harmonic from Fig. 5.4/
5-8
5. E l e c t r ic a l D esig n
especially if smooth torque is important.
On the other hand, adding the additional coils 3 and 4 increases the
number of steps in the overall back-EMF waveform, and although it may
not be strikingly obvious from Figs. 5.2/and 5.4/ the waveform of the 4-
coil winding has a smaller harmonic content and is closer to a sinewave.
The fringing (and also any skew) further reduces the harmonics, and it
can be correctly inferred that for a sinewave brushless AC motor the
additional coils are beneficial, because the production of smooth torque
requires the combination of sinewave back-EMF with sinewave current
(Chapter 6).
The back-EMF waveform ecl appears to lead the corresponding flux-
linkage waveform i(rcl by 90: this is also true of the fundamental
harmonic components T t and Ecl, which are phasors and are therefore
related by the equation
^1 = <52>
where o) = 2ti/ and / is the supply frequency. This equation does not
apply to the actual waveforms, because they are not pure sinewaves: it
applies only to the fundamental harmonic components.
5.2.3 Lap windings and concentric windings
The manner in which coils 1-4 are wound, inserted, and connected
together is extremely important from a manufacturing point of view,
where the cost of winding is important. The addition of coils 3 and 4 in
the previous section causes phase 1 to occupy 8 of the 12 slots, so that
when phases 2 and 3 are added every slot contains two coil-sides: i.e., a
double-layer winding. This is more difficult to wind than the single-layer
winding of Fig. 5.1.
Fig. 5.5 shows the principle of a lap winding corresponding to Fig. 5.3. In
the lap winding, all roils are identical in pitch and number of turns.
When the coil pitch is greater than 1 slot pitch, the concentric winding is
common. It can be seen from Fig. 5.5 that the flux-linkages and back-
EMFs of both windings are identical because the disposition of
conductors is identical, and so is their electrical connection (i.e., all in
series). The windings differ only in the end-region, by having slightly
different resistances and inductances in the end-windings.
5-9
D esig n o f bru sh less perm a nent -m agnet m o t o r s
WINDINGS
3 ACTIVE
LENGTH
(a) LAP
5-10
5. E l e c t r ic a l D esig n
A "developed" winding diagram for the motor in Fig. 5-1 is shown in Fig.
5.6, for phase 1 only. The other phases are similar. For coil-winding, the
route taken by the wire is designed to minimize the length and number
of interconnects in the end-windings. This helps to minimize the volume
of copper in the end-windings and to minimize the winding resistance.
$.2.4 Multiplepole machines
So far the discussion has been confined to a 2-pole motor, but the same
principles apply to multiple-pole motors. The waveforms in Figs. 5.2 and
5.4 remain unchanged if 0 and are in electrical degrees. TTie 4-pole
equivalent of the motor in Fig. 5.3 has 24 slots, so that the number of
slots/pole is the same. The coils are wound with the same pitches as a
fraction of the pole-pitch, which is reduced to 90 actual degrees (= 180
electrical degrees). The period of the waveforms in Figs. 5.2 and 5.4
covers 180 actual degrees {= 360 electrical degrees). An angle in electrical
degrees is p times the same angle in actual degrees, (p = poU-pairs).
5-11
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
In the 2-pole motor of Fig. 5.3 there is one coil-group per pole, so that
with 2 poles there are 2 coil-groups and 4 coils in each phase. If the 24-
slot motor retains 1 coil-group/pole there will be 4 coil-groups and 8
coils per phase. The additional 2 pairs of coil-groups can be connected
in series with the first group; or in parallel, giving 2 parallel paths through
the phase winding. This multiplies the back-EMF at the phase terminals
by 50%, and doubles the phase current required to produce the same
torque. In other words, for a fixed number of coils the back-EMF
constant ftg and the torque constant kj (torque/amp) are both inversely
proportional to the number of parallel paths.
5.2.5 Consequent-pole vnndings and magnets
In the 4-pole motor it is not mandatory to have 4 coil groups per phase.
An alternative arrangement is to have only two coil groups diametrically
opposite each other. This is called a consequent-pole winding. Such a
winding is shown in Fig. 5.7 with a 12-slot stator. The 4-pole flux pattern
could be produced by any one of the four configurations acting alone:
Either or both the windings and the magnet may be of the consequent-
pole configuration. The consequent-pole configuration is simpler to
assemble and can save copper or magnet material. For example,
removing the two N magnets would leave the flux pattern essentially
unchanged, but the airgap flux-density and the flux per pole would be
slighdy reduced because each magnet is now forcing flux through two
airgaps instead of only one. The thickness of the magnet may need to be
increased to compensate for this. The increase can be worked out from
equations (4.9) and (4.10). In order to restore the remaining magnets
5-12
5. E l e c t r ic a l D e sig n
to the same operating point, their thickness would have to be
doubled. However, it may be that when all four magnets are used the
thickness is greater than it needs to be, owing to the fact that there is a
minimum thickness to which magnets can be manufactured. If this is the
case, then the consequent-pole arrangement makes better utilization of
the magnets even though they may be working at a slightly lower
permeance coefficient and flux-density.
5.2.6 Computer-aided design of windings
The PC-BDC computer program includes a winding editor which is shown
in Fig- 5.8 with the same winding as in Fig. 5.7. The winding editor can
be used to construct any combination of coils, or alternatively it can
construct many "standard" types of winding automatically. Whatever the
distribution of coils, the program can subsequently calculate the EMF
waveform as well as the resistance and inductance of each phase and the
mutual inductance between phases. This is especially useful when the
winding is non-standard or very complicated. A winding-construction
algorithm is described in Section 3.8.3.
PC-BDC 3 .1 Cross-sect Ion editor CC) 1992 TJOI.Wfce
Z1 12 Z
12 0
5
11
3
3
5-13
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
Since the EMF is synchronous with the rotor position, the shaft position
sensor ensures the synchronism between the EMFs and the line currents,
even though there is usually a voltage drop in the winding resistance and
leakage inductance. This voltage drop means that under loaded
conditions the terminalvoltages are notin phase with the back-EMFs, and
do not have quite the same waveform.
5-14
5. E l e c t r ic a l D esig n
JSl'.vi.v.v?
1
\
OJ
m m i - - 1*......... l / 3
e12
23 \ / e31
V
\ /
:V :.
/
N X y
/
/
fig. 5.9a Idealised squarewave motor : wye connection, 120 flat-top EMF
Waveforms
The 120 squarewave currents require a commutation every 60, and the
switching sequence that achieves this is given at the bottom of Fig. 5.9a.
5-15
D e sic n o f bru sh less perm a nent -m agnet m o t o r s
e12 x 112
j j N y^ n '31M s
K
t
\
// m
\\
Q5 Q1 Q3 Q5
Q6 Q2 Q4 Q6
Fig. 5.9b Idealised squarewave motor : wye connection, 50* flat-top EMF waveforms
5. E l e c t r ic a l D e s ig n
In any 60 interval, the basic electromagnetic torque production is given
simply by
where eis the "reigning" line-line voltage (i.e., the one connected to the
supply through the two conducting power transistors), and i is the line
current. Since there is only one conduction path through the winding,
there is no ambiguity about the meaning of e and i For example, during
the period 30-90 e = and * * ip with transistors Q1 and Q 6
conducting. If all the phase waveforms are assumed to have a peak value
of 1 unit, then the peak line-line EMF is 2 units and the peak line
current is 1 unit, and if wm is taken to be 1 unit then the torque during
this 60 interval is 2 x 1 /I = 2 units.
The current ij during the 30-90 interval flows in the positive direction
in phase 1 and in the negative direction in phase 2, with transistors Q 1
and Q 6 conducting. This current can be regarded as a loop current and
it is expressed by the notation and similarly for i >3 and ij, in later
intervals (see Fig. 5.11). During every 60 interval the same conditions
prevail, the only difference being that is substituted in turn by eJ2,
while i is substituted in turn by ij2> *23, _*i2>The alternation
(i.e., polarity reversal) of the line-line EMFs is natural, being caused by
the passage of the N and S magnet poles. The alternation of the loop
currents is forced by the commutation process. Note that during the
commutation from i,2 to -ijj, remains unchanged but ig switches off
and -ij switches on.
A "block" of the torque waveform is shown immediately below the line
current waveform i 12 in Fig. 5.9a, labelled e12 x ij2- Its amplitude is 2
units and it remains constant throughout the 60 conduction interval
because e12 and i12 are both constant during this interval, and there is
no other current in the machine.
During the next and subsequent intervals the same block of torque is
replicated but with a different set of EMFs and currents. From 90-150
it is (~<3j) x (>3i)> then from 150-210 it is e2g x *23>etc- Consequently
ihe electromagnetic torque remains constant from each conduction
interval to the next, as shown in the lowest trace in Fig. 5.9a.
5-17
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
5-18
5. E le c t r ic a l D e s ig n
ampere-conductors, leaving two unexcited belts each 60 wide. A
winding which will produce this pattern is the one shown in Fig. 5.1 and
discussed in secdon 5.1.1. Note that this winding is not truly
concentrated, became the conductors of like polarity are "distributed"
over a 60 arc.
The rotor is shown as having a 180 magnet pole-arc, and it is tacitly
assumed that the magnet is radially magnetized, to produce a perfectly
rectangular flux distribution around the airgap. With a 60s phasebelt,
this magnet pole-arc produces phase EMFs with a 120 flat-top.
The diagram in Fig. 5.13a shows the principle of the squarewave motor
in a particularly graphical way. It can be assumed that positive
contributions to the torque are produced at all angles where there is
overlap between magnet and ampere-conductors of like polarity. There
is an arc of 120 of overlapping N-pole with one ampere-conductor
polarity, and 120 of S-pole with the other ampere-conductor polarity.
The position shown in Fig. 5.13a corresponds to 60 in Fig. 5.9a. At this
position the rotor can rotate 30 forwards or backwards with no change
in these overlap angles. At the end of this interval (90) there is a
commutation, which "resets" the overlap pattern, whereupon the next
"conduction interval" begins. The constancy of the torque follows from
the fact that the magnet pole-arc exceeds the ampere-conductor belt
width by 60.
Fig. 5.13a also shows that the ideal phase EMF has a 120 flat top, as this
is the difference between the magnet pole-arc and the phasebelt arc.
This is perhaps not immediately obvious, but it becomes clear if the BLv
waveforms are plotted and added together for all the conductors in the
phasebelt, especially if they are considered to be uniformly distributed
through the phasebelt.
The effect of reducing the width of the flat top of the phase EMF
waveform can be seen in Fig. 5.96 which shows the effect of a 60 flat-
topped phase EMF waveform. This waveform would be produced with
the winding of Fig. 5.1 if the magnet pole-arc were reduced from 180
to 120. The line-line EMF now has no flat top at all, and consequently
the torque production is not constant throughout the 60 conduction
interval. In fact, the peak-peak torque ripple is 28.6% of the mean
torque.
5-19
D esig n o f brushless perm anent -m agnet m o t o r s
It was stated in Ref. [10] that the amperc-conductor distribution in Fig. 5.13*
catmol be realized with a wye-connected winding, but that is only true for a single-layer
winding. The winding in Fig, 5.3 is a double-layer winding.
5-21
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
kzzzzzzm
Fig. 5.10a Idealised squarewave motor : delta connection, 60' flat-top phase EMF
waveforms
at any one time, exactly the same as for the wye connection. For sinewave
operation there are generally three transistors conducting at any time.
5-22
5. E l e c t r ic a l D esig n
Fig. 5.10b Idealised squarewave motor : delta connection, 120 flat-top waveforms.
The idea] phase current waveforms are not realisable, because of
distortion by the icro-sequence cuirent.
5-23
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
The lines are labelled A,B,C and the phases are labelled 1,2,3. In the
delta connection the line-line voltages and EMFs are identical to the
phase voltages and EMFs, i.e. AC = vv t^c = v%, and = v3. The line
currents are *a = *1 - *B = *1> an^ *c = *3 " *2-
The delta connection is the dual of the wye connection, in the sense that
relationships between line and phase voltages in the wye connection are
transferred to the currents in the delta connection, and vice versa. A
complete set of waveforms is shown in Fig. 5.10a, assuming phase EMF
waveforms with a 60 flat top. Such waveforms would be produced by the
motor of Fig. 5.136, which has a magnet pole-arc of 120 and the same
stator winding as in Fig. 5.1. Since the machine is delta-connected, the
line-line EMF waveforms are identical to the respective phase EMF
waveforms.
In Fig. 5.10a it appears that there is a 30 phase shift between the
fundamental component of the line current and the fundamental
component of the phase current (e.g., between iA and ij). This is the
same as in the sinewave motor, where ideally the fundamental is the only
non-zero component.
To understand the ideal form of this machine it is necessary to recognize
that throughout each 60 interval the delta is connected between two
lines with the third terminal of the delta open-circuited. For example,
during the 30-90 interval Ql and Q 6 are on, so the delta is connected
as shown in Fig. 5.12, with phases 2 and 3 connected negatively in series
across the supply, and phase 1 connected positively across the supply. If
the motor is "properly designed", then the line current / divides between
the two parallel branches in the ratio 2:1, with (2 /3 )/ going through
phase 1 and (1 /3 )/going negatively through phases 2 and 3.
During the first half of the line A conduction interval, from 30-90,
= 1 unit while ij = 2/3 unit, so the torque contributed by phase 1 is Tj
= fij x = 2/3 unit. During this period is decreasing from its flat-top
value of = -1 unit to zero, while = -1 /3 unit. The average torque
contributed by phase 2 is therefore 1/2 x (-1) x (-1/3) = 1/6 unit
Similarly is increasing from zero to -1 unit and so the torque
contribution from phase 3 averages 1/2 x (-1) x (-1/3) = 1/6 unit, the
same as the average from phase 2. The instantaneous torque
contribution T2 decreases at the same rate as the instantaneous
5-24
5. E l e c t r ic a l D e s ig n
contribution 73 increases, so their sum + Tg remains constant at 1/3
unit. Added to Tlt this produces a constant torque of 1 unit throughout
the 60 interval.
During the second half of the line A conduction interval, from 90-150,
the process is repeated but with all the respective EMF's and currents
commutated to the successive interval: thus el - - eg, *j -e^ - j, etc.
Thus the ideal squarewave delta-connected machine, correcdy
commutated and with the correct EMF and current waveforms, also
produces perfectly constant torque.
The production of constant torque by the delta-connected motor with
60 flat-topped phase EMF's is shown in Fig. 5.136. The magnet has a
120 pole-arc and the phasebelts are 60 wide. Unlike the wye
connection, all three phases conduct simultaneously, even though only
two lines are conducting. Moreover, the ampere-conductors in the three
phasebelts are not all equal. In Fig. 5.136, the instant drawn is at 30 in
Fig. 5.10o: e$ = 0, while el and are both equal to 1 unit. As the rotor
rotates counterclockwise, diminishes as the phasebelts of phase 2 are
"uncovered by the passing magnet, while increases as the phasebelts
of phase 3 are progressively "covered' at the same rate. Meanwhile e]
remains constant at 1 unit as the phasebelts of phase 1 remain covered
throughout the whole 60 interval from 30-90. The current in phase 1
is (2/3)7, and this produces a constant positive torque throughout the
interval. The current in phases 2 and 3 is (-1/3)7, and these phases
produce positive torque contributions decreasing and increasing
respectively at the same rate, as described earlier. The constancy of the
total torque follows from the fact that the effective ampere-conductor
belt width exceeds the magnet pole arc by 60.
The 2:1 division of current in Fig. 5.12 is not as obvious as it looks. If the
phases were pure resistances of equal value, this division of current would
be obvious. But the phases have back-EMF (and leakage inductance
both self and mutual). Under pure DC conditions the inductances have
no effect, but the designer should ensure that the back-EMFs are
correcdy balanced at all times, otherwise, with an imbalance in back-EMF
between the two branches of Fig. 5.12, there will be a net EMF around
the delta and a potentially large current will flow, limited chiefly by the
winding resistances, which are generally small. This current does nothing
useful, but it produces additional I^R losses and torque ripple.
5-25
D e sig n o f b ru sh less perm a n en t -m a gnet m o t o r s
Fig. 5.10i> shows what happens when a delta connection is used with a
motor having 120 flat-top EMF waveforms. As we have seen, such
waveforms would be produced by the winding of Fig. 5.1 with a magnet
pole-arc of 180. The resulting zero-sequence EMF has a peak value
equal to that of the phase EMF. The phase current waveforms can no
longer be assumed to be of the same ideal form as in Fig. 5.10a, because
the zero-sequence EMF drives a potentially large current around the
delta which increases one of the branch currents in Fig. 5.12 while
decreasing the other one. The resulting current waveform depends on
the size of the zero-sequence current.
Fig. 5.14 shows a computer simulation of the phase current waveform
with a delta-connected motor having a magnet pole-arc of 180 and the
same stator winding as in Fig. 5.1. With no fringing this produces 120
flat-top phase EMFs. This figure is included to show the extreme
distortion of the phase current {mainly third-harmonic) and the
resultant torque ripple, which is very large. The zero-sequence current
dominates the phase current and distorts its waveshape almost beyond
recognition. Since the circulating current is absent from the lines, this
undesirable state of affairs can pass completely undetected. In fact, it
may appear only as an u nexplained" tendency of the motor to overheat
Notwithstanding the problem of circulating currents, many brushless DC
motors are made with delta windings and in some case no precautions
are taken to eliminate the residual EMF. In very small motors the phase
winding resistance may be large enough to limit the circulating current
to a safe value, but it still produces unnecessary losses.
5-26
5. E le c t r ic a l D e sig n
12 '2 3
31 , u
------------- >
u i -------------------------------
Kg. 5,11 Loop currents in wye connection. Each one flows for 60
5-27
D esig n o f brushless perm a nent -m a gnet m o t o r s
Fig. 5.13 (a) Squarewave motor with 180 magnet pole-arc and 120 ampere
conductor distribution, (b) Squarewave motor with 120 magnet pole-arc
and 180 ampere-conductor distribution. The phase axes correspond to
those in Figs. 5.1 and 5.3. The numbers indicate the conductors belonging
to phases 1,2.3. Filled circles represent conductors in one direction;
crossed circles represent return conductors in the opposite direction,
5-28
5. E l e c t r ic a l D e s ig n
Tig. 5.14 Computer simulation of delta-connected motor with 180 magnet pole-arc
and near-I20 flat-top phase EMF waveforms, showing the large zero-
sequence EMF around the delta and the consequent distortion of the
phase currents and the torque ripple. The line currents are 120
squarewaves, and the zero-sequence current docs not appear in the lines
or in the controller: consequently it may pass undetected. The winding is
the same as in Fig. 5.1.
5-29
D esig n or bru sh less perm a nent -m a gnet m o t o r s
[Aaptf] \ ft.B_lB.BCC
1.80 * 1.0*1
PHArf onlu clbotm ROTDS PCflTYION
^ S"
^ \ /
-2.00 Z e ro -s e q u e n c e vo ltag e e 0 V ----------------------- /
C-N TOBflUE Tt fiOTOfl POSITION, A,t 15.BDC
2.60
[N.l K 1.0.-I
2.00
I.SO Torque
1.00
0.60
0. 00 0.39 O.tfO 0.00 1.20 I.BO 1.00 2.10 2.AQ 2.70 3.00 3.30 3-<0
Pto>- position [*lc dq' x 1.0*2
f .b.5 .15 Computer simulation of delta-connected motor with 180 magnet pole-
arc, with the winding of Fig. 5.3. The phase EMF has a narrower flat top
and the zero-sequencc EMF ii eliminated by the third-harmonic winding
factor.
Interestingly enough, the winding of Fig. 5.3 also has k = 0 provided
that all coils have equal numbers of turns, even though it has two
separate coil-pitches neither of which is 2/3. In effect, the outer coils 1
and 2 are "under-chordcd" relative to the ideal 2/3 pitch, while the inner
coils 3 and 4 are "over-chorded"; in the superposition of EMF's the
triplen harmonics induced in these coil-pairs cancel, provided that they
are connected in series.
Fig. 5.15 shows a simulation of the motor of Fig. 5.3 with delta-connected
windings, 180 magnet pole-arc, and the double-layer winding. It can be
seen that the zero-sequence loop EMF is zero and so is the torque
ripple.
The designer thus has an additional task when designing motors for delta
connection, namely to ensure that the zero-sequence EMF around the
delta is zero. The PC-BDC. program plots the waveform of the loop EMF
Kq = + <2 + ^ along with the phase and line-line EMFs when the
5-30
5. E l e c t r ic a l D e s ig n
Ending connecdon is delta, Figs. 5.14 and 5.15. Any departure from zero
shows up immediately and can be corrected by the necessary adjustment
ro the parameters mentioned. In sinewave motors, the same requirement
exists. In wye-connected motors the problem does not arise because the
zero-sequence current is forcibly suppressed by the three-wire connection
the neutral point of the windings, and there is only one current path.
5,3.3 Flux/pole and magnet utilization
Itis helpful to construct a model of Figs. 5.13a and b using construction
paper, in which the three separate rings, suitably shaded or coloured, are
cut out andpinned at the centre so that the two inner ones can be
independently rotated while the outer phasebelt ring remains stationary.
This model will prove invaluable in sorting out the sequence of events as
the rotor rotates.
While the flux-distribution of the magnet rotates with the rotor in a
continuous fashion, the MMF distribution of the stator remains stationary
for 60 and then jumps to a position 60 ahead. This motor is not a
rotating-field machine in the sense associated with AC machines.
In Fig. 5.13a, the production of smooth, ripple-free torque depends on
the fact that the magnet pole arc exceeds the MMF arc by 60. The
magnet is therefore able to rotate 60 with no change in the flux-density
under either of the conducting phasebelts. An inevitable result of this is
(hat only 2/3 of the magnet and 2/3 of the stator conductors are active
at any instant, although all of the stator ampereconductors are active.
Similarly in Fig. 5.13b the whole of the magnet is overlapped by
conducting phasebelt, but 60 of ampere-conductors are wasted, either
waiting for the magnet to arrive, or waiting for the next commutation
after it has passed. The motor of Fig. 5.13ft may therefore appear to have
higher per-unit copper losses than that of Fig. 5.13a. Offsetting this
disadvantage is the fact that for the same magnet flux-density, the
flux/pole in Fig. 5.136 is only 2/3 that in Fig. 5.13a, so that only 2/3 of
ihe stator yoke thickness is required. If the stator outside diameter is kept
the same, the slots can be made deeper so that the loss of
ampere-conductors can be at least partially recovered. Consequently the
efficiency of the motor of Fig. 5.136 may not be very much lower than
that of Fig. 5.13a, provided that the extra copper is used.
5-31
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
and twice the current, and the remaining power transistors must have
double the current rating. So it is unlikely that there will be any major
saving in total Silicon area. At the same time the bus-splitting capacitors
add cost and bulk and may limit the performance in other ways.
Moreover, there is less freedom to design a two-phase motor with
sufficient overlap or even any overlap between the flat tops of
successive phase EMFs, when compared with the three-phase motor.
These considerations may help to explain why the two-phase brushless
DC motor whether squarewave or sinewave is rare, although it is in
production by a number of companies.
One of the concerns with the two-phase brushless motor is the ability to
start from any rotor position. This is of less concern with sinewave
motors than with squarewave motors. However, with single-phase motors
ilxs a fundamental problem becaue, with symmetrical classical designs of
The type discussed so far in this chapter, the torque over half of each
electrical revolution would be zero or negative. In order to produce
positive torque over the entire revolution, even-order torque harmonics
jttiy be introduced by the addition of saliencies as described by Kenjo
<ind Nagamori [ 1].
5-33
D e s ig n o f b r u sh l e s s p e r m a n en t -m a g n e t m o t o r s
0 30 60 90 120 150 180 210 240 270 300 330 360 Elec ctogrwa
-30
Z T
'2
Q1 Q3 Q1
I
Q2 Q4 Q2
Q1 Q3
02] Q4
ISP Q1 duty-cycled
Chopping transistor
Is p - D4 duty-cycle 1-d
Chopping diode
ISP Q2
Commutating transistor
D3
Commutating diode
^ <5 7 >
where <J> is the airgap flux due to the magnet, B is the airgap flux-demtfy
due to the magnet, D is the stator bore, and L is the stack length (active
length). Hence
ec = NcB umDL (5 .8 )
In [V]. If all the coils in one phase have the same back-EMF induced in
them, in phase with each other, the subscript 1 is unnecessary, as in
equation (5.8), and the total phase EMF has a peak value eph equal to ec
multiplied by the number of coils in scries per phase. If the number of
turns in series per phase is N^h, then
^ = N^B<*mDL (5 .9 )
If Zis the total number of conductors in the machine, and the number of
parallel paths is a, then = 1/3 x Z/2a.
In squarewave 3-phase motors, if the windings are wye-connected then
the line-line back-EMF is = 2e h. In delta-connected windings =
This is the back-EMF "seen" by the controller.
The EMF constant is defined as Thus, using equation (5.9),
5-35
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
(5.10)
in Volts per (rad/s). Alternative expressions for Aj. are developed in
Chapter 7, which also discusses methods of measurement.
The EMF ec in a full-pitch coil can also be thought of as twice the EMF
in each of its two conductors, or 2BLv, where v is the linear velocity of
the magnetic field past the conductor, v = w^D/2. This expression can
easily be used to develop the back-EMF formulas discussed hitherto, and
it is tempting to use it, but it is subject to a number of uncertainties. The
BLv concept of back-EMF is that of a conductor moving through a
magnetic field, as in every physics text-book, but in most electric motors
the conductors are not located in the flux at all: they are located in slots,
and for all practical purposes the permeability of the teeth is so high that
no flux passes through the conductors at all! To overcome this difficulty
it is assumed that the conductors are equivalent to filaments at the
diameter D, located at the slot centres, or to uniformly distributed
current sheets on a smooth stator surface. But this is artificial and is not
a satisfactory assumption when the number of slots/pole is small or
fractional, and especially when the slot-openings are large (see Chapter
8). It is for these reasons that the EMF equations are derived here
directly from Faradays Law (equation (5.1)). This is a more modem
approach and it is more rigorous because the concept of flux-linkage is
more rigorous than the concept of flux-cutting by conductors which are
not even in the magnetic field.
5-36
5. E l e c t r ic a l D e s ig n
FLUX-LINKAGE
Ktg. 5.18 Idealised flux-linkage vs. position characteristics with impressed constant
current, showing the production of torque by incremental changes in co-
energy
5-37
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
We have already been using diji/d in equation (5.1) and in the previous
section to define kE, and it follows immediately that kT = k^. Further
discussion and analysis of the torque constant and the EMF constant, and
their measurement, are given in Chapters 7 and 8.
5.7.2 Torque linearity
It is central to the design of servomechanisms that the torque of a
brushless servo motor is proportional to the current, with a fixed1
constant of proportionality kj. A graph of torque vs. current is a straight
line, k^I. In practice the torque/current graph may deviate slightly
from a straight line, mainly because of saturation of the stator teeth and
other parts of the magnetic circuit. The torque linearity is defined as the
ratio of the actual torque to the value of k jl at a given current I, which
is typically quoted as 100% of rated current.
5.7.3 Demagnetization
The magnets can be partially demagnetized by overcurrent or
overtemperature, or a combination of both. Brushless motors should be
specified to suffer no more than a certain percentage demagnetization
at a certain current and temperature, for example, 5% at 300% rated
current at a winding temperature of 155C. The 5% refers to the
permanent decrease in the value of fej- (or k^) following a test at this
level.
Test procedures should ensure that the demagnetizing current is applied
at all orientations so that the worst case is definitely covered. The
calculation of partial demagnetization effects is difficult by manual
calculation methods and is best tackled with finite-element or boundary-
element methods.
5-38
5. E l e c t r ic a l D e s ig n
The total number of conductors and parallel paths, and the number of
strands-in-hand in the winding of each conductor, must be adjusted to
m atch the available supply voltage while maximizing the slot-fill factor to
keep the winding resistance and copper losses as low as possible.
If the torque constant is not specified, the operating speed of the motor
certainly will be. Maximum speed will usually correspond to operation
with maximum voltage, i.e. with no chopping. In most cases the
maximum speed will be only slightly less than the no-load speed because
the slope of the speed/torque characteristic is generally quite shallow
because it is proportional to the winding resistance, which is made as
small as possible in the interests of high efficiency. This means that the
no-load speed JV0 can be taken as representative of normal operating
speeds. In mechanical rad/s, the no-load speed is given by equation
(1.7), so in rev/min
N0 = x J = J l * L. (5.13)
0 ^ 2-n- kE 2-rr
From this equation, if N0 and the DC supply voltage Vs are known, AE
can be calculated and then the number of turns in series per phase can
be calculated from equation (5 .10).
This process is simple and is adequate for many purposes, but it is
sometimes necessary to refine the estimate of the required number of
turns particularly if the design constraints in the specification are very
tight. For example, in low-voltage systems (12V or 24V) the number of
turns can be critical in determining the correct motor operation, and
because it has a bearing on the required current, it also affects the
choice and rating of power transistors.
For sinewave motors the number of turns can be calculated in the same
way, but the formula for is different: see sections 7.4.2 and 7.4.3.
= Vs I E (5.14)
dt L
where L is the circuit inductance. For example, in a wye-conncctcd
squarewave motor, L is the inductance of two phases in series. At low
speed the back-EMF E is much less than the supply voltage Vs, so the rate
of rise of current is large. This is shown in the left-hand diagrams in Fig.
5.19a. The current rises so quickly to the set-point value 7jp, that it has
to be limited by chopping the supply voltage.
At high speed the net driving voltage Vs - E is reduced because E is
closer to Vs. Consequently the rate of rise of current is lower, and at a
sufficiently high speed the current fails to reach the set-point value
during the available conduction period. Clearly the average current is
reduced, and so the torque is reduced, as shown in Fig. 5.20.
Matters are somewhat worse than indicated by equation (5.14) because
the current is really intended to rise to the set-point value within a
certain angle of rotation, not a certain time-interval (see bottom diagram
in Fig. 5.19A). As the speed increases, the angle of rotation during a
given time interval increases proportionately, or, put the other way
round, the time interval available to build the current decreases in
inverse proportion to the speed. Therefore, in a fixed angle of rotation
at high speed, the current rises to a lower value than it would at low
speed, even if the net driving voltage was the same.
These two factors combine to cause the torque to collapse as the speed
is raised above a certain level. Mathematically, the effect can be
expressed by the rate of rise of current with respect to rotor position,
rather than with respect to time:
A = dI>dt = Vs ~ E = (5.15)
dO d d /d t w mL a) m L
5-41
D e s ig n o f b r u sh l e s s p e r m a n en t -m a g n e t m o t o r s
5-42
5. E l e c t r ic a l D e s ig n
methods), which solve the entire field problem and do not distinguish
between "airgap flux" and "slot-1eakage flux". These methods give the
total flux-linkage of a winding, from which the self- and mutual
inductances can be obtained by dividing by the respective currents.
Alternatively, they compute the total stored energy in the magnetic field.
This energy is then expressed in the form
fKF = -2 L I 2 (5.16)
where I is the total current at the terminals. The inductance L is
extracted by re-arranging this equation. An alternative method is to
evaluate the flux-linkage of the winding as an integral of the vector
potential A along the length of the conductors:
(5.17)
From a circuit-analysis point of view, it is important to recognize the
separate effects of self-and mutual inductance. For example, in the
three-phase squarewave motor with two phases on, the inductance
between two line terminals of the motor (say, A and B) is
(5.18)
where LA and are the self-inductances of phases A and B, and is
the mutual inductance. The positive sign applies if the two phases cany
current in such a direction that their fluxes arc essentially additive, as in
Fig. 5.21a. The negative sign applies if they are in opposition. It is
possible for two phases to have very low or even zero mutual inductance,
if their axes are orthogonal (Fig. 5.21ft), as in the two-phase motor.
(a) (b)
fig 5.21 Total self-inductance of two coils connected in series with mutual
coupling, (a) Fluxes are essentially additive, so L - LA + Lp + L ^ . (b)
Winding axes at 90*, giving zero airgap mutual inductance.
5-43
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
It is perhaps worth spelling out in more detail why the fluxes are
essentially additive in Fig. 5.21a. The dot convention means that when
positive current is applied, the flux is in the positive direction; and
positive current is that which enters at the dotted end of the coil. In a
wye-connected three-phase motor (with no neutral connection), positive
current entering phase A is negative current leaving phase B.
Accordingly, the flux produced by phase A is in the positive direction
(shown leaving the dotted end), while the flux produced by phase B is in
the negative direction (shown entering the dotted end). The winding axes
are not aligned, and therefore the fluxes do not add directly. If the
winding axes are at 90 there is no common flux-linkage and no mutual
inductance. If the angle between the winding axes were less than 90
the fluxes would be essentially in opposition and the negative sign would
be required in equation (5.18).
5.9.3 Airgap self inductance of single coil
The basis forcalculating the airgap self-inductance L of a single coil is
shown for a full-pitch coil in Fig. 5.22. Thisshows the magnetic flux
established by a full-pitch winding with one slot per pole per phase. The
total MMF around a complete loop or flux-line is equal to Nci, where Nc
is the number of conductors in the slot and i is the current. Nc is also
the number of turns in the coil.
If the steel in the rotor and stator is assumed to be infinitely permeable,
then the MMF is concentrated entirely across the two airgaps. Across
each airgap the MMF drop is Nci/2. If the flux is assumed to be radial in
the gap, the magnetizing force in each gap is
H - 2sL. (5-19)
2/
In a surface-magnet motor the gap g " includes the radial thickness of
the magnet as well as the physical airgap g, which may be modified to gl
= Kcg by the Carter coefficient Kc for the stator slotting. A reasonable
approximation for g " is then
g " = g< + J . (5.20)
Mrec
5-44
5. E l e c t r jc a l D e sig n
'I'll =
(lrr 7T1 ' 7r (5.25)
; . 6 2 , + 2 " eJ
The positive and negative signs account for the direction of the
5-46
5. E l e c t r ic a l D esig n
flux-density in the airgap. Substituting the expression for from
above, we get
A. _ _____________________________
8 h 3 2g
547
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
L. (5.29)
where
(5.30)
is the winding factor for q = 2 slots per pole per phase, i.e. 0.833. The
self-inductance is thus only 83.3% of the value which would be obtained
with the same number of turns per phase concentrated in one slot per
pole per phase. This concurs with the general rule that the inductance
of a coil is increased when its conductors are concentrated, together.
When the mutual inductance is evaluated, using the same method as
before, it is found that the distribution of the second winding cancels the
effect of the step in the flux distribution, so that the actual value of the
mutual inductance is the same as with one slot per pole per phase
(provided the total turns are the same). The ratio between the self and
mutual inductances is therefore
(5.31)
5-49
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
It is again found that the distribution of the second winding cancels the
effect of the steps in the flux distribution, so that the mutual inductance
has the same value as with one slot per pole per phase (provided the
total turns are the same). The ratio between and is given again by
equation 5.81, and its value is -0.415. Once has been calculated, (his
equation can be used for provided that the flux distribution is as
shown in Fig. 5.24.
5-50
5. E l e c t r ic a l D esig n
In field
fig, 5.25 Geometry of a jingle stator coil and associated flux-paths. The coilside
locations are defined by the angles 0G for the "go" conductor and 0R for
the "return" conductor.
5.9.6 General case of airgap inductance
The airgap self-inductance of any distribution of conductors can be
calculated automatically by computer, following the principles described
in the previous sections, and this calculation can be extended to include
the mutual inductance between any two windings regardless of the
distribution of their conductors, provided these arc known. The
accumulation of flux-linkage in the winding is done by exciting each coil
in turn, and adding the flux-linkage of every coil including the excited
coil. In this way the total inductance can be seen as being composed of
a sa of n self-inductances and n (n -l) mutual inductances, where nis the
number of coils in the winding. The formulation of this process is
ttmple in electromagnetic terms, although it requires careful
programming. The PC-BDC computer program uses a coil table to
manage the inductance calculation. The coil table is a list of coils, each
identified by its number, the number of its turns, and the slot-numbers
of the "go" and "return" conductors.
The basis of the method is shown in Fig. 5.25, which shows a single coil
with the "go" conductor located at 0G and the "return" conductor at 0R.
Applying Amperes and Gauss laws,
5-51
D esig n o f brushless perm a nent -m a cn et m o t o r s
(H i * H 0 ) g " - N cj (5-33)
and
4>i = 0O (5-34)
where H-t is the magnetic field strength in the airgap "inside" the coil
(i.e., between 0G and 0R) and H0 is the magnetic field strength in the
airgap "outside" the coil, g" is the effective airgap which can be
approximated by g-+ fci/l-irec in surface-magnet motors. These sections
of the magnetic field are labelled "infield" and "outfield" in Fig. 5.25.
<t>; is the flux crossing the airgap in the "infield", "inside" the coil, and
is the flux crossing the airgap in the "outfield", "outside" the coil. Now
where
r _ irl*ojVc2 /'stk'ri C5.391
-^m ax "
--------- v
2g '
5-52
5. E l e c t r ic a l D esig n
G1
R2
Fig. 5.26 Geometry of jtator coils for the calculation of airgap mutual inductance.
where 0G1 is the location of the "go" conductor of coil 1 and 0R1 is the
location of its "return" conductor, and similarly for coil 2. The mutual
airgap inductance between coil 2 and coil 1 is evaluated as
5-53
D esig n o f bru sh less perm a nent -m agnet m o t o r s
Fig. 5.27 Idealised flux distribution for the calculation of airgap mutual inductance
between the two stator coils of Fig. 5.2fi.
A number of different possibilities arise, depending on the nature of the
overlap between the coils. If the conductors of coil 1, the excited coil,
are represented by [ ], and if the "go and "return" conductors of coil
2 are represented by G and R respectively, then four basic categories of
overlap can be identified as
(i) []GR No overlaprGo 2 and Return 2 both outside coil I
(ii) [G ]R Go 2 within coil 1; Return 2 outside
(iii) G[ R] Return 2 within coil 1; Go 2 outside
(iv) [G R] Go 2 and Return 2 both within coil 1
The equations for the flux-linkage of coil m due to current in coil
n, are derived in the same way as equadon (5.40), which is the correct
formula for case (ii), [ G ] R. The total airgap self flux-linkage of the
phase winding is then
(5.41)
tn-l n-\
The mutual inductance between two phases is evaluated in the same way,
cxcept that the summation over m is taken for the coils of one phase
5-54
5. E l e c t r ic a l D esig n
while the summation over n is taken for the coils of the second phase.
5.9.7 Slot leakage inductance : self and mutual
The slot-leakage component of the phase self-inductance and of the
phase-phase mutual inductance is typically of the same order of
magnitude as the airgap component. It is evaluated in the same way as
for induction motors, except that there is an additional component of
slot-leakage flux due to fringing between the tops of adjacent teeth. This
fringing flux can be considered a space-harmonic addition to the airgap
component of armature-reaction flux. In the induction motor this
component of flux would cross the airgap and flow along the rotor
surface without linking the rotor flux, and it is then known as zig-zag
leakage. In the surface-magnet brushless motor the magnet is generally
so thick that there is no zig-zag effect as such.
The procedure for calculating slot-leakage inductance follows that used
for induction motors, with a few differences in technique in order to
adapt the calculation for automatic computation. The procedure is first
to determine the slot permeance coefficient appropriate to the various
combinations of conductors that may be found in one slot (including the
case where there is only one conductor per slot); and then to add up the
contributions to the total phase flux-linkage from every slot, taking into
account the distribution of conductors from the separate phases.
The slot permeance coefficient can be understood by considering the
inductance of a bunch of N conductors occupying a rectangular stator
slot, as in Fig. 5.28. The slot-leakage flux follows the paths illustrated by
dotted lines. Assuming that the steel is infinitely permeable, the main
reluctance is the cross-slot reluctance, which evidently depends on h and
w, the depth and width of the slot Intuitively we can see that if the ratio
w/h is small, the cross-slot reluctance will be small and the cross-slot
permeance and the inductance will be high. The total flux-linkage of the
conductor in Fig. 5.28 is calculated as follows.
The cross-slot flux-density is given by
B = p.H = * -N I. (5-42)
w h
The flux in the elemental tube shown in Fig. 5.28 is <&)>= RLaVdx and this
flux is linked by a fraction x/h of the total number N of conductors,
5-55
D esig n o f brushless perm a nent -m agnet m o t o r s
Fig. 5.28 Calculation of slot permeance coefficient Tor open rectangular slot with
uniform ampere-conductor distribution throughout the slot.
0 hw 0 (5.43)
5-56
5. E l e c t r ic a l D e s ig n
fif. 5.29 Slot leakage inductance: effect of conductor location within the slot.
4aOt = ^ N\ L *k i : (5*45)
* Jt-1
in [H], where a is the number of parallel paths and NQis the number of
turn* per coil. It is assumed in equaion (5.45) that the slot permeance
coefficient is different for every slot, allowing for different coilside
positions within the slot. In practice this refinement is rather impractical
and a single permeance coefficient (e.g. equation (5.44)) can be used
outside of the summation.
For the mutual slot inductance between two phases A and B, the
corresponding formula is
= i^ ^ E , W Urua][^CA[^]CB[i-] (5-46)
S jhl
>n [H], where CA and Cg are the coilside incidence vectors for phases A
and B respectively.
5,9,8 End-winding inductance
End-winding inductance is difficult to calculate accurately with simple
formulas because the conformation of the endwindings is complex and
difficult to characterize mathematically in simple terms. Fortunately the
end-winding inductance is generally quite small, and it suffices to have
an approximate formula that includes the effects of the main dimensions.
A simple calculation of end-winding inductance is based on the sum of
the end-winding inductances of each coil, without taking account of the
5-59
5. E l e c t r ic a l D es ic n
Fig. 5.31 Geometry for calculation of end-winding inductance. The same geometry
is used in the calculation of mean length of rum (MLT) and winding
resistance.
mutual coupling between coils. To calculate the end-winding inductance
of one coil, the end-windings are developed into a circular arc as shown
in Fig. 5.31. First, imagine the steel stator core dissolved away. Then,
imagine the coil flattened into a plane, as in Fig. 5.31 b. In c the flat coil
is shown with two semicircular end-windings and two straight sides of
length Z ^ . The diameter of the semicircular end-windings is D = r^a,
and two such semicircles from opposite ends of the motor combine to
make a complete circle whose inductance is
Z,cire *
circ 2 (GMD J
- 2) (5.47)
in [H], where CMD is the geometric mean distance between the
conductors in the coil cross-section. If the coil cross-section is assumed
square, with area A, then CMD = 0.447 -JA. To get the total contribution
from the phase windings to the phase inductance, Lcnd, the inductance
Lcirc is multiplied by the number of coils per phase and divided by a2,
where a is the number of parallel paths.
A more accurate estimate of the end-winding inductance could be
obtained by means of equation (5.17), with the vector potential A
5-60
5. E l e c t r ic a l D esig n
evaluated by a three-dimensional calculation using the finite-clement or
boundary-element method.
5-61
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
5-66
6. SINEWAVE MOTORS
6.1 Introduction
that represent the magnitude and direction of the the spatial distribution
of these quantities in a polyphase machine with a rotating field. They are
analogous to the time phasors which represent the magnitude and phase
of individual phase currents, voltages, etc., and they are closely related
to them. The space vector is also closely related to the d,q-axis frame of
reference, which is the basis of classical AC machine theory. Space
vectors actually have a long history, but they are increasingly important
and popular today because of the widespread use of vector control or fieId-
oriented control for synchronous and induction motors. Certain pulse-width
modulation (PWM) control strategies used with vector control are more
easily understood and analysed in terms of space vectors, than in terms
of tfj^-axis theory.
6.1.2 Practical motors designed to approximate the sinewave motor
The most fundamental aspect of the sinewave motor is that the back-EMF
generated in each phase winding by the rotation of the magnet should
be a sinewave function of rotor angle. The purity of the sinewave
depends partly on the magnet flux-distribution, which should be as near
as possible to a sinewave, and pardy on the winding distribution. If the
winding were perfecdy sine-distributed it would have no flux-linkage with
space-harmonics of the magnet flux-distribution, but practical windings
are not perfecdy sine-distributed and therefore it is important to make
the magnet flux distribution as nearly sinusoidal as possible. The rotor
configurations shown in Fig. 6.1 are commonly employed for this.
(a ) (b ) (c )
Fig. fi.l PM rotors commonly used in sinewave motors.
In Fig. 6.1a the magnets are parallel-magnetized (not radially
magnetized). In Fig. 6.1A the varying thickness of the magnet in ihf
direction of magnetization naturally profiles the flux-distribution and a
6-2
6. S inewave M o t o r s
very good sinewave is possible with this configuration. In Fig. 6.1 c the soft
iron pole-pieces can be profiled to give a variable airgap length which
produces the same effect. A difficulty with this motor is the effect of
cross-magnetization, i.e. 9-axis armature reaction flux. In all three cases
Ihc magnet pole arc is chosen to maximize the ratio of the fundamental
flux to the total flux.
The windings can be made approximately sine-distributed by three main
methods:
1. short-pitching or "chording";
2. skew; and
3. distribution or "spread".
Short-pitching means winding the coils with a span less than n electrical
radians; this has the additional advantage of lowering the resistance and
decreasing the amount of copper in the end-windings, as well as making
the end-windings more manageable in the factory. Winding pitches of
5/6, 2/3, and even 1/2 are typical, the fractional pitch being relative to
one pole-pitch or 7t electrical radians. "Concentric" windings are
essentially made up of combinations of short-pitched coils, all of which
have the same axis.
Skew can be applied to either the winding or the magnets, and both
methods are used in production.
The distribution or spread of a winding means that the conductors are
distributed throughout an angular belt as discussed in connection with
Fig. 5.13. In large AC machines the spread is achieved by means of a lap
winding, in which all the coils are identical. In small PM machines it is
more usual to use concentric windings, of the type discussed in Chapter
5.
The sinewave PM motor is a simple synchronous motor. It has a rotating
stator MMF wave and can therefore be analyzed with a phasor diagram;
this is especially useful in designing the control system and calculating
the performance. In this chapter we determine expressions for the
torque; the open-circuit phase EMF due to the magnet; the actual
winding inductance; and the synchronous reactance. These results are
6-3
D e sig n o f b ru sh less perm a nent -m a gnet m o t o r s
modified for practical windings by means of the standard winding factors
of AC machines. They provide the basis for the phasor diagram, which
is used to develop the circle diagram and study its variation with speed;
from this the speed/torque characteristic is derived. It is shown that the
surface-magnet sinewave motor has limited capability to operate along a
constant-power locus at high speed. The chapter finishes with a
theoretical comparison of the torque per ampere and kVA requirements
of squarewave and sinewave motors and a comparison of wound-field and
PM motors which justifies the preference for PM motors in smaller sizes.
1 = ^ (6.2)
2 v p p
so the total number of conductors per phase is Ns/p x 2p = 2Nt. The
total number of turns per phase is half the number of conductors per
phase, i.e., Ns. This is illustrated for a two-pole winding in Fig. 6.2.
6.2.2 Airgap flux produced by sine-distributed winding
For the calculation of back-EMF and winding inductance it is necessary
to calculate the flux-linkage of the sine-distributed winding. Fig. 6.2 shows
the self-flux produced by current in the winding itself, and Fig. 6.3 shows
the MMF which forcesthe flux across the airgap at two points located at
0 and n /2 p - 0 electrical radians. The equations will be developed for
the general case of a machine with 2p poles, even though Fig. 6.2 b
drawn for p = 1. The MMF enclosed by the flux line is given by
6-4
6. S inew ave M o t o r s
FLUX LINES
COIL A X IS
ELEM ENTAL
COIL
wip-e v . iN . (6.3)
F = f i smp6 d9 = -----cospO.
Je 2 p
The airgap flux-density at 0 is therefore
B = MoH ~ = B cospO
b = (6.5)
2p g "
and g is given by equation (5.17). The flux linking the coil whose
conductors are located at the angles 0 and -0 is given by
6-5
D e sig n o f bru sh less perm a nent -m a g n et m o t o r s
6-6
6. S inewave M o t o r s
in [H]. If there are a parallel paths through the winding, this formula
ii unchanged provided that Af is interpreted correcdy as Nc x 2p/a,
where Nc is the number of sine-distributed turns per pole. Ns is then the
number of turns in series per phase, in the same sense as in Chapter 5,
section 5.8.3. Comparing equation (6.10) with equation (5.23), the sine
distribution reduces the self-inductance by 50% compared with that of
a single concentrated full-pitch coil having the same number of
conductors. As noted already, the flux is reduced by the factor 2/ n while
the linkage of that flux is reduced by the factor ir/4, so that for the same
ampere-conductors the inductance is reduced by 2/ti x ti/4 = 1/2,
compared with the concentrated coil.
6-7
D esig n o f b ru sh less perm a n en t -m a g n et m o t o r s
From this it is easy to show that the mutual inductance between two
otherwise identical sine-distributed windings with Na and JVp series turns
per phase is
cos y = Mjnm cos Y. (6-13)
6-8
6. S inew ave M o t o r s
where Y is the angle between the axes of the windings, in electrical
radians. These results are among the most fundamental in the theory of
AC machines. The vanishing of the integral in equation (6.11) for p *
q means that a sine-distributed winding has no flux-linkage with any sine-
distributed flux that has a pole-number different from its own: by
implication, it therefore rejects all space-harmonics of the magnetic flux
set up by the rotor magnet, since this field is no different in principle
from the field set up by another winding or set of windings. The sine-
distributed winding is therefore a perfect "notch" filter for space-
harmonic fluxes of its own pole-number.
The cosinusoidal variation of the mutual inductance in equation (6.13)
is equally fundamental. In particular, it forms the basis of the two-axis
theory of the induction machine, and it also plays a central part in the
two-axis (dj^-axis) theory of synchronous machines, including the PM
machines of this chapter. If y = 0 and Nat = Np = Ns, then the mutual
inductance Map is equal to the self-inductance of equation (6.10).
6.2.5 Generated EMF
Suppose the flux is established by a second winding which rotates relative
lothe first winding. The flux-linkage in the stationary winding ais still
given by equation (6.12) but with
Y = t V + Yo (6-14>
6-9
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
6.2.6 Torque
Suppose the flux is established by a second winding or a magnet with y
pole-pairs, whose axis is located at an angle p from the reference axis of
the first winding, Fig. 6.5. The radial flux-density at the winding is
B cos ( g9 - f3) and this produces a force on the winding element and
a resulting torque equal to
= y, * B cos (g$ - /9) * N sin pO * (6.17)
The total torque is the integral
e 2 (6-18)
^ f {sin [{p + g)6 0] + sin [ (p - g)8 + 0]]dB.
22 Jn
ty jp s m fi
-
6-10
6. S inew ave M o t o r s
The rotation of the amperc-conductor distribution is achieved by means
of a two- or three-phase winding carrying balanced currents. If three
phase windings a,b,c have their axes at 0, + 120, and - 120 and are
supplied with currents i cos 0)at, cos (&)at - 2tc/3), and i cos (Ci>st -
2n/3), the resulting ampere-conductor distribution is given by
N [sin p 9 costds/ + sin (p Q - 2tt/3) cos {(i3s/ - 2 tt/ 3 )
+ sin (p6+ 2ir/3) cos (ws/+2ir/3)] (6.21 )
t N
= / sin (p9 -
2 2 s
6-11
D e sig n o f bru sh less perm anent -m a gnet m o t o r s
where
(6.26)
and I - /V2 is the RMS phase current. The associated flux per p o le is
6-12
6. S inew ave M o t o r s
/A rotating flux wave, established by armature reaction,
generates voltages in all three phases. In each phase the voltage is
proportional to /an d is therefore regarded as the voltage drop ^/across
a fictitious reactance, the 'synchronous reactance, By substituting the
flux/pole into the expression derived earlier for EMF, and dividing by I,
we get
y _ 3 tt Mo^i-^ak (6 27)
^ 8 p ig "
in [Ohms], This expression applies to an ideal 2/>-polc sine-distributed
three-phase winding with Af turns in series per phase, and it neglects the
leakage inductance of the slots and end-turns. To obtain a practical
formula for a real winding, we must first find an effective value for the
iinc-distributed turns. This is done by means of Fourier analysis and
winding factors in the next section.
Fig. fi.6 Full-pitch coil, shown divided into two equal halves, one per pole
6-14
6. S inewave M o t o r s
2N p C O N D U C T O R S /P O L E
N T U R N S /P O L E
P
N c TU R N S /C O IL
FUNDAMENTAL
SPAN = 7 SLOTS
Bn is the nth space harmonic of the flux distribution. The nth harmonic
can be eliminated from the flux wave produced by a winding if = 0,
which requires e = n /n . In the winding of Fig. 6.7, 0 = 2n/9, so no
integral-order harmonic is eliminated- If the coil span was reduced from
7 to 6 slots, however, e would be 3n/9 = n/S and the third harmonic
would be eliminated from the self-flux because = cos (3 x ti / 6) =0.
The winding would also have zero linkage with the 3rd harmonic flux
produced by any other winding or by the magnet. Short-pitching by 1/n
of a pole-pitch eliminates the nth harmonic flux-linkage from all sources,
both self and mutual.
In wye-connected three-phase motors there is little point in using a
chording angle e that is n /3 (or a submultiple thereof), because the wyr
connection itself cancels the 3rd harmonic EMFs from the line-line EMF,
and no third-harmonic current can flow provided that the star point of
the winding is isolated. However, in delta-connected motors it is essential
6-16
6. S inew ave M o t o r s
(0 eliminate the third harmonic (see section 5.2.2), and the use of a 2/3-
pitch winding does this most effectively.
,\ concentric winding with more than one coil per pole contains coils of
differing span, and even different numbers of turns. Provided that all the
coils have the same winding axis, the overall pitch factor can be
calculated using
_ -^i^pn(l) + pn(2) + + -^m^pnfrn) /fi 391
^ ----------------- a w v T a T------------ (6-32)
where m is the number of coils, JVj, M,, etc. are the numbers of
turns/coil, and i n(1j, fcpn(2)> etc- are t^e individual pitch factors for the
individual coils. For example, a winding of 2 coils per pole having spans
of 7/9 and 5/9, with equal numbers of turns, would have a third-
harmonic winding factor of
sin ~3 -----
7 TT + sin -3 x -----
5 7T
92 92
2 (6.33)
sin (210*) + sin (150;)
2
= 0.
This shows the possibility of eliminating a particular harmonic by means
of a "composite" pitch factor, even though no coil has the exact pitch
required to eliminate that harmonic from its own flux-linkage.
6.3.3 Distribution or spread
Lap windings are made up of groups of coils which all have the same
span, but which are displaced from each other by an electrical angle y
(see Fig. 5.5). Often y is equal to the slot-pitch angle, but this is not
necessarily the case, particularly in fractional-slot windings.
Consider two coils such as those in Fig. 5.5. Each produces a
fundamental airgap MMF that is sinusoidal and whose wavelength is, by
definition, 2n electrical radians. The two fundamental sinewaves are
displaced from each other by y electrical radians, so that the resultant
airgap MMF is proportional to
sin + sin (0 - Y) = 2 sin cos (6.34)
6-17
D esig n o f b ru sh less perm a n en t -m a g n et m o t o r s
If both coils were concentrated together in the same slots then y = 0 and
the MMF would be proportional to 2 sin 0. The ratio of the amplitude
of the fundamental of the distributed winding to that of the concentrated
winding is cos ( y / 2), and this is known as the fundamental distribution
factor, fedI. If there are m coils in a group, the resultant fundamental
MMF is proportional to
sin 8 + sin(0 - y) + sin(0 - 2 y) +...+ sin [9 - (J37- 1) Y]
s in ^ l
= sin 8 + (in~Y) v2
(6.35)
2 sin-^-
2
(This result can be derived by multiplying both sides of the original sum
by 2 sin (y / 2) and expanding the sin-product terms into sum- and
difference sin terms, then cancelling common terms). If all the m coils
were concentrated together then y = 0 and the MMF would be
proportional to m sin 0. The fundamental distribution factor is then
given by the ratio
sin m y
I
m sin Y
[2 J
The same procedure works also for the space-harmonic components of
the MMF, so that the nth harmonic distribution factor is
sin 'nBH.
2 (6.37)
m sin n l
2
Equation (6.35) shows that the axis of the resultant MMF wave ij
displaced by an angle (m - 1 ) y /2 by the distribution, relative to ihc
position it would have if all the coils were concentrated together with the
first coil. The summation in equation (6.35) can be represented
vectorially as in Fig. 6.9, where the vector sum of the MMFs is
represented by the large chord.
6-18
6. S inew ave M o t o r s
fi.9 Vector sum of coil MMF'j, illustrating the winding distribution factor
6-19
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
where
sl = f F{6) cos n& d6 and
2 ir Jo
(6.39)
IT / n 7^0) sin nO d9.
2
O.ir j
+ J (/j^cos jj0
fl<M (6.40)
r27r
* J (~Foq)cos 1,9 d6
2
(Nf)a cos n<pnnai
sin
nv 4
and
(Nf)a sin n<f> sin (6.41)
IITT M 2
where a = (9Rq ~ 0G ) is the span of the coil in electrical radians, (|>^
= ( 0R + dGc[)/2 is the location of its axis, and (M)q is the ampere-turns
of me i/th coil. For a winding with N coils the overall harmonic
coefficients are given by
E a n,q At = E Awi (6 '42)
q-l ^1
and the magnitude of the nth harmonic is
^ = W * V- (6-43)
If all the ampere-conductors were redistributed and concentrated in full-
pitch coils, one per pole, then the MMF distribution would be a
rectangular wave of peak value F /2, where
6-20
6. S inewave M o t o r s
n
(6 .4 4 )
The amplitude of the nth harmonic component is 4/y'wi, and this is the
base from which the nth harmonic winding factor can be defined:
In the machine of Fig. 6.7 with 18 slots, a skew of 1 slot-pitch gives Asl =
0.995, = 0.0583, and fcjig = -0.05326, and these low skew factors
attenuate the most troublesome harmonics associated with slotting. A
skew of one slot pitch is not necessarily optimum from all points of view,
and smaller values are sometimes used, e.g. 0.75 of a slot-pitch.
6.3.6 Design formulas for practical windings
All the design formulas for sine-distributed windings can now be
rewritten for practical windings simply by replacing the sine-distributed
6-21
D e sig n o f bru sh less perm anent -m a g n et m o t o r s
series turns per phase with the equivalent sine-distributed series turns
per phase for the fundamental:
7T
where Nph is the actual number of series turns per phase 2pNp/a, and
is the fundamental winding factor.
K i = *pdi^i- (a48)
The open-circuit phase EMF is
E - A (6.49)
J2
where $>M1 is the fundamental flux due to the magnet. If, as is usually the
case, the magnet flux distribution is not perfectly sinusoidal, the
fundamental component should be extracted using Fourier analysis as
outlined in section 6.4 below. In that case the nth harmonic EMF can
be computed using equation (6.49) with Awl replaced by kmi. The EMF
can be written in an alternative useful form by recognizing that the RMS
phase flux-linkage due to the magnet is
^iul
Wl ph Ml (65Q )
Ml =
v/2
With this, the EMF can be written
Eq = wsl).M1. (6.51)
The subscript 'q here means that the EMF phasor is aligned with the
<f-axis in the phasor diagram since it leads the flux-linkage by 90 electrical
degrees.
The torque is given by equations (6.19), (6.21-23) and (6.50):
T, = 3 ^ mi I P sin P (6.52)
6-22
6. S inew ave M o t o r s
E J s in /3 (6.53)
q
jn [Nm). o>m is the mechanical angular velocity given by equations (6.23)
and (6.22). For a 2-phase motor the 3 in equations (6.41) and (6.42)
should be replaced by 2.
Turning now to the actual phase inductance, it is meaningless to
substitute the effective sine-distributed turns. The actual inductance must
include all the self flux-linkage, not just the fundamental component.
The inductance formula for a practical winding therefore remains the
same as in section 5.8, including the leakage inductance.
The synchronous inductance or reactance is quite different from the
actual inductance, being associated with the voltage drop in one phase
caused by the fundamental component of rotating armature-reaction
flux, under balanced conditions with all three phases in operation.
Substituting for the effective sine-distributed turns per phase, we get
(6.54)
in Ohms per phase. To this value must be added the per-phase leakage
reactance Xa, giving the total synchronous reactance
(6.55)
Potential
^ F ladc o sP e
1 magnet
Potential u f 1------ n
Zero potential 2p
Fig. 6.10 Geometry for the calculation of XA.
The geometry for the calculation of is shown in Fig. 6.10 and the
axis flux distribution in Fig. 6.11.
6-24
6. S inew ave M o t o r s
This geometry is derived from the spoke-type motor shown in Fig. 6.1 (c),
by developing it into Cartesian or rectangular form. The projection is
used purely to facilitate a clear picture and does not introduce any
additional approximation, since the circular shape of the airgap is
retained in the mathematics. Although the geometry appears to be
specialized to the spoke-type rotor, in fact it applies to all rotor
c o n f i g u r a t i o n s provided that the symmetries of the magnetic circuit are
correcdy observed. Fig. 6.12 shows how the basic geometry of Fig. 6.10
can be developed for three different rotor configurations. Similar
developments apply to the geometry for calculating X^.
The MMF distribution fjad cos pB is determined from Fig. 6.13. The
actual winding has 2p poles, and each pole has N turns. For example,
if there are m coils per pole each with Nc turns/coil, = mNc. The
equivalent sine-distributed winding has a conductor distribution (Ns/2 )
tin pQ conductors/rad, so that the number of conductors per pole is
v = fJirfp _Vs sin p6d6 = i 2x - Ai n lw = N-, if-
t6-56)
v Jo 2 ir 2 p p
6-25
D esig n o f bru sh less perm anent -m a gnet m o t o r s
M A G N ET
Fig. 6.12 Development of geometry for calculation of X ^. (a) Spoke type (b) Erat
type (c) Surface magnet
6-26
6. S inewave M o t o r s
and the number of sine-distributed turns per pole is half this, i.e.
N = (6.57)
p 2 Ip
If all turns are in series then the number of sine-distributed turns in
series per phase is
2p * % = Ns. (6.58)
Ip s
In a practical phase winding with all Arph turns in series,
N. - +7r K , <6-59>
From Fig. 6.13 the MMF per gap has a peak value
6-27
D e sig n o f brushless perm anent -m a gnet m o t o r s
K
F* ' N* t P
2 2 p
(6'M)
3y/2 AvI
IT
ampere-conductors/gap. This equation shows that in a multiple-pole
machine the total armature-reaction ampere-tums are divided among p
pole-pairs. If the phase winding is divided electrically into a parallel
paths, then the MMF per gap is divided by a, and this is taken into
account by defining JVph as the number of turns in series per phase, i.e.
N _ T o ta l turns/phase
Pb " Paths
The peak MMF per gap given by equation (6.60) is made equal to
^lad by using the rf-axis current 7d from the phasor diagram (section
6.5), or to by using the y-axis current 7^.
Returning to the magnetic analysis of Fig. 6.10, the pole-piece is floating
magnetically and has an undetermined magnetic potential u. Since the
q-axis is taken as the datum of magnetic potential, is themagnetic
potential drop across one magnet. "One magnet" isdefined as the
segment of magnet associated with one half-pole. In the spoke-type rotor
this means splitting the actual magnets into two sections in series. The
permeance P ^ is the permeance of "one magnet", i.e.
Am/ (L ra/ 2 ) , where Lm is the total thickness of one block of magnet. The
airgap flux-density over the pole-piece is given by
3 .dW = [^iad COS P - (6 62)
g
6-28
6. S inewave M o t o r s
and the form of this distribution is shown in Fig. 6.11. If the pole-piece
is sufficiendy wide and the negative potential-drop u induced in the
airgap by the reluctance through the magnet is sufficiendy large, a
proportion of the flux can re-emerge from the pole-piece and return
across the airgap in the reverse direction, completing its path to the q-
axis via the stator teeth at the edges of the pole arc. These re-entrant
flux-paths were termed "whorls" by V.B. Honsinger in his analysis of line-
siart versions of the PM AC motor [1],
6-29
D esig n o f b ru sh less perm a n en t -m a g n et m o t o r s
to the base Then
u - a<l (6.67)
This is the total <axis flux produced by the armature reaction current
Its fundamental component is what generates the voltage in the
phasor diagram. The fundamental component is determined by Fourier
analysis of as described in [2]. Thus the amplitude of the
fundamental armature-reaction airgap flux-density symmetrical about the
d-axis is
jrP-P
?,ad = iIT Jf0
(6.69)
g
l ^ ud- V I -
The constants fc, and fclad arise in the Fourier analysis and are given hy
_4 an
v
and
r Sill OC7T
lad = a +
7r . ( 6 .7 1 )
If equations (6.67) and (6.68) are substituted into equation (6.69), there
results a simple equation for
*.ad - - ^ a d (6-72)
8i
where gd ' is the effective airgap presented to the fundamental
component of d-axis flux, given by
6-30
6. S inew ave M o t o r s
The use of the concept of the equivalent airgap makes it possihle to use
equation (6.54) for Xd, simply by substituting g instead of g : thus
+^ ^ i^ph )2 + ^ (6-74)
PSa
jfoie the addition of the leakage reactance Xo to the airgap component
V d to get the total reactance. For a two-phase machine the airgap
component Xad has 2/3 the value calculated by equation (6.74). The slot-
leakage reactance is calculated using methods described in Chapter 5.
for completeness, the fundamental armature reaction flux associated
with .Blad is given by
* = A ad ^stk (6.75)
* lad p
in [Wb]. The fundamental flux-ftn&jge associated with Jlad is =
iad and the peak induced voltage is G)ip]ad. The RMS induced
voltage is wt|lad/'/2 = ( 2 7 1 / ^ 2 ) ^ ^ /3> lad = Xdd/d V/phase.
The analytical derivation of equation (6.74) for Xd is essentially similar
io die procedure followed by Honsinger [1] and Miyashita [2] although
both these authors worked with pole-arcs of 180 electrical degrees (a =
1 ). The technique described here is similar to that of Richter [3-5].
6.4,2 Calculation of
The component of the stator ampere-conductor distribution associated
with / is symmetrical about the 9-axis and produces a flux that does not
pass through the magnet. Fig. 6.14 shows the ideal form of the airgap
ilux distribution. The airgap flux-distribution symmetrical about the <7-axis
i* given by
5 aq(0) = ^aq s <676)
g
and the total q-axis flux corresponding to is
SLTttlp
6-31
D e s ig n o f b r u sh l e s s p e r m a n en t -m a g n e t m o t o r s
This is the total 9-axis flux produced by the armature reaction current I .
Its fundamental component is what generates the voltage Xdq/ in the
phasor diagram. The fundamental component is determined by Fourier
analysis of 4> as described in [2]. Thus the fundamental armature-
reaction airgap'Vlux-density symmetrical about the 9-axis is
tt(2
8 (6.78)
= Alaq
k , Mac
F
g
where
*laq = IT (6-79)
Equation (6.78) can be used to determine Xq in the same way as
equation (6.54) was used for the symmetrical synchronous reactance X^
in the non-salient pole machine, and as equations (6.69) and (6.74) were
used for thus
xq = + = 6^ Lf + Xt (6.80)
pga
where
V = (6.81)
-*iaq
Note the addition of the leakage reactance Xa to the airgap component
to get the total reactance. For a two-phase machine the airgap
component X ,q has 2/3 the value calculated by equation (6.80). The slot-
leakage reactance is calculated using methods described in Chapter 5.
For completeness, the fundamental armature reaction flux associated
with filaq is given by
* laq = ffaq ^stk (6.82)
6-32
6. S inewave Moto rs
^mo + 2 * + Pt\
where
Pa - (6-84)
and /*L is the leakage permeance per half-pole, i.e. the leakage
permeance in parallel with Pm0-
The corresponding flux-density produced in the m agnet is given by
B . 5 . (6.85)
where is the pole-face area of one magnet. This flux-density is
superimposed on the open-circuit flux-density in the magnet (equations
(4.10) and (4.13)). If 7d < 0, then flma < 0, i.e. the d-axis armature
reaction is demagnetizing, and the magnet operating point is driven
further down the demagnetization characteristic (Fig. 4.4).
6.4.4 Cross-magnetizing effect of q-axis flux due to 7q
The y-axis armature-reaction flux produced by I is given by equation
(6.77). This flux splits into two equal halves which flow across adjacent
pole-pieces. At the centre of each pole-piece (Fig. 6.14) the resulting
flux-density component is
* qad = (686>
This flux-density should be checked in design calculations to ensure that
the pole-piece has enough radial depth to avoid saturation.
6.4.5 Significance of rotor leakage
Rotor leakage has two main effects. First, it wastes magnet flux. On
open-circuit the airgap flux is less than the magnet flux. Accordingly the
6-33
D esig n o f brush less perm a nent -m a gnet m o t o r s
Fundamental Blaq
| Potential
jF la q ^ P 0
1 magnet
^mO
/> n
Zero potential
2p
A1 (6.89)
'q
vd 'd d
This equation applies also in Fig. 6.16fc, where y < 0 and the current lags
behind the ^-axis.
The current phasor is given by
(6.92)
where
1^ = /co s (3 = -/s in y; and (6.93)
Jq = /sin P = / cos Y-
Similarly the terminal voltage phasor V leads the ^-axis by the angle 6,
sometimes known as the load angle, and
(6.94)
where
V cos (5 + ) = - V sin S ; and
2 ( 6 .95)
V sin (5 + ) = V cos S .
2
6-36
6. S inew ave M o t o r s
JXJ
q'q
(a) (b)
Fig. 6.16 Phasor diagram of salient-pole sinewave motor in motoring mode, with
currents and voltages resolved into if- and ^ axis components, (a) rf-axis
current is 'demagnetizing'' (b) it-axis current is "magnetizing1'.
Also
produced by the MMF associated with /d induces the voltage jXd/d in the
q-axis, which adds to ]E , as in Fig. 6.166. The magnet flux-density is
increased, so the operating point moves up the demagnetization
characteristic. It may even end up in the first quadrant with > Br
Conversely, a negative d-axis component, /d < 0, produces an MMF
distribution that opposes the magnet flux in the d-axis. The armature
current is said to be demagnetizing. The voltage jXd/d is in the
opposite direction to jq, as in Fig. 6.16a. The magnet flux-density is
decreased, so the operating point moves down the demagnetization
characteristic.
The power factor angle is given by
<f> = S - Y- (6.98)
in [Nm], where the flux-linkages ijtd and i|r are RMS per-phase values
given by
s'J'd = Eq * x d fd (6.100)
The first term is called "magnet alignment torque" and the second term,
proportional to (Xd - Ar((), is called "reluctance torque". If 7d and are
substituted from equations (6.93) the torque equation becomes
6-38
6. S inew ave M o t o r s
(6.103)
4 AX I
(6.104)
This equation is the same as equation (6.53). A contour of constant
torque is therefore a horizontal line in the phasor diagram, with / =
constant.
6.5.3 Operation as a generator
fig. 6.17 shows the phasor diagram for generating, with both
demagnetizing (7d < 0) and magnetizing (7d > 0) orientations of the
stator current. It is usually more convenient to exchange the current
phasor for its negative, so that generating current appears positive when
leaving the machine, rather than when entering it: in other words, the
machine is treated as a source rather than as a sink. Then equation
(6,97) becomes
6-39
D e sig n o f bru sh less perm a n en t -m agnet m o t o r s
Reversing the current in Fig. 6.12 causes the arrowheads on the HI, j-X ^
and jX^/ phasors to switch to the opposite ends of the respective
phasors. Ilie phasor diagram then appears as in Fig. 6.18, which shows
the usual case of lagging current. This is the classical phasor diagram for
an over-excited AC generator. The term "overexcited" generally means
that E > V. In other words, the excitation (in this case, the magnet flux)
must be increased above the value corresponding to rated terminal
voltage, in order to overcome the voltage drop in the synchronous
reactances and X^. The d-axis component of armature-reaction MMF
opposes the magnet flux.
Fig, fi.17 Phasor diagram of salient-pole sinewave motor in generating mode, with
currents and voltages resolved into A- and ^-axii components, (a) d-axis
current is "demagnetizing" (b) rf-axis current is "magnetizing".
6-40
6. S inewavk M o t o r s
fig. 6.18 Classical phasor diagram for generating wilh lagging load.
6-41
D esig n o f bru sh less perm a n en t -m a g n et m o t o r s
6-42
6. S inew ave M o t o r s
In c re a sin g sp ee
At point D,
> k - - 4 (6115)
"Tst)
Equating the two expressions (6.81) and (6-82) for 7C at the two
respective speeds,
V
k = ---------- c (6.116)
Z fi ~ J Vc ~ V
Suppose we define ^ as the per-unit open-circuit voltage at the comer-
point, with the maximum RMS voltage of the controller as the base
voltage:
^ (6-117)
Vc
Then
k = (6 .118)
" ft ~
6-45
D e sig n o f bru sh less perm a n en t -m a g n et m o t o r s
References
1. Honsinger VB [ 1982] Thr fteUh and parameters of interior type ac permanent magnet
machines, IEEE Transactions on Power Apparatus and Systems, PAS-101, 4, 867-575
I. Miyaahiu K, Yamashita S, Tanabe S, Shimozu T and Scnto H [1979] Development
of a high-speed permanent magnet synchronous motor, IEEE Transactions, Power
Apparatus and Systems
S Lafuze DL and Richter E [1976] A high-power rare-earth cobalt permanent magnet
generator in a variable speed constantfrequency aircraft starter-generator system, NAECON
conference record, 971-977
< Bailey LJ and Richter E [1976] Development report on a high-speed permanent-magnet
generator of the 200kVA rating class utilizing rare-earth cobalt magnets. Proceedings of the
second international workshop on rare-earth cobalt magnets and their applications,
Dayton, Ohio
6-47
D esig n o f bru sh less perm a nent -m a gnet m o t o r s
5 Richter E [1978] Trade-off studies for permanent-magnet machines tiling rar*-earth cobalt
magnets. Paper 1-4 of the third international workshop on rare-earth cohalt magnet*
and their applications, University of California, San Diego
6 Leonhard, W [19851 Control of electrical drives, Springer-Verlag, Berlin
6-48
7. kT and kE
7.1 Introduction1
The torque constant fej- and the back-EMFconstant A introduced in Chapter
1 are widely used to match the motor to its controller, especially when
the motor and controller are obtained from different sources. Even more
importandy, fcj. is used in the control-system design of complete servo
mechanisms that are driven by electric motors, because it represents the
essential "gain" of the motor in converting current into torque. Yet there
is scope for confusion in the way these factors are used. In S.I. units it is
often tacidy assumed that hj. and kL are identical. In English units, they
are numerically different, giving rise to the impression that they are
independent of one another. Sometimes kE is expressed in Volts per 1000
rpm, which seems at first sight to have no relation to the torque per
ampere.
The widely used Electro-Craft handbook [1) provides definitions for DC,
squarewave brushless DC, and two-phase sinewave brushless AC motors,
but it docs not discuss the three-phase sinewave BDC motor, neither does
it explain how these constants can be calculated from dimensions. The
scope for uncertainty is increased by two other factors :
1. Squarewave motors can be fitted with resolvers and operated
from sinewave drives. Indeed, in some manufacturers ranges the
differences between squarewave motors (brushless DC) and
sinewave motors (AC servo) are so small that the distinction
between them is not clear.
2. When applied to the three-phase sinewave motor, the "natural"
definitions of kj and kE used with commutator and squarewave
motors lead to a ratio of v^3/2 between kj and A. Ref. [1]
overlooks this factor. It only discusses the two-phase sinewave
motor, for which the problem does not arise.
There is some overlap between this chapter and other chapters that define Jfcj. and
kjr (Chapters 1,5 and 8); and also with Chapter 11 on measurement. The function of this
chapter is a detailed treatment of the two constants together with their measurement, in
which the similarities and differences among two- and three-phaae, and squarewave and
sinewave motors are brought out.
7-1
D esig n o f bru sh less perm a n en t -m a gnet m o t o r s
7-2
7. Kj. AND Kf
7,3 Definition and measurement of kj. and Ag
7J. 1 DC commutator motors
The DC commutator motor is the most basic of all electrical machines
from a control point of view. Viewed from the DC source, the ideal
brushless DC motor is electrically identical to the commutator motor.
The back-EMF constant ky and the torque constant form the basis of
Lhe control theory of both machines. To put this theory on a clear basis,
the equations of the DC commutator motor are summarized first.
The DC commutator motor is described by three simple equations as
follows:
T = Jfe, I Nm (7.1)
where Tis the electromagnetic (airgap) torque, Tis the DC current, and
Jtf is the torque constant in Nm/A. Next,
E = kE o m V (7.2)
where E is the back-EMF, com is the angular velocity in mechanical
radians/sec, and is the back-EMF constant in Vs/rad. Finally Ohms
Law: in the steady state
Ks = B * R^I Kb (7.3)
where is the supply voltage, RA is the armature resistance, and is the
combined voltage drop across both brushes. Many of the operational
characteristics of the DC commutator motor can be derived from these
equations, including the speed/torque characteristic and the variation of
current and voltage with speed and torque (see Chapters 1 and 5). For
the ideal DC motor,
kj = k 2 (7.4)
provided that hj. and are in consistent units (such as Nm/A and
Vs/rad). The basic energy conversion process is described by the
equation
7-3
D e sig n o f b ru sh less perm a n en t -m a g n et m o t o r s
Torque T
s
/ ^ E f f e c t of
( armature
Jq- reaction
0 /
Friction C, Current I
torque
Fig- 7.2 Errors in measurement of Jfcj. can arise from armature reaction and
friction
with units Vs/rad. At full speed, with no chopping, if the line-line back-
EMF waveform is trapezoidal with a flat top wider than 60, and if the
mean voltage drops in the transistors and the winding resistance are
small compared with the supply voltage, then
- Ks (7.7)
7-5
D esig n o f b ru sh less perm a nent -m a g n et m o t o r s
O n e phase
ph
7-6
7. K j-ANDK j .
where Pclcc has the same meaning as before, i.e. the electromechanical
power conversion. The ideal squarewave brushless DC motor thus has the
same basic energy-conversion equation as the DC commutator motor.
7.3.3 Two-phase squarewave brushless DC Motors
for the less common two-phase squarewave BDC motor the definitions
are similar and equations (7.6)-(7.10) can be used, except that the peak
line-line back-EMF e ^ is replaced by the peak phase back-EMF ph. In the
measurement of kE by the generator/rectifier test, only one phase of the
motor is used at a time, as in Fig. 7.36.
7.3.4 Two-phase sinewave brushless AC motors
The definitions of and fcp follow those given in Ref [1], Thus
(7.11)
with units V-s/rad, where ph is the peak phase voltage. This is measured
a
using capacitively-smoothed rectifier, as in Fig. 73b. If the back-EMF
waveform is sinusoidal, I h can be measured with an oscilloscope
connected direcdy across tne phase terminals; alternatively, an RMS AC
voltmeter can be used, and the reading multiplied by / 2.
(7.12)
with units Nm/A, where i is the peak phase current during normal
operation with two phases, i should be measured with a current-sensor
that is connected lo measure the phase current direcdy and display it on
an oscilloscope.
With these definitions, for the ideal two-phase brushless sinewave motor
J cj - kE (7.13)
7-7
D esig n o f bru sh less perm a n en t -m a g n et m o t o r s
and
7^ -*/ 2 ^ ^ - Pclec (7.14)
E
where Pclcc is the electromechanical power conversion, as before. In the
ideal case also
^elec = (7-15)
where I is the mean currcnt from the DC supply.
The equations of the two-phase sinewave brushless motor, and its
definitions of and ftp, are virtually the same as those of the three-phase
squarewave motor and the commutator motor, even though the
waveforms and principle of operation are quite different: the nvo-phase
sinewave motor is a classical rotating-field synchronous machine, whereas
the other two motors are DC motors, one being mechanically
commutated, the other being electronically commutated.
7.3.5 Three-phase sinewave brushless AC motors
Ref. [1] does not discuss the definitions of i E and ftp for the three-phase
sinewave motor. In fact there are several different ways in which they can
be defined. The one chosen here is selected so that
(a) the method of measuring is the same as for the other
motors; and
(b) the equivalent of equation (7.5) is satisfied in the natural
form for the three-phase motor (see equation (7.19)).
Thus *E is defined by
4 = (7.16)
with units V-s/rad, and it is measured by the circuit shown in Fig. 7.3a,
exacdy as for the squarewave motor, ftj. is defined in exacdy the same way
as for the two-phase sinewave motor, that is,
JcT = I (7.17)
T /
7-8
7. Kj. AND Kg
^rjih units Nm/A, where t is the peak line current when the motor is
operating normally, and is measured in the same way as described for the
fvvro-phase motor. However, with these definitions
(7.18)
and
^ Su.t An* v/24* (7.19)
7-9
d e s ig n o f bru sh less perm a n en t -m a gnet m o t o r s
where the symbols a,b,c refer to the phase voltages and currents, and d
and q refer to the transformed voltage and currents in d,q axes. This
equation expresses the principle that the instantaneous power measured
by the obvious direct method of summing vi products should produce
the same result in either the abc or the dq reference frame. But this i&
only possible if the reference-frame transformations contain appropriate
factors such as 3/2. The particular value (/3/2) of die ratio between kT
and arises because we have chosen to measure the peak line-line EMF
and the peak line current, rather than the RMS phase values.
7.3.6 Summary
The following table summarizes the definitions of kj and developed
in this section.
At/* e 1 1 1 /3 /2
7-12
7. Kp AND Kj.
and if we substitute for from equation (7.26) we get
k, - \ k . (7.30)
3 air
which is exactly the same as equation (7.28), showing that ftp = for this
ideal motor. If there are a parallel paths, the expression for ftp is reduced
by the factor a. The corresponding waveforms of line-line EMF and
current are shown in Fig. 7.5. The equality of AE and ftp holds regardless
of the connection (wye or delta) or the number of parallel paths.
60 JL^L
T _L
= B \DL (7.34)
P
The actual winding produces an MMF distribution whose fundamental
component is the same as that of a concentrated winding having &wl jV)h
turns. This is equivalent to a sine-distribution of C\cos />0
conductors/radian where
c, -7T2-A ,,A r1*. <)
The other phase winding has an equivalent sine-distribution of
conductors sin pft. With currents * cos oz and * sin to* there is a
rotating ampere-conductor distribution
Cl /cos pB cos ai t + C J sin p 6 sin o> t
1 1 (7.36)
= C,/cos {p 8 - (i>/)
and the resulting torque is
7-14
7. KpANDKj.
T = ( /^ A ^ ,) ! = V- <738>
By comparison with equation (7.32), we see that fep and kF are identical.
If there are a parallel paths in the winding, the term in brackets in
equation (7.38) is divided by a.
With two phases, if the MMF waveform is oriented so that its axis is
orthogonal to that of the magnet flux waveform (i.e. if the current is
oriented in the q-axu), the internal power-factor angle between the
generated EMF phasor E and the current phasor I is zero and
r o m = k, /x j k = h S i- 2 (7-39)
as in equation (7.14).
7.4.3 Three-phase sinewave brushless A C motors
In Che three-phase motor, assuming balanced sinusoidal operation and
wye connection,
7-15
D e sic n o f b r u sh less perm a n en t -m a gnet m o t o r s
7-16
8. THE BACK-EMF WAVEFORM
S,L INTRODUCTION
"This chapter is concerned with methods for the rapid calculation of the
back-EMF waveform, including the methods used in the design program
pC-BDC (see Chapter 13 and Ref. [1]). A good estimate of the back-EMF
vaveform is required for two main reasons. In the first place, it is an
important indicator of the ability of the motor to produce smooth
torque. Squarewave motors need a back-EMF waveform that is essentially
flat throughout the commutation zone, while sinewave motors require
essentially sinusoidal back-EMF waveforms. In theory it is possible to
profile the current waveform by chopping so that smooth torque is
produced with any back-EMF waveform, but this requires sophisticated
electronics and is only occasionally proposed in practice [2]. Most of the
time, designers aim to get the back-EMF waveform as close as possible to
the trapezoidal or sinusoidal norms, within reasonable limits imposed by
manufacturing constraints.
The second reason for requiring a good estimate of the back-EMF
waveform is for accurate simulation of the motor operating with its
controller, and for the determination of the current waveform and the
correct control strategy.
We have seen in Chapter 7 that the usual formula for the peak line-line
back-EMF of a 3-phase, wye-connected squarewave brushless DC motor
operating with "two phases on" is
^LL = ^EWra
where is the back-EMF constant given by equation (7.28). These
formulas give no information about the EMF waveform, which is generally
assumed to be trapezoidal or sinusoidal. However, when the designer is
making basic choices about the slot number, pole arc, slot opening, coil
pitch, and other dimensions, he or she may have no a priori rules which
guarantee that the back-EMF waveform will have an acceptable shape. It
is therefore desirable to have a quick means of calculating it, with all the
key dimensions and parameters taken into account.
The calculation of the whole back-EMF waveform is inevitably more
complicated than the calculation of ftE or hj, because the values of these
8-1
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
constants depend only on the total flux, and when they are calculated ft
is usually assumed that the EMF waveform is of the correct shape.
However, we have already seen in Chapter 3 that when the basic choices
of slot number, pole number, pole arc, coil span, etc., are being made,
there are no a priori rules which guarantee the correct EMF waveshape.
The process of selecting the correct values of these parameters needs to
include a visual inspection and perhaps also a harmonic analysis of the
EMF waveshape for each trial design. This requires a computer program
because the number of variations is far too large to be comfortably
handled by manual calculation and graph-plotting. Moreover, the
influence of fringing is very' difficult to calculate by hand. Even though
methods exist, such as conformal transformation, a computer is still
required to perform the numerical computation of the results, and to
work through the variations of key parameters such as magnet length,
slot opening, skew, and other factors.
Methods for calculating the back-EMF waveform can be classified into
analytical and numerical methods. The main analytical methods are (1)
the lumped-parameter reluctance-network (magnetic equivalent circuit);
(2) conformal transformation; and (3) analytical solution of Laplace's
equation. The main numerical methods are (1) the finite-element
method and (2) the boundary-element method, both of which are
available in well-developed computer software packages.
What is easily overlooked is the amount of numerical calculation involved
in design, which is an iterative process involving typically dozens or
hundreds of parameters, all of which have to be varied over quite wirir
ranges and finally fine-tuned to get an "optimal" design or an acceptable
compromise. Not all of these are electrical or magnetic: they include
thermal and mechanical parameters and calculations. Much of the
current research and development in motors is overly concerned with the
use of ever more sophisticated techniques to analyse one particular design:
this is especially characteristic of publications relating to the iinite-
element method. But the finite-element method is orders of magnitude too
slaw and expensive for use in normal design work. For the present, and
probably for some time to come, design calculations will be found to be
more productive and more efficient when they are based on analytical
methods which are much faster, even though they may be less accurate.
The proper use for finite-element analysis is the checking and refinem ent
of designs, or the analysis of problems that are simply too difficult for
analytical techniques.
8-2
8. T h e Back -EM F W aveform
f\ n elegant and effective example of the application of computerized
analytical methods to the EMF waveform calculation is the work of Boules
[3,4]. Boules method is based on the representation of the magnets by
equivalent current-sheets, using a formulation that dates back to Hague
[5|. Unfortunately the technique does not account for the effects of slot-
opening geometry or skew, and it is limited in the rotor configurations
which can be dealt with. Yet several current designs of commercial
importance use a small number of slots per pole (including fractional
values such as 1.5), and many brushless motors are skewed, either in the
stator or in the magnets. On the other hand, Boules method is ideal for
analysing slotless motors (Chapter 5).
The finite-element method is possibly the most powerful tool for
analysing the effects of slotting, as has been demonstrated in the
extensive papers of Demcrdash and his colleagues [6 ]; but it is too
cumbersome for the present purposes, where virtually instant results are
called for, and it is arguable whether it is yet a practical tool for
modelling the effects of skew.
Most authors have treated the back-EMF calculation and the core-loss
calculation as completely separate exercises, without mentioning the fact
[hat in a comprehensive design theory the two calculations must be
absolutely consistent with each other. Ref. [7] combines both analytical
and finite-element models of the EMF waveform and iron losses in
brushless machines, and goes some way towards answering this criticism.
In this and the next chapter it is shown how the core-loss calculation can
be made consistent with the EMF waveform calculation, when both are
based on the tooth Jlux waveform.
The theory in this and the next chapter is based on relatively simple
magnetic field computations modified by smoothing or fringing functions
which, in the PC-BDC computer program, may be adjusted or turned on
or off at will, giving physical insight into the effects of the design and
layout of the slots, magnets, and windings on the back-EMF waveform,
core losses, and performance. The fringing functions are simple
analytical functions, based on only a few points on the waveform.
This chapter describes the back-EMF calculation by three alternative
procedures, indicating their appropriateness for different situations. The
simplest is the "BLV" method, which is the most widely used. A discussion
of its limitations leads to two methods based on the tooth-flux waveform,
8-3
D esign o f bru sh less perm a nent -m a cn et m o t o r s
and this provides the necessary link with the core loss calculation in the
next chapter.
8-4
8. T h e B ack -EM F W aveform
vfhere V= rtom is the linear velocity at the stator bore and and are
die flux-densities at 0j and 02 respecdvely. In a full-pitch coil, further
simplification results from the fact that B^ = -B^, giving e = 2 BLV.
In the "BLV method 5(0) is the static magnet flux distribution around
the airgap, unmodulated by slotting. According to the "BLV" method the
EMF waveform in a full-pitch coil has the same shape as the unmodulat
ed airgap flux-density distribution. In a surface-magnet motor this has the
form shown in Fig. 8.1.
8-5
D esig n o f bru sh less perm a n en t -m a g n et m o t o r s
( 8.10)
g /r>
where Lm is the magnet length and |J.rcc is its relative recoil permeability.
This formula, which was proposed by Dr. R Rabinovici [8], has its roots
in Hagues analysis of the unslotted motor with L^ = 0 [5], and is found
to give good results in practice (see below). The total width of the fringe
zone on each side of the magnet is taken to be fa = 7a, a range which
encompasses 97% of the exponential transition. The significance of the
product term in equation (8.10) is that fringing vanishes if either g or
(Lm + g) is zero; both of these conditions agree with physical intuition.
The N and S magnet poles are treated independently according to
equations ( 8.8) and (8.9), and the resulting EMF waveforms are added.
If the magnet arc is very narrow, the fringing function from the left can
overlap with the one from the right. In the overlap region the resultant
is taken to be
y = i - y% - yr (8-n )
where y2 is the fringing function from the left and y3 is the one from the
right. The justification for this is explained in Fig. 8.2. A narrow magnet
g,4 Skew
A skewed magnet can be considered as being made up of many small
magnets arranged as in Fig. 8.3. The flux 4>T passing through the whole
axial length of one tooth is nearly the same as if this array of magnets
was replaced by a stack of thin sheet-magnets, each having the full length
/.in the axial direction, but with graded arcs. The combined strength of
the sheet magnets is such as to produce the same airgap flux distribution
as the actual magnet.
If the fringing functions of equations (8.8) and (8.9) are applied
individually to each sheet magnet, while their thicknesses are allowed to
decrease to an infinitesimal value, the total effect can be obtained by
integrating the field contributions of the sheet-magnets over the range
-o/2 to o/2, where o is the skew angle as shown in Figs. 8.3 and 8.4. If
the contribution of one infinitesimally thin sheet-magnet to the total flux
distribution is dB = (Bpk/o)d0j, then in region 1 of Fig. 8.4 the total is
given by the integral over all the sheet magnets, i.e.,
and in region 3 as
B^B) - q, k{ " 7 ~ (8.14)
8-7
D e sig n o f b r u s h le s s p e rm a n e n t-m a g n e t m o t o r s
L L
8.5 S lo ttin g
Slotting causes difficulties with the "BLV method. It is not obvious how
the EMFs in conductors located in slots are related to the EMFs in
filaments on the bore of the unslotted stator. Moreover, slotting
modulates the airgap flux-distribution ij(0) at the stator bore, Fig. 8.5.
The modulating function is fixed to the stator while the fundamental flux
rotates with the rotor: the 5(0) waveshape changes as the rotor rotates,
and H and 0 in equation (8.5) are not simply related to each other.
Evaluation of e therefore requires the prior evaluation of the flux-linkage
integral as a function i|r(E) that can subsequendy be differentiated with
respect to
8-9
D esig n o f bru sh less perm a nent -m a g n et m o t o r s
such a building process is based on the full-pitched coil, i.e., 10 j - 02|
7T electrical radians, but not all windings can be decomposed into full,
pitch coils. A better choice is the single-tooth coil, which has the
following advantages:
1. It is more general in the sense that any winding can be
"decomposed" into an electrically-equivalent series of single-tooth
coils. Some motors are in fact wound with single-tooth coils.
2. The tooth flux-density is approximately proportional to the flux
<f>T linking a single-tooth coil, and its waveform can be used to
compute the core losses in the teeth more rigorously than with
conventional core-loss formulas.
3. The flux waveform <J)y in any yoke section can be reconstructed
from the tooth-flux waveforms. This can be used to compute the
core losses in the yoke, and it is also useful as an indicator of
cogging torque.
4. Single-tooth search coils are convenient for measurement, and
they can often be fitted after the stator is wound. It is more
difficult to fit full-pitch search coils particularly if they have several
turns.
5. Analysis based on the single-tooth coil is particularly useful
when considering stator saturation conditions with the machine
loaded.
Notwithstanding its limitations, the "BLV" method is often satisfactory
particularly if the slot openings are narrow. It has the advantage of being
simple and fast. Although not every phase winding can be decomposed
into full-pitch coils, the total phase EMF can be reconstructed from the
totality of conductor EMFs.1 It can also deal with skewing if the airgap
flux-density waveform is modulated according to equations (8.12-8.14).
1Because the fringing flux enters the sides of the teeth the effective slot openings are
considerably narrower than the actual ones. This effect is probably more pronounced in
surface-magnet PM motors than conventional nanow-gap machines because of the larg
effective airgap through the magnet.
8-10
8. T h e B ack -EM F W aveform
8.6 Calculating back-EMF from Tooth Flux
8.6.1 Single-looth flux and EMF
The single-tooth EMF is the back-EMF in a coil wound around one
tooth, and is given directly by Faradays Law:
e. = (8.15)
^ dt m^
where <j>T is the tooth flux due to the magnet (with no current flowing
in the stator), and (i)m is the angular velocity in mechanical rad/s. In
terms of the tooth flux-density, is given by
e, - (8.16)
where B j is the flux-density averaged over the effective tooth area Ar and
f; is the rotor position, is the tooth width; and ks is the lamination
stacking factor. In this analysis, variations of flux-density across the tooth-
width are ignored, and the flux through the tooth Is assumed to vary only
as a result of the rotation of the magnet.
As the edge of the magnet sweeps across the tooth surface, the tooth flux
<j>T varies as shown in Figs. 8.6 and 8.7.
Fig. 8.7 shows the idealised variation of <J>T with no fringing or skew. It
is easier to understand if the magnet is considered fixed while the tooth
sweeps across it from position 1 through position 5. At position 1 the
tooth flux is zero. It reaches its maximum value aT radians later at
position 2, where the whole tooth overlaps the magnet. After that, from
position 2 through position 4, there is no variation in the tooth flux.
Finally, between position 4 and position 5 the tooth flux falls to zero.
Because of the fringing at the edges of the magnet, the "transition angle"
between zero and maximum values of <}>,. is wider than the actual tooth
arc. It is as though the tooth arc a T were augmented to a larger value
a-pp. The transition essentially takes place over the augmented tooth arc
ar r In Fig. 8.6 the augmented tooth arc would be nearly equal to the
slot pitch. This supports the assumption on which the "BLV" method
depends, namely that the slot openings are negligible; however, the slot
openings in Fig. 8.6 are relatively narrow. The maximum tooth flux is
S-ll
D esig n o f bru sh less perm a n en t -m a g n et m o t o r s
clearly gathered from the augmented rather than the actual tooth arc.
A possible formula for augmenting the tooth arc is
rr = ys - K wo (8-17)
where is the augmented tooth arc, yt is the slot pitch, and is the
slot opening (all in electrical radians). The Carter coefficient kQ is
obtained as a function of the ratio w0/g-from Carters graph [9]. For the
surface-magnet PM motor, we replace g by the effective airgap g +
V ^ re c
The tooth EMF is the derivative of the <t>T waveform in Fig. 8.7, and
the idealised trapezoidal <j)T waveform therefore produces rectangular
pulses of back-EMF. The next two sections describe two alternative means
for determining the <t>T and waveforms.
8-12
8. T h e B ack -EM F W aveform
Fig- 8.7 Accumulation of tooth flux as the rotor rotates. The back-EMF waveform is the
derivative of the tooth-flux waveform
8-13
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
C tfC V A / A N i m F a T O O TH T2
L2
0<rr MAGNET
o Li v l-c - -
(a) Low skew (b) High skew
Fig. 8.8 Tooth flux accumulation with skew, (a) Low skew (b) High skew
The ffj. waveform as described hitherto is the result of one edge of one
magnet passing one edge of the tooth. The other edge of the magnet
passing the other edge of the tooth produces another EMF pulse whose
edge is shown dotted and inverted in Fig. 8.10. Where these waveforms
overlap, they should be added together, producing the resultant eTS (for
the south magnet pole) which passes through zero as shown. A similar
image exists, folded about n, and the same addition must be performed
with it.
The north magnet produces an EMF pulse ,?TN identical to that of the
souLh magnet, but displaced symmetrically about the angle n / 2 and
shown in Fig. 8-10 as The total tooth EMF is given by
^TS + ^TN' ( 8 .20)
The overlap between EMF pulses coincides with the region of minimum
tooth flux, implying that the superposition is valid even though the tooth
may be saturated at other rotor positions.
8-15
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a c n e t m o t o r s
RESULTING WAVEFORM ;
FROM S MAGNET
LEADING
EDGE
TRAIUNG
EDGE
BTp is the peak flux-density in the tooth when it is aligned with a magnet
axis. The use of the waveform functions means, of course, that this
magnetic field calculation is performed at only one rotor position an
important factor in the overall economy of the method. The correct
value of the phase EMF, and in particular its peak value, depends on an
accurate calculation of the peak value of Bj. The quickest method for
this is a nonlinear reluctance network in which the teeth, yoke, magnet,
and airgap are modelled as series elements, with appropriate allowances
for magnet leakage flux, as described in Chapter 4. Alternatively, the
magnet can be represented by an equivalent surface-current distribution
provided that its relative recoil permeability is close to unity. Of course,
8-16
8. T h e B ack -E M F W a v efo r m
finite elements can also be used to calculate Bj accurately but with a
little more effort.
S m agnet 2s Jl___i[
3S j l Z j v
"U Lf3N
4S_n__ n_
u U"4N
5S_n__ n_
U L f5 N
6 s_n___ n
U U" 6N
7S_n__ n.
U Lf 7N
8S j i ___ n_
u LT0 N
9S j i __ n_
U----- LT 9N
d im m
SMOOTH WAVEFORM
WITH FRINGING
Full-pitch coll EMF
Coll-pltch = 9 Blots
7a = / i " 0i ' 02 - - - 0*
Adding equations (8.24),
Yi + (Si - 0i) + Oi - 0i - 0j) + - (8.25)
+ (Ti " 0i - 02 " - - <f>t) = 0
fro m w hich
8-18
8. T h e B ack -EM F W aveform
y \ = 4> ( * - i) * j- (8 -26)
" j=l
This means that the yoke flux in any section can be constructed as a
weighted sum of all the tooth fluxes. If the number of slots per pole-pair
is even, the expression simplifies to
*2
A - \ Ej=i *i- (8-27>
Each & is a complete waveform and the summation must be executed
iamplc:by-sample. An example of this construction is shown in Fig. 8.12
for a motor with 12 slots. If the number of slots/pole is non-integral, the
yoke flux waveform becomes irregular.
References
Miller TJE, Staton DA and McCilp MI [1993] High-tpeed PC-Based CAD for motor
drives, 5th European Conference on Power Electronics and Applications, EPE9S,
Brighton, 13-16 September 1993.
Ackermann B, Janssen JHH, Soltek R and van Steen RI [1992] New technique, for
reducing cogging torque in a dais of krushJes* DC. motor*, IEE Proceedings 139, No. 4,
315-320.
Boules N [1985] Prediction of no-load flux density distribution in permanent magnet
machine*, IEEE Transactions, Vol. IA-21, No. 4, May/June 1985, pp. 633-643.
8-19
D esig n o f bru sh less perm a n en t -m a g n et m o t o r s
&-20
9. CORE LOSSES
9J INTRODUCTION
After copper losses, core losses are generally the second largest
component of power loss or inefficiency in the brushless motor, although
their significance may become overriding at very high speeds. They arise
from the variation of magnetic flux-density throughout the core,
particularly the stator core. This variation incurs hysteresis and eddy-current
losses, (Chapter 16). Briefly summarizing, the hysteresis loss results from
the "unwillingness" of the steel to change its magnetic state, and as the
flux-density varies cyclically the magnetic state describes a locus in the
B/H diagram: the energy loss per cycle is proportional to the enclosed
area, so the average power loss due to hysteresis is proportional to the
frequency of the variation in the magnetic field. Eddy-current loss is also
caused by variations in flux-density, which induce current to flow in the
jtator steel at the same frequency as the variation in the magnetic field.
The EMF which drives these currents is proportional to the peak
magnetic field and to the frequency of variation, but the power loss is
proportional to the square of the EMF and therefore also varies with the
square of the peak flux-density and the frequency. Eddy-current losses
can be reduced by using thinner lamination steels. This is because the
EMF's which drive them are usually in a direction perpendicular to the
plane of the punching. Lamination lengthens the return path for these
currents by forcing them into the circumferential direction, increasing
the resistance. Provided that the frequency is low enough, this causes a
reduction in current and since the power loss is notionally of the form
the reduction in J 2 overwhelms the increase in R and the power loss
is reduced.
In traditional AC machine theory the core loss is viewed as being caused
mainly by the fundamental-frequency variation of the magnetic field at
50 or 60Hz, and this variation is essentially sinusoidal because the supply
is usually a low-impedance utility voltage source. Accordingly the
characterization of core losses in electrical steels has been developed over
the years in terms of Watts per lb or Watts per kg, typically quoted at a
peak flux-density of 1.5T. In brushless motors this fundamental-frequency
lunation is still present, but only in sinewave motors is it even
ipproximately sinusoidal. Most brushless motors, including sinewave
motors, are fed from switched DC sources with pulse-width modulation of
the switches. This means that the applied voltage, and therefore the flux,
9-1
D esig n o f b ru sh less perm a nent -m a g n et m o t o r s
contains many harmonics which may reach frequencies of several tens of
kHz. Although the harmonic components of flux-density are small, they
produce additional core losses over and above the fundamental-frequency
component.
The magnetic field variation in the stator teeth and yoke is primarily due
to the rotation of the magnetized rotor. The time waveshape of the flux-
density in the teeth and yoke is closely related to the space waveshape of
the airgap flux distribution, whose harmonics induce additional core
losses.
A difficulty in the calculation of core losses is that the magnetic flux-
density not only varies in time but also varies widely between different
points in the stator punching. The simplest approach distinguishes two
flux-densities, one for the teeth and one for the yoke, and finer
distinctions are ignored. This makes it possible to obtain manageable
core-loss formulas which include the influence of the main dimensions,
the level of excitation, and the frequency.
Recent attention has been given in the literature to the calculation of
core losses. Bertotti [1] and Slemon [2] recognized the importance of
high-frequency flux pulsations in various parts of the magnetic circuit,
and modified the Steinmetz equation (see below) to accommodate non-
sinusoidal flux waveforms. Bertotti [2] applied the finite-element method
over a range of rotor positions of an induction motor to determine the
flux-density waveforms, subsequendy decomposing these waveforms into
harmonic series and computing the loss components harmonic-by-
harmonic, with various modifications to the material coefficients. Ilowe
[3] reported a similar procedure for the brushless DC motor.
A more direct approach was taken by Slemon [2], who expressed the
basic core-loss equation in terms of the rate of change of flux-density
dB/dt instead of the frequency, and he calculated this rate of change in
the teeth and yoke, assuming idealised waveforms of flux-density in these
sections. A similar procedure has been used in the PCSRD and Pf'cBDC.
computer programs for several years (4,5]. This "waveform" method
produces elegant and simple formulas from which the influence of major
dimensions and parameters can be readily seen.
Most works on core-loss calculation treat the back-EMF calculation and
the core-loss calculation as completely separate exercises, and do noi
9-2
9. C o r e L osses
mention the fact that in a comprehensive design theory the two
calculations must be absolutely consistent with each other. The approach
follow ed here is strictly consistent with the EMF calculation methods
outlined in the previous chapter.
TOOTH
MAGNET
Nl I TS 11.
Tp
r0 - B,
r
0
*
J
(a) w
Fig. 9.1 Toolh flux waveforms for calculation of core Iom
depending on the relative values of the tooth arc aT and the gap
between the magnets With trapezoidal transition shown in Fig
9.1a or 9.1 b ( a ^ s n - PM), the specific eddy-current loss is
For the stator yoke, with the waveform shown in Fig. 9.2 the eddy-current
loss is
8
[W/kg] (93)
v Pm
where Byp is the peak yoke flux-density.
In reality the tooth- and yoke-flux waveforms are not perfecdy trape-
94
9. C o r e L o sses
Stator Yoke
180
Pig. 9.2 Yolce flux waveforms for calculation of core loss
zoidal, but have rounded corners. For the tooth-flux the effective
transition angle is much closer to the augmented tooth arc (equation
(8.17)) than to the actual tooth arc a T, and is used in equations
(9.3) and (9.4). The augmentation of the tooth arc tends to decrease the
specific eddy-current loss.
where Aj. is the cross-section of the tooth (allowing for the stacking
factor of the laminations), and is the angular position of the rotor.
Substituting in equation (8.15),
(9.7)
dt a t
and therefore the RMS value of the j- waveform can be directly used as
it is proportional to the RMS value of dB/dl Equation (9.7) is an
important link between the EMF calculation method and the core-loss
calculation method.
9-5
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
so that
<30y 0r(O (9-9)
~dt
and therefore the RMS value of ey can be used in the calculation of the
yoke eddy-current losses. ey is the EMF waveform of a single-turn search
coil wound around the yoke. The RMS value can be extracted from the
waveform using the standard formula for RMS value:
^RMS (9.10)
\
where 5 is the rotor angle in electrical radians. If the waveform eft) or
e(l) is available as a set of N samples e}, covering a completed
period of 2it electrical radians, the integral in equation (9.10) becomes
a sum and
jv
(9.11)
Kig, 9.3 Augmentation of tooth weight with triangle* representing the transition zone
between tooth flux and yoke flux
fig. 9.4 Augmentation of tooth weight viewed over the entire machine crow-section
The weights of the triangles can amount to a 50% increase in the
effective weight of the teeth, Fig. 9.4, and a corresponding increase in
the total computed tooth core-losses. This tends to compensate for any
dif ference between the waveform method in the specific loss calculation.
9-7
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
References
1. Bcrtotti G, Boglictti A, Chiampi M, Chiarabaglio D, Fiorillo F and Lazzari M [1991]
An improved estimation of iron (tun m electrical machines, IEEE Transaction* on
Magnetics, Vol. 27, No. 6, November 1991, pp. 5007-5009,
2- Slemon GR and Liu X [1990] Core loots in permanent magnet motor*, IEEE
Transactions on Magnetics, Vol. 26, No. 5, September 1990, pp. 1653-1655.
3. Atallah K, Zhu ZQ, and Howe D [1992] The prediction of iron losses in brushless
permanent magnet DC, motors, International Conference on Elcctrical Machines,
ICEM92, Manchester, 15-17 September 1992, pp. 814-818,
4. Miller TJE and McGilp M [1991 ] High-speed PC-based CAD for brushless motor drives,
4th European Conference on Power Electronics and Applications, EPE 91,
Florence, $-6 September 1991, pp. 435-439.
5. Miller TJE and Rabinovici R [1994] Back-EMF waveforms and core losses fn brushless
DC motors, IEE Proceedings 141B, pp. 144-154
9-8
10. ELECTRONIC COMMUTATION
OF SQUAREWAVE MOTORS
10.1 Introduction
This chapter describes the process of electronic commutation in
squarewave brushless DC motors and their controllers. It also describes
the differential equations used by the PC-BDC computer program for the
dynamic simulation of 3-phase squarewave brushless DC motors, with wye,
delta, and unipolar half-bridge connections. The commutation process
is important for detailed understanding of the switching of the power
transistors.
The equations include the freewheeling periods following each
commutation. The integration of the differential equations falls naturally
into "base intervals" of 60 or 120 electrical degrees between successive
commutations. The periodic current waveforms can be constructed from
a knowledge of the currents in one base interval, provided that the
system is in a steady state. The calculation of an isolated base interval
without iteration is possible only if the initial currents can be calculated
algebraically. This is possible at all but the highest speeds, and the
necessary formulas are developed together with the conditions under
which they apply. Many physical insights arise from this analysis into the
structure of the waveforms of the brushless DC motor. Although the
differential equations were developed specially for PC-BDC, which
integrates them using Eulers method, they could equally well be used as
externally-defined system equations in general-purpose simulation
packages.
The importance of a detailed model of the commutation process is
illustrated in the calculation of the no-load speed. Except under special
ideal conditions, this speed cannot always be calculated reliably for
brushless DC motors by means of the simple back-EMF constant used
with DC commutator motors, because the back-EMF waveform may not
be perfectly flat and the supply voltage may be chopped to a lower
effective value than the nominal value. Computer simulation is used to
determine the no-load speed accurately, and the difference between the
no-load speed for motoring and the no-load speed for generating is
discussed.
The quest for computational speed and memory-efficiency places certain
10-1
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
10-2
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
For both wye and delta connections, Figs. 10.3 and 10.4 reveal that the
waveforms repeat every 60 electrical degrees, with each 60 segment
being "commutated" to another phase. For example, in Fig. 10.3 the
10-3
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
10-4
10. E l e c t r o n ic C o m m u t a t io n o f squarew ave M otors
-30 0 30 60 90 120 150 180 210 240 270 300 330 0 lec
'SP Lin<3
I\
'A Cur rents
/
y
\
f
'B
'C
\
Ph ase
ENIFs
/
e1
' /
>
f
e2
1
Unis-Lin e
EM
e12 1
<D
CM
= e 1~
Q5 Q1 Q3 Q5
Q6 I Q2 I Q4
10-5
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
-----------------------
PHASE
PHASE
61 EMF
EMFxv
------------------------------------------------
X
2/3*1
2/3 * leo
SP
1 / 3 * ls
spp / ,SP -----------------------------
.3 ------ iJ.-----
f f
Q5 Q1 Q3 Qi
06 02 Q4
10-6
10. E lectronic Com mutation o f Squarewave M otors
10.3 Circuit Equations - Wye
10.3.1 Commutation
Commutation is initiated by a switching event and is characterized by the
currents in two separate meshes. Following the switching event, one of
these currents builds up from zero and the other one decays towards
zero. The switching event taken as the initiator of the "base" interval is
the turn-off of Q5 and the simultaneous tum-on of Q l. In Fig. 10.3 this
interval is from 30 to 90. The two mesh currents are as shown in the
top-left diagrams of Figs. 10.5 and 10.6 respectively. Fig. 10.5 shows the
current building up through Ql and Q6 in phases 1 and 2 (lines A and
B). Fig. 10.6 shows the current freew heeling through diode D2 and
transistor Q6 in phases 3 and 2 (lines C and B). Ideally the (negative)
current in line B should remain constant, while the line C current falls
to zero and the line A current builds up to the set-point value.
(a) Building (b) Q1 chopped
10-7
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a c n e t m o t o r s
(a) Freewheeling (b) Q1 chopped
Fig. 10.6 "Freewheel" mesh during commutation and chopping - wye connection
The currents in the corresponding diagrams a,b,..d in Figs. 10.5 and 10.6
are flowing simultaneously. The reason for having two separate diagrams
is to associate them clearly with their respective mesh-voltage equations.
It is assumed, initially, that the set-point current /sp is flowing through
phases 3 and 2 in series, so that ig = / and ^ = - / . All branches of the
circuit are inductive, so that when Q5 switches off the current in line G
continues to flow, causing diode D2 to become forward-biassed, clamping
the positive terminal of phase 3 to the negative rail. At the same time,
although Q l is on, the current in line A is initially zero. The positive
terminal of phase 1 is held at +V^. The potential of the negative terminal
of phase 1 is not known, but it is normally at a potential lower than +VS,
so the current ij begins to rise. In a similar way, the voltage across phase
3 is normally negative and therefore begins to decay.
10-8
10. E l e c t r o n ic C o m m u t a t io n o f Sq u a r e w a v e M otors
'The process continues until ^ = 0 , at which point it remains zero
because D2 switches off and there is no conduction path in line C. There
is then only one mesh for current to flow, i.e., the loop through phases
1 and 2. This current continues to rise until it is limited by the chopping
action of the current-regulator, which turns transistor Q1 (or Q6) on/off
to maintain the current at the set-point value /Jp. If there is insufficient
voltage for the current to reach 7 , then it is limited instead by the
resistances, inductances, and back-EMFs of phases 1 and 2 in series. This
condition tends to arise at high speed.
10,3.2 Period A and Period B
Period A is the initial freewheeling period, just after switching, when
both mesh currents are non-zero. During Period A, all three lines are
conducting. The subsequent period when only phases 1 and 2 are
conducting is called Period B. Period B begins when the freewheeling
mesh current extinguishes. During Period A, ^ is decaying and i, is
increasing. Ideally di^/dt = - di^/dt so that ^ remains constant. It is
shown in Fig. 10.7, which also shows the reverse recovery of D2. Any
inductance in line C (including motor inductance) multiplies the di/dt
of the reverse-recovery current in D2 to produce a positive voltage spike
across Q5 (not analyzed here).
PERIOD A
PERIOD B
Isp
10-9
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
or
10-10
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
If Ql is chopped at a very high frequency then Sqj can be set equal to
the duty-cycle (mark/period ratio) of Ql, and in this case yb)d can be
interpreted as the average voltage across the terminals AB. (This is the
principle of state-space averaging).
The state-space average value is useful in algebraic calculations of the
steady-state currents; in this case Sq j will have a fractional real value. But
the same formulas for ^bld and can be used in digital simulation,
where Jqj is the actual state of the chopping switch; in this case Jqj has
a binary value (on or off).
Similar equations result if Q6 is chopped instead of Ql: the result is
^wh = + V i + Kd>+ a - + 2 ^ )- (1 0 n )
When the line A current is building up there is no difference between
chopping Ql and chopping Q6. However, chopping Q6 will accelerate
the decay of the freewheeling current in line C by connecting the supply
voltage against the flow of freewheeling current during the periods when
Q6 is off.
10.3.5 Euler form of voltage equations (wye connection)
In the wye connection
h + h. 4 h ~ 0 (10.12)
and therefore
Px* P i* Pi = 0. (10.13)
10-11
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
gj + + (L - A/)A (10.15)
(10.16)
It is now a matter of algebra to solve equations (10.14-16) for the
derivatives fa, p%, and py the result is
(10.17)
3 L>
~ J'fwh + 13R ~ L 'P \ (10.18)
1 2L
Pi = - Pi ~Pi (10.19)
where
enx ~ + + h) ( 10.20)
~ % ~ ~ i + 2yj)
r ( 10 .21 )
L = L - M, ( 10.22)
To find the final values ijF, ^ F, and ^ F, assume that by the end of Period
B the line current iy = has arrived in the hysteresis-band of the
current-regulator, and that this band is a very small percentage of /s ; see
Fig. 10.7. The current tj is essentially a DC value. rHiis is possible only if
the duty-cycle of the chopping transistor Ql is less than 1. From equation
(10.25), with py = 0 (steady-state DC),
. Hid ~ (ei ~ 5 ) (10.29)
1 2R
If we set iy = I (the set-point value) then the duty-cycle of Q l can be
calculated from equations (10.8) and (10.29) as
= gi - H * 2 RIsV + VA * \ + ^ / s p (10.30)
K ~ K + V, - Rq I
10-13
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
If this expression gives Jqj < 1, then the initial conditions can be
assigned from
7IS = 0 (10.31)
4s 4p (10.52)
^3S = V (10.33)
If, on the other hand,turns out greater than 1, it means that there
is insufficient voltage to drive the current up to the set-point value of the
regulator. This can mean one of two things. Either the set-point current
is greater than the resistance-limited DC value of the current at the end
of the 60 interval. Or, the current is never reaching a steady state within
the 60 interval. In the first case the final steady-state DC value can be
calculated as
J \r = Vs ~ 2 *q - (C[ " (10.34)
,F 2(R + R J
with = 1, (The current-regulator will be saturated in this case and Ql
will remain on for the entire 60 interval). The second case can arise at
high speed. Unfortunately there is no way thefinal current can be calculated
analytically. What is done instead is to run a trial 60 integration with the
initial conditions calculated by equations (10.31-33) or (10.34), and then
test the final values, suitably "commutated", to see if they match the
starting values. If they do not, then the final values from the integration
are "commutated" into the starting values and a second 60 integration
is run. The procedure is repeated until the final values and starting
values converge to within a predefined tolerance.
When Q6 is the chopping transistor, the equations are identical except
that .?Qt is replaced by Jq 6 in equation (10.30).
10-14
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
** Is p /3
Fig. 10.8 Condition of ciclta-conncctcd circuit jujt before commutation of Q5/Q1
that the current 7sp is flowing in line C: that is, V through phases 3
and 1 in series, and 2/,p/3 in the reverse direction through phase 2, so
3
that i, = i, = 7sp/3 and i> = -2/jp/3.
The 2:1 ratio between the currents in the two parallel branches of the
delta is intuitively clear if it assumed that the currents are resistance-
limited while the sum of the EMFs e-y+e^ = -e^. This EMF condition is
satisfied by the EMF waveforms in Fig. 10.4, but it is not always the case
because it depends on having the correct magnet pole-arc and coil pitch.
(See Chapter 5). When the current is being regulated (chopped) by Q1
to a value within the hysteresis-band around J , the 2:1 division may not
be obvious, but is proved below.
AU branches of the circuit are inductive, so that when Q5 switches off the
current in line C continues to flow, causing diode D2 to become forward-
biassed, exactly as in the wye circuit This clamps the positive terminal of
phase 3 close to the negative rail, as shown in the freewheeling circuit
diagrams of Fig. 10.10. At the same time, although Q1 is on, the current
in line A is initially zero. The positive terminal of phase 1 is held at
+Vt~Vd. The negative terminal of phase 1 is held close to zero by Q6, so
that normally the current tj begins to rise. The circuit condition is shown
10-15
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
in Fig. 10.9a. Note that there is as yet no current in line A, even though
Ql is on.
(a) Main conduction mode (b) Q1 chopped
Fig. 10.9 "Build" meih during commutation and chopping - delta connection
By similar reasoning the voltage across phase 2 is close to zero, and the
current in phase 2 therefore freewheels. The voltage across phase 3 is
~(VS-Vd) initially, and the current jg begins to decay. The freewheeling
mesh is shown in Fig. 10.10a. This process continues until Iq reaches
zero, at which point D2 switches off and begins to increase in the
opposite (negative) direction. There is now no conduction path in line
C. There is only one loop for current to flow through the converter, that
is, the loop through Ql and Q6, assuming that both transistors remain
on. The current in this loop divides between the two parallel branches
in the delta-connected motor, and eventually it is expected that a steady-
state will arise with ij = 2/sp/B and ig = ^ = - /sp/3, before the next
commutation. This final condition is shown in Fig. 10.9a.
10-16
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
e f hjri 4 >h
A
\ 4
l A ! > ) ' \ }
10-17
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
10-18
10. E le c t r o n i c C om m utation o f Squarew ave M o to r s
Pi (10.41)
L" -
M"
Pi - ~ M '* * Rn ] (10.42)
I" (10.44)
II
M" (10.45)
*
U
*fwh - l) (10.48)
^ L (
(10.49)
Hig;
1
Jb
i
i
D.
z, fwh
10-19
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
In Period B there is only one active mesh, but this divides into two
parallel branches in the delta-connected motor. Accordingly there are
two differential equations. With D2 off,
4 = h, (10.50)
VUA = v\ = ei + R i\ + L P \ + 2 M Pi< (10.51)
and
= ~r2 ~v3
Kbld (10.52)
= - ( V ^ ) - ZOh+Jb) -
Solving these equations for p\ and p%, we get
ks7 - *4 *
Pi =
81 1 l +M 2
(10.53)
, _ 2 A/2 1
L* M\
_ ["( ^bld + " 2 A//7t|
A 2(+A0
where
10-20
10. E l e c t r o n ic C o m m u t a t io n o f Sq u a r e w a v e M otors
(10.57)
(10.58)
To find the final values ijF, and i^y, again assume that by the end of
Period B the line current has arrived in the hysteresis-band of the
current-regulator, and that this band is a very small percentage of isp; see
Fig. 10.7. The current A is essentially a DC value, and can be regarded
as a DC source fed to the two parallel circuits of Fig. 10.11, from which
the following equations can be written down:
Hid ~ e i + R i A (10.59)
Hid = + **j) - ( 4 + (10.60)
Note that i,, ig and i$ have all been taken as positive when flowing away
from the line terminals A,B, and C respectively, as in the original circuit
diagram, Fig. 10.2. The line current iA is given by
ja = h h- (10.61)
Solving these equations for i1F and igF,
/IF - 2 ; -
3 A
+ % * *
3 /?
(10.62)
(10.63)
O o
PHASE 1
while
% - j ' . - \ h v <1 )
The current in the branch containing only one phase is thus twice the
current in the branch containing two phases. Since equations (10.62-66)
do not contain Vb1d> they are independent of the state of the chopping
transistor Q l and are valid for all values of duty-cycle including 1.
Equations (10.62) and (10.63) show that if the loop EMF e, + ^ + % is
not zero, the division of current between the phases of the delta is
disturbed from the ideal 2 /3 :l/3 ratio. In a severe case this can prevent
the motor from reaching the desired torque, and it may add considerably
to the losses.
Of course, the attainment of a steady DC line current at the end of
Period B is possible only if there is sufficient voltage, i.e., if Jqj s 1. For
a given value of iA (e.g., iK = /sp), the duty-cycle, Vqj can be calculated
directly from equations (10.37),(10.59) and (10.65) as
_ el * (2R/3 + # q)^.p Vd + Vq (10.67)
K - K, + t'd ^
If this expression gives Jqj < 1, the initial conditions can be assigned
from equations (10.56-58), with *j, ^ and ^ obtained from equations
(10.62-63). If, on the other hand, Sqj turns out greater than 1, it means
that there is insufficient voltage to arive the line current up to the set-
point value I . This can mean one of two things. Either the set-point is
greater than the resistance-limited DC value of the current at the end of
the 60 base interval. Or, the current is never reaching a steady state
within the 60 interval. In the first case the final steady-state DC value
can be calculated from the DC loop equations with ^ = ig :
10-22
10. E l e c t r o n i c C o m m u ta tio n o f S q u a re w a v e M o t o r s
* 2V 2 *qO\ ~ h) = + R l\ (10.68)
= - ( e j + ,) - 7Ri3
r j 3 + /?y,
2 + (e , + Cj + = o (10.69)
to which the solution is
(10.70)
10-23
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Building Freewheeling
Current Current
10-24
10. E lectronic Commutation o f Squarewave m o t o r s
' 7 T
Freewheeling
current
e1 , Phase 1 EMF
J
| 30 90 150
0 180
_ .... Current regulated
current^ y chopping
Freewheeling current
(May contain chopping ripple
coupled from other phases)
Fig. 10.13 Half-bridgc unipolar 3-phase waveforms
current at the set-point value 7jp) assuming that it ever reaches this level.
I f there is insufficient voltage for the current to reach /5p, then it is
limited instead by the combined effects of resistance, inductance, and
EMF. This condition tends to arise at high speed.
10.5.4 State-space averaged voltages
The "build" and freewheel voltages are defined by the connection
equations
Kbld = (1 0.72)
10-25
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
- v2. (10.73)
where v,, v^, are the voltages across phases 1,2,3 expressed by
equations (10.2-4).
Ql is the controlled (chopping) transistor, and
* *Q.[ k - yq - v ) + (i - v [- - v j; (10-74>
Kfwh = - <10-75)
* = L -1 M,.2 [L 4 - M yl ] (10765
* =ri
L -. *M1~MV'+ L V' ] * (10>77)
where
<= - R h\ (10-78)
r ' = - Vd - (JR * - e, (10.79)
These equations hold until i^ reaches zero. Then the freewheeling period
A terminates. In the following period B only phase 1 conducts. The
controlling equation is:
/>. = 3 <10-80)
10-26
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
(10.81)
(10.82)
*Q I = vs- V H +( 4 r 4 , H p
Jqj cannot take a value greater than 1. If equation (10.82) gives a value
greater than 1, the regulator will be saturated with Jqj = 1, and i1F will
be given by equation (10.81) with Jqj = 1:
10.6 Over-running
Another conduction mode which occurs in all of the circuit configura
tions is the regeneration mode, when the generated line-line EMF
exceeds the supply voltage. In this case the current may flow in the
reverse direction back to the supply, as shown in Figs. 10.5d and 10.6d for
the wye connection and Figs. 10.9d and lO.lOd for the delta connection.
Referring to Fig. 10.5 if, reverse current flows through the diodes D1 and
D6, and these diodes communicate the supply voltage to the series
combination of phases 1 and 2 in opposition to the line-line EMF. The
reverse current is unaffected by the chopping of either transistor Q l or
because it flows through D1 and D6. Accordingly, Fig, 10.6d shows
Only the freewheeling current in phases 2 and 3, which is independent
of the reverse current in phases 1 and 2.
This condition tends to arise at speeds close to, or above, the no-load
Hid - K - 2 vd (10.84)
speed, when the load may be overhauling or over-running the motor.
The voltage equations are as follows : for both the wye and the delta
connections, where Vbld is related to the motor voltages by equations
(10.5) and (10.35) respectively.
10-27
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
10-28
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
0 . 60 -
0. 40-
0 . 20 -
0 .4 0 0. BO 1 .2 0 1 .6 0 2 .0 0
ELECTRICAL DEGREES x 1.0 e 2
10-29
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
10-30
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
This condition can be simulated on the computer, but it cannot be
calculated directly (unless the back-EMF is perfectly flat and all volt-drops
ar.d losses are known exactly).
Al the no-load speed, it is possible for the back-EMF ^ to exceed the
supply voltage for short periods during the commutation zone, as shown
in Fig- 10.16. When this happens, di/dt becomes negative and the line
current tends to decrease; it may even become negative as shown in Fig.
10.17. The simulated current waveform shown in Fig. 10.17 is for a 4-
po)c. 12-slot machine at 3750 rpm, with windage and friction loss
arbitrarily set to zero. The electromagnetic torque waveform has an
average value of practically zero, and since the windage and friction loss
U set to zero, this is also equal to the shaft torque. The no-load speed is
therefore 3750 rpm, compared with the value 3655 rpm calculated from
equation (10.85), a difference of 2.5%.
The windage and friction power of the example motor is proportional to
speed cubed and is 7W at 3000 rpm. When these figures are incorpo
rated in the computer simulation, the no-load speed falls to 3625 rpm.
The corresponding waveforms are shown in Fig. 10.18. This value is
closer to the value calculated from equation (10.85), but the apparent
l.. i -t. (y a w oMtHii,
Tftapa] * .0*0
0.BQ
[\ f\ \ y - \\
-am
CUoltrl 1.0*1
<.00 --------a ^ x c w d * [24V] atthla point
-------x y -----
^ ____ ^ ^
-2.00
-4.00
rM-i K 1.0t-2
tf.oa /------ -M e a n torque * 0
4.00
2,Du
-a.tfr
/\ / T a A A A S.KK^.SO s.
-4.00
__ Doip*- BOfiu#n [l*e dol x 1.0*2
fig- 10.17 Line current (top), line-line EMF (centre), and torque waveforms at 3750
rev/min, with windage and friction assumed zero
10-31
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
Fig. 10,18 Line currcnt (top), line-lincEMF (centre), and torque waveforms at 3625
rev/min, with windage and friction equal to 7W at 3000 rev/min
accuracy of the simple formula is fortuitous, because the error due to the
neglect of windage and friction in the simple formula is compensated by
the error due to the assumption of a perfectly flat-topped back-EMF
waveform. The true no-load speed must be determined iteratively by
successive simulations. At no-load the difference between Vt and e11 is
just enough to raise the current to the level needed to equal die windage
and friction torque.
An exacting test of the no-load speed calculation is to compare it with
the measured value, and the results of such a test are summarised in
Table 1 for the motor whose current waveform is shown in Fig. 10.14. In
this case the simple formula is unable to predict the correct value, even
when the supply voltage is multiplied by the modulating index or duty-
cycle of 0.30. The simulated waveforms for this condition are shown in
Fig. 10.19.
10-32
10. E l e c t r o n ic C o m m u t a t io n o f S q u a r ew a v e M otors
T able I
M easured and calculated N o -L oad S peed
Fig. 10.19 Simulated line current (top), line-line EMF (centre), and torque
waveforms for motor of Table 1 at 3472 rev/min
Further insight can be obtained by considering what happens as the
motor speed rises steadily, with fixed commutation angles, fixed supply
voltage, and no current limit. At low speeds and the current
Waveform is generally positive, with positive torque much greater than the
windage and friction torque. At the no-load speed, the electromagnetic
10-33
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
torque isjust sufficient to overcome the windage and friction torque. The
DC supply current is still positive, as it supplies all the losses.
At higher speeds, the shaft torque becomes negative, and a mechanical
prime mover is required. At first, at speeds only slightly higher than the
no-load speed, the electromagnetic torque may still be positive
(motoring), even though the shaft torque is negative due to the windage
and friction. At some speed the electromagnetic torque is zero: the prime
mover is then supplying all of the windage and friction torque, while the
DC supply provides all the electric and magnetic power loss. At still
higher speeds the average electromagnetic torque becomes negative
(generating). The average DC supply current remains positive until the
machine is going fast enough so that the generated electromagnetic
power exceeds the electric and magnetic power loss. This speed is the no-
load speed for generating. Between this speed and the original no-load
speed for motoring, the machine absorbs power from both the mechanical
and electrical "ports". At higher speeds, it becomes a pure generator.
The speed ranges are illustrated in Fig. 10.20 which shows the shaft
torque and the DC supply current. Motoring is when both are positive,
and generating is when both are negative. "Absorbing" is when the
torque is negative and the DC supply current is positive. The no-load
References
1, Miller TJE [1988] Switched reluctant* motor drives, PCIM Reference Book, Intertec
Communications, Ventura. California
2. Electro-Craft Handbook, Fifth Edition, August 1980, ISBN 0-960-1914-0-2
). Bolton HR and Mallinson NM [1986] Investigation into a class of brushle.ts DC motor
with quasisquan voltages and currents, IEE Proceedings, Vol. 133, Pt. B, No. 2, March
1986, pp. 103-111.
10-35
11. PERFORMANCE EVALUATION BY TEST
11.1 Introduction
Many performance issues have been dealt with of necessity within some
of the previous chapters, in order to provide background and justification
for the rotor and stator design methods. However, several important
performance parameters must be considered more carefully in order to
facilitate a proper design for a particular application. For example, the
speed vs. torque curve has been mentioned, but a more detailed
presentation is given. This treatment leads up to the issue of sizing a
brushless motor at the outset before detailed design is performed. The
problem of heating is also related to the sizing, materials used, and
cooling methods. Temperature rise is a very difficult parameter to
calculate unless the thermal time constant has been measured on an
actual sample. Finally in this chapter, the so-called basic brushless motor
constants will be summarized to illustrate how the design is summarized
in terms of the performance specifications, why some of the motor
constants are desired, and how they characterize a particular motor.
11-1
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
The following parameters should be measured after the first samples are
built. A schematic diagram for each test is provided.
1. Back-EMF for each phase, using a synchronous motor to
drive the test motor and view the generated voltage on an
oscilloscope.
2. Resistance and inductance/phase.
3. Speed vs. torque & current vs. torque curve using x-y
plotter and dynamometer.
4. Thermal resistance.
5. Torque linearity with increasing load, to determine effects
of stator currents (armature reacdon).
6. Torque ripple at very low speed using a large inertia driven
by a 1-5 rev/min gearmotor.
11-2
11. P er fo r m a n c e e v a l u a t io n by t e s t
11-3
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
where E is the value of the open-circuit voltage per phase at the same
speed. The short-circuit current may well be much larger than rated
current, and may even be sufficient to partially demagnetize the magnets,
so this test should be conducted with caution. It is important not to apply
the short circuit suddenly while the machine is running, but to connect
the short circuit while the machine is stationary and then bring the speed
up slowly to the test value. This is because a sudden short-circuit
produces a higher transient current with DC offsets that may well
demagnetize the magnets.
With interior-magnet motors, i.e. salient-pole motors, it is necessary to
measure Aj and separately. The short-circuit test can still be used to
measure which replaces in equation (11.2), but X poses more of
a problem. The slip test normally conducted with wound-field synchro
nous machines may not be suitable with permanent magnet motors
because the excitation cannot be turned off and large currents would
flow when E and V were out of phase. These currents might
demagnetize the magnets. A simple method is to load the machine with
a three-phase resistive load following the short-circuit test, and measure
the current generated into the resistance, it is necessary to measure also
the phase angle y between and the current, and this can be done using
the motor encoder and an oscilloscope displaying the current waveform
along with the index pulse from the encoder, (The phase relationship
between E and the index pulse can be recorded in an open-circuit test).
Then equations (6.90-97) can be used to reconstruct the phasor diagram
anti extract a value for X .
11-5
D e sig n o f b r u s h l e s s pe r m a n e n t - m a g n e t m o t o r s
Fig. 11.3 Measurement and plotting of speed and current versus torque
11-6
11. P e r fo r m a n c e e v a l u a t io n by t e s t
standards for the plates in order to relate one motor to another. It would
be advisable to review the test conditions of the published data provided
by the competitor and use the same size plate for a heat sink.
The thermal resistance test can be performed with natural or forced
cooling, provided that the conditions are carefully recorded. Further
more, if the temperature rise of the winding is plotted as a function of
time, the initial rate of rise gives the thermal capacity of the motor.
Together with the thermal resistance, this can be used to estimate the
temperature rise under intermittent loading, as explained in Chapter 15.
11-9
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
1 -5 RPM
but this method should never be used because the compass needle is
liable to be remagnetized by motor magnets in an unpredictable
direction.
A very good and simple test for the degree of magnetization of a magnet
is shown in Fig. 11.7. The magnetized rotor is fitted into a close-fitting
steel cylinder which has a search coil wound in two semi-closed slots very
close together. As the rotor is rotated within the ring, the EMF generated
in the search coil can be integrated to give the flux passing through the
search coil, and this is a good measure of the remanent flux-density if the
rotor is a close push-fit within the steel ring. A Hall element can be used
instead of a search coil wound in slots. Alternatively, a Grassot fluxmeter
can be used with the search coil.
DRIVE SUPPLY
DATA
ACQUISITION
+
PROCESSING
T/S
POWER
LOAD ANALYSER
CONTROL TORQUE
SPEED T/S
XL
LOAD TEST
MACHINE T/S MACHINE ENCODER
In Fig. 11.9 the data acquisition system has the capability of sampling
voltage or current waveforms at up to 10 million samples per second with
12-bit resolution (1 part in 4096). Waveforms with up to 64Ksamples can
be recorded, and many systems can record far larger numbers of samples.
It is important in power electronics and motor drive testing to have
differential inputs on measuring instruments, to avoid the problem of
single-ended input terminals (on oscilloscopes particularly, these are
usually grounded for safety).
Modem "wattmeters" are electronic, with the capability of measuring
voltage and current waveforms with harmonic content up to 400kHz or
more. They can typically provide peak, mean, and RMS readings of
voltage and current as well as mean and peak power, and some
instruments can even provide a harmonic analysis like a spectrum
analyzer.
11-13
D e s ic n o p b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
LOAD TEST
MACHINE T/S MACHINE ENCODER
fig. 11.9 Precision dynamometer configured for complete drive system testing
Electronic wattmeters can also be set up for the 2-wattmeter method, or
the 3-wire, 3-wattmeter method, or the 4-wire, 3-wattmcter method in 3-
phase systems. Such wattmeters are necessary especially when measuring
the separate efficiencies of the motor and its controller, because the
motor voltage and current waveforms generally are rich in harmonics.
Even with AC line current waveforms at the input to rectifiers etc., the
electronic wattmeter is a necessary instrument for power measurements.
The oscilloscope (Fig. 11.9) may not be an essential part of the
instrumentation, but is essential during setup to make sure that
everything is working properly and to help solve problems. Oscilloscopes
used in power electronics and motor drives work should have at least one
set of differential inputs, and digital storage oscilloscopes are preferred,
with single-shot (non-repetitivc) sampling rates of at least lOOMs/s. Many
digital storage oscilloscopes have optional waveform processing
calculators which can be used to determine peak, mean, and RMS values
and even to multiply waveforms together and calculate mean power.
11-14
11. P e r fo r m a n c e e v a l u a t io n by t e s t
E le c tro n ic ^
w a ttm e te r s
Digital scope
Load m a c h in e !
D a ta a c q u is itio n s y s te m
Tig. 11.10 Layout of precision dynamometer. Note the current probe amplifiers next
to the wattmeters; the inline torque transducer; and the emergency stop
button. The safety glass window at right permits tests to be observed from
outwith the dynamometer room when necessary.
The instruments and computer must be electronically linked, preferably
via the IEEE488 bus and protocol, or equivalent system. Software is
available from companies such as National Instruments and many of the
instrument makers (Hewlett-Packard, Tektronix, etc) for managing and
coordinating the instruments and for controlling the data acquisition and
processing. Any laboratory wishing to set up a precision dynamometer
should consult the suppliers of test equipment, measurement transducers,
and even complete dynamometers, for expert advice. Many engineers will
be amazed at the capability of modern instrumentation. Money invested
in good test equipment is well spent because it lasts for a long time and
gives quality information on the operation of prototypes and products.
To paraphrase Lord Kelvin, if you cant measure it you dont understand it.
11-15
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
References
1. Jones CV [1968] Unified theory of electrical machines, Butterworthl
2. Miller TJE [1981] Methods for testing permanent magnet AC motors, IAS Annual
meeting, Toronto, October 1981
3. Parker RJ [1990] Advances in permanent magrulitm, John Wiley and Som, ISBN ft-
471-82293-0
4. Staton DA and Miller TJE [1992] Validation of PC.-CAD Using a Precition DynamomtUr,
International Conference on Electrical Machines (ICEM), Manchester, 15-17 Sep
92,1221-1225
11-16
12. SIZING & COMPUTER-AIDED DESIGN
12.1 The modem design environment
The most usual situations which require a new brushless motor design
include a set of performance specifications and a physical size or
envelope. It is seldom that the performance requirement is given and
the size is open. In many cases a new performance specification must be
met through minor modifications to existing laminations and other
components, in order to avoid additional tooling costs.
When new designs are evolved from old ones, computer-aided design is
valuable in two particular ways:
1. Calculating and evaluating a large number of options,
often characterized by small changes in a large number of
parameters; and
2. Performing very detailed electromagnetic and mechanical
analysis to permit the design to be "stretched" to its limit
with confidence, while avoiding the need for a large
prototyping and test program, which would be expensive
and time-consuming.
Modern computer methods are rapidly reaching the stage where a new
prototype can be designed with such confidence that it will be "right first
time", without the need for reiteration of design and test that would
otherwise be necessary.
The computer-aided approach to design goes hand-in-hand with the
moder design engineering environment. Custom designs are increasingly
required within a very short space of time, while cost pressures force the
designer ever closer to the limits of materials and design capabilities.
Moreover, customers are becoming ever more sophisticated in their
requirements, and may specify (or ask to see) particular parameters that
traditionally were part of the "black art" of the motor builder. Often
these parameters are required for system simulation purposes long before
the motor is actually manufactured. Regulatory pressures on matters such
as energy efficiency, acoustic noise, and EMC also continually tighten the
constraints on the motor designer.
12-1
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
TOV = 4 r s<k ( 1 2 -2 )
Hence
K = Z a = Z try (12.4)
n
The airgap shear stress o is measured in lbf/in or "psi". If Z>r and 1^.
are in inches, then T is in lbf-in. Note that an airgap shear stress of a =
1 lbf/in 2 corresponds to TRV = 13.8 kNm/m3. Typical values of K are
given in Table 12.1.
Electric and magnetic loadingsThe electric loading A is defined as the linear
current density around the airgap circumference:
^ _ Total ampere- conductors _ 2 /n A ^J ^ (12 5)
Airgap circumference trDr
12-2
12. S iztnc & C o m p u t e r -a id e d d e s ic n
where I is the RMS phase current, m is the number of phases, and Nph
is the number of turns in series per phase.
The magnetic loading B is considered as the average flux-density over the
rotor surface. In AC motors the flux-density is distributed sinusoidally so
that the fundamental flux per pole is given by
$ - B * wD' L* ( 12 .6)
1 2p
12-3
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
(or radius) appears squared in any expression for specific output On the
other hand, if the length is increased, only the flux increases, not the
current. Therefore the length appears linearly in the specific output.
Thus the specific output is proportional to D ^ L ^, or rotor volume. In
practice as the diameter is increased, the electric loading can be
increased also, because the cooling can be made more efficient without
reducing the efficiency. Consequently the specific output ( t r v ) increases
faster than the rotor volume.
For totally-enclosed motors the lower values of o, TRV, and ATwould apply
with natural convection, while the higher values would apply with forced-
air cooling supplied by an external or shaft-mounted fan.
It is of interest to relate the electric loading to the current density in the
slots. With a slot depth of 15mm, a gross slot fill factor of 40%, and a
tooth width/pitch ratio of 0.5, the current density is
J = ------------------------------- ---------------------------------
Slot-fill x Slot-width/slot-pitch * Slot depth ( 12. 10)
= --------
0.4 x 0.5--------
* 15 = 6.7 A/nun2.
Typical values of current density for use in different applications are
given in Table 12.2.
Condition A/mm A /in2
Totally enclosed 1.5-5 1000-3000
Air-over 5-10 3000-6000
Fan-coolcd
Liquid cooled 10-30 6000-20000
liquid cooled motors would have a passageway around the entire outside
diameter of the stator with a cooling fluid circulating to remove the heat
The higher numbers would be appropriate to motors in which, in
addition to the outside cooling jacket, there would be tubes up and down
the slots potted in epoxy. If hollow conductor wire is used with cooling
fluid circulating inside, no potting is necessary. (This is called "direct
conductor cooling").
When a variety of motor types and sizes of machines are evaluated to
determine their airgap shear stress at their name plate ratings, a broad
range of values is encountered, with variations as much as 2000% for a
given motor type. It is, therefore, difficult to use this method of "sizing"
a design unless a particular airgap shear stress figure can be associated
with a particular method of construction and cooling. The permanent
magnet brushless motor will exhibit a more consistently predictable
airgap shear stress than most other types of motors, because for each
different magnet grade the magnetic loading is fixed within fairly narrow
limits, while the method of construction and cooling is reasonably
consistent among different motors.
After the magnet grade has been selected and the first estimate made of
the rotor diameter and active magnetic length, the stator OD can be
estimated. For interior-rotor motors, the rotor diameter can be divided
by 0.45 to 0.50 to arrive at a stator lamination OD. For exterior-rotor
motors the rotor OD is determined by adding twice the magnet thickness
plus twice the rotor cup thickness to the rotor diameter Dr. These
dimensions are calculated according to the practice described in earlier
chapters.
Option 7...
(c) TJE Hiller,HI HcCllp.DA Staton. SPEED Laboratory. Glasgow University. 1994
Licensed to Prof. TJE Miller
||nlp: Choose an o p t i o n by p r e ssing thu h iyh I iyiited ken.
12-7
DESICN o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
12-8
12. S iz in g & C o m p u t e r -a id e d d e s ig n
Help; F2 Edit FAB Kent field Shift<Tgb frev field Ctil*S Save ESC Exit
Fig.12.5 shows the winding editor which can be used to modify or build
any form of winding. The program can automatically build concentric,
lap, and fractional-slot windings, but it also provides a facility for
insertingcoils entirely at the users discretion. Regardless of the number
or disposition of the coils, the program can calculate the back-EMF
waveform, the resistance, self-and mutual inductances, and the
performance with squarewave or sinewave drive.
12-9
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
Uinding Parameters
DdgTypa Lap Throw 5 Co i1E/P 1 TC 10
HSH 1 PPftTHS 1 Ext B.000 Liner B.4B8
WireSpec BareDIo Wire 1.226 Skew B.60B
Control Parameters
KPH 2006.006 Conns* 3-Ph Uua Idaus Square Su Ctl C120 Q6
ISP 10,990 DuCy 1.000 CFrq 5.BBS Us 24.B00
0* 1.000 If b .b b s IM 0.600 THB 9.000
fltfcer Parameters
IUU n ita tm UdgTemp HagTenp
bDDDnm
25.000 25.0B8 Ik B.BBB
Uf0 0.006 RPMB oqqq UUU HUFT 2.000 XLph 1.060
XFs 1.000 Xrl 1.900 XET 1.008 XBtpk 1.0BB
TenpCalc DegCU DegCU 0.100 HTranflct IB.BBS HTranEnd 6.0GB
flubSent 20.000 EndFI11 0.500 1Of \
| Helji: Shaft radius Fl-Hulp |
Fig. 12.6 Template editor for input data in PC-BDC
12-11
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a c n e t m o t o r s
yw x 1.0-0
<^WMyyVWwvH|yvvwwvv\yyvvvvvm^y^
B Miscellaneous:---------------
in terms of A, and the other "output" quanddes are calculated from the
nodal values of A in the "postprocessing" phase.
Within one element, the vector potential is assumed to vary according to
a simple shape function, which may be a linear, quadratic, or higher-
order function of the three sets of node coordinates for the vertices of
the triangular element. Linear elements give the fastest solution but the
least smoothness in the field variation.
Modem finite-element software is extremely robust and accurate, and has
innumerable features to assist the user to set the problem up and extract
the engineering parameters of interest. However, the point should be
made that the finite-element method differs from rapid-design software
like PC-BDC in two important ways:
1 . The finite-element method is generally limited to one specific
type of problem, such as electromagnetic or thermal analysis,
whereas rapid- design software calculates a wide range of
parameters ranging from weights and inertias through to
performance and dynamic waveform calculations, temperature
rise, and many non-electromagnetic parameters.
2. The finite-element method is intended for accurate analysis,
and the emphasis on accuracy means that setup and execution
time is much longer than with rapid-design software. A typical
simple finite-element exercise might take days or weeks, but a
complete motor can be designed in less than one day with a
program like PC-BDC. Inevitably, PC-BDCs electromagnetic
calculations cannot be expected to be as accurate as those of the
finite-element method, although the difference in accuracy is
often too small to be of concern. On the other hand, many
detailed problems such as the calculation of cogging torque,
which are beyond the scope of rapid-design software, may require
extremely lengthy finite-element calculations lasting several weeks.
Application of the finite element method to machine design involves
three stages:
1. Pre-Processing
2. Field Solution
3. Post-Processing
12-14
12. S iz in g & C o m p u t e r -a id e d d e s ig n
12.4.2 Pre-Processing
In most cases this is the most user-intensive part of finite-element
analysis. Three tasks must be performed:
1. Mesh Generation
2. Material Definition
3. Problem Definition
Mesh, generation involves division of the motor cross-section into a set of
triangular elements (2-D solutions) or division of the motor volume into
'bricks' (3-D solutions). Modem mesh generation is carried out using
either interactive graphical techniques (using conventional CAD drafting
software such as AUTOCAD, or using the internal specialist drafting
facilities of the finite-element software itself. Another alternative is the
use of using specialist mesh generation code written in a high-level
language or command file.
Interactive graphical mesh generation is the quickest way to form a finite-
element mesh in the majority of cases. However, a drawback of using this
technique is that when it is required to calculate a series of solutions for
motors of the same general type, but with different dimensions, it will
usually be necessary to generate the mesh individually from the
beginning for each case. This problem can be overcome by writing
specialist mesh-generation software, which may be in the command
language of the finite-element program, or alternatively in C, PASCAL or
FORTRAN. The interface to the finite-element program may m e a
standard data format such as .DXF or a format specific to the particular
vendor. This method of mesh generation is especially useful when
generating a range of meshes for motors of similar type but having either
different dimensions or different rotor positions.
Specialist mesh generation software calculates the coordinates required
to define the motor geometry. The cross-section is usually split up into
regions representing different "materials" such as current-carrying
conductors, air, steel, and magnets. Each region may define a different
component used in the construction of the motor, for example, the shaft,
rotor core, magnets, stator lamination, airgap, etc. In most cases it is
beneficial to split the components further into smaller polygons along
lines of symmetry.
12-15
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a c n e t m o t o r s
Fig. 12.11 Finite-element mesh for one pole-pitch of a. brushless DC motor, showing
the use of periodic boundary conditions
The node spacing on the central sliding surface is set to a constant such
thatit is possible to rotate the rotor by any multiple of this constant. Fig.
12.10 shows a mesh in which the airgap region is divided into four layers
and the sliding surface is central to the airgap. Fig 12.11 shows the full
mesh for one pole-pitch of the same motor.
Fig. 12.12 Leakage flux paths in n "spoke" type brushleu permanent-magnet motor
Problem definition involves the application of the correct boundary
conditions, imposing the correct current densities in the appropriate
winding elements, and definition of the direction of magnetization of
magnets. Periodic boundary conditions should be used if possible, as
they make it possible to model only a fraction of the cross-section (Fig.
12.11). For example, in the case of a 4-pole motor, if the number of
slots/pole is an integer, it is only necessary to model the motor over one
pole pitch.
12.4.3 Field Solution
The solution of the discretized partial differential equation uses
specialized mathematical algorithms developed over many years [4]. The
algorithm is often based on the minimisation of an energy functional,
that is, a mathematical function that is related to the stored potential
energy in the field.
12-18
12. S iz in g & C o m p u t e r -a id e d d e s ig n
The discretization transforms the partial differential equation into a large
number of simultaneous nonlinear algebraic equations containing the
unknown node potentials. Iteration is essential and the Newton-Raphson
and congjugate-gradient procedures are widely used. With linear
elements, the potential is assumed to vary linearly between nodes and the
flux density is constant within each element. Current density is also
assumed to be constant within each element associated with a winding.
12.4.4 Post-Processing
The field solution is in terms of magnetic vector or scalar potential, but
the design engineer needs quantities such as flux densities, force and
torque. The extraction of these quantities from the potential solution is
called post-processing. A good interactive graphics facility is important for
SO that the essential information and parameters can be extracted from
the large number of node potentials effectively and quickly. Finite-
element analysis can be used to generate the following output:
1. Flux plots. These are especially useful for forming a picture of the
flux. They can also be used for estimating leakage flux and
calculating leakage permeanccs. Fig 12.12 shows a flux plot for a
spoke type motor, in which the finite-element method is useful for
calculating rotor leakage flux.
2. Fhtx calculations. The flux between two points of interest is
calculated from the difference in vector potential at the two
points, multiplied by the axial length. This calculation can be
extended to obtain flux-fiwAagtf, and hence inductance of windings.
8. Fhix density contours. Coloured filled zones can be used to indicate
areas of high local saturation. Flux density values at any point can
be readily obtained by using a cursor.
4, Graphs offlu x density variation. The required component of flux
density (radial, x-component, y-component etc.) can be plotted
along a pre-dctermined path. For example, the variation in radial
component of airgap flux density can be plotted around the rotor,
and examples are shown in Figs. 12.8 and 12.19.
Flux density vector plot A field of arrows is plotted over the cross-
section, representing the local flux density vector.
12-19
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
While the magnet flux remains substantially constant, the field set up by
the armature windings is proportional to the current. Motors are usually
designed such that the armature reaction does not affect the torque per
ampere, ky. Under heavy load conditions armature reaction is liable to
decrease kT.
Even under normal load conditions, the distortion in the airgap flux-
density distribution tends to increase the core losses. It is not unusual for
the core losses at rated load to be double the no-load value, even though
Jfcf may not vary significantly between no-load and full load. This is
because depends on the magnet flux alone, whereas the core losses
depend on the total airgap flux and its distribution.
The effects of armature reaction can be classified into 9-axis effects and
tfaxis effects:
1. f-axis : cross-magnetization or distortion
2.d-axis : demagnetization or reduction of airgap flux density.
These effects are illustrated with the help of flux plots and flux density
graphs generated using finite-element analysis. A small squarewave
brushless DC motor with four poles and twelve slots is used as an
example.
The examples can be understood by looking first at the flux distribution
set up by the magnets alone, then at the flux distribution set up by the
armature current alone, and finally at the superposition of both, keeping
in mind the fact that the superposition is non-linear due to magnetic
saturation effects.
12.5.1 Open-circuit flux distribution
Fig. 12.13 shows the flux distribution created by the rotor magnets
alone. This is also referred to as the open-circuit flux distribution since
the armature or stator windings are not excited in this case.
Many important features are immediately apparent in Fig. 12.15, for
example, the radial magnetization of the magnets, the concentration of
flux in the teeth, and the variation of flux-density in the stator and rotor
yokes.
12-21
D e s ic n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
Fig. 12.13 Flux distribution due to magnets acting alone (open-circuit condition)
Closer examination shows more subtle effects such as the fringing around
the slot openings, discussed at length in Chapter 8. The high coercivity
and low recoil permeability of the magnets is the reason for the extreme
regularity of the field lines in the magnets. "Hard" magnets such as
ferrite or rare-earth magnets act as "rigid" sources of flux, and there is
very little distortion of the field inside the magnets due to slotting.
12.5.2 Armature reaction field alone
Fig. 12.14 shows the flux distribution set up by the armature currents
acting alone, assuming two-phase-on operation with a severe overload.
The airgap as seen by the armature includes the magnet thickness and
hence appears as a high-reluctance path for the armature field. The
magnets are considered to be removed or unmagnetized, and have no
effect on this distribution. Note that the flux encircles the ampere
conductors in the manner of Amperes Law, and appears in four loops.
12-22
12. S iz in g & C o m p u t e r -a id e d d e s ig n
Kg. 12.14 Flux distribution due to 'armature current acting alone (two phases on).
The dotj and crosses show the polarities and locations of the armature
currents. There are approximately 1600 Ampere-conductors per slot, with
a high value of current density (17.3 A/mm2).
A proportion of the flux in each loop crosses the long airgap into the
rotor yoke twice. Most of the remainder crosses the tooth-tops, while a
small fraction travels circumferentially around the space left by the
magnets. These separate components of flux are estimated by simple
formulas in Chapters 5 and 6, in the calculation of the self-inductance of
ihe winding and the mutual inductance between windings. The
somewhat complex shape of the flux paths shows that this type of
calculation can only ever be an approximation, although surprisingly
accurate results are often achieved. With finite-element analysis, the
inductance can in principle be calculated more accurately.
Note that all the flux-plots shown here are two-dimensional, and three-
dimensional effects (end-effects) are neglected.
12-23
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
Fig. 12.15 Resultant flux-diatribution with magnets and cross-magne tizing armature
reaction. The currents are as defined in Fig. 12.14.
The inductance associated with the flux pattern in Fig. 12.14 is a static
inductance, which is directly useable in time-stepping simulation of
squarewave or sinewave brushless motors, but is quite distinct from the
synchronous reactance discussed in Chapter 6.
The synchronous reactance cannot be directly calculated from a static
finite-element flux-plot, except in the special case when the windings and
the flux are perfectly sine-distributed. In the general case, the
synchronous reactance calculation requires the stepping of the rotor
through at least one electrical revolution, followed by a differentiation of
the flux-linkages of the phase windings and a harmonic analysis to extract
the fundamental component. This is because the synchronous reactance
is defined for a fundamental space-harmonic field so that it can appear
correctly in the phasor diagram.
12-24
12. S iz in g & C o m p u t e r -a id e d d e s ig n
Values qIB M O D
___ V bIu m o IBM OD
Fig- 12.16 Variation of airgap flux-density under one pole. Dotted line : magnets
alone. Solid line : resultant with cross-magnetizing armature reaction.
12.5.3 Cross-magnetization
The cross-magnetization effect is greatest when the rotor magnet field is
in quadrature with the armature field, as in Fig. 12.15. Many significant
features of the effect of armature reaction can be observed from Fig.
12.15, most important of which is the increase in flux-density at the
leading tip of die magnet pole and the decrease in flux-density at the
trailing tip. This effect is illustrated in Fig. 12.16, which shows the
variation of airgap flux density under one magnet pole around the
airgap. The dotted line corresponds to Fig. 12.13 showing the variation
in flux density due to magnets alone. The solid line corresponds to Fig.
12.15 showing the resultant distorted flux distribution when both
magnets and armature current are present.
12.5.4 Demagnetization
The demagnetizing effect is greatest when the axis of symmetry of the
magnet (the <axis) is aligned with the axis of symmetry of the armature
12-25
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
Fig. 12.17 Flux distribution due to magnets acting alone. The rotor is turned 45*
clockwise relative to its position in Fig. 12.13
ampere-conductor distribution. Fig. 12.17 is again the open-circuit flux
distribution due to magnets alone, but the rotor is rotated 45 degrees (90
electrical degrees) to align the two axes as required.
The armature ampere-conductor distribution remains unchanged from
that of Fig. 12.14, and the resultant flux distribution is shown in Fig.
12.18. The airgap flux density at the centre of the magnet is much less
than the open-circuit value in Fig. 12.17. The MMFs of the magnet and
the armature current combine in the region of the quadrature axiSj
where the flux is forced to return from one magnet pole to the next
across the tooth-tops, rather than following its normal course through the
teeth and round the stator yoke. The stator yoke flux is gready reduced.
The armature reaction in all these examples is for very high current,
corresponding to locked-rotor condition.
12-26
12. S iz in g & C o m p u t e r -a id e d d e s ig n
Fig. 12.18 Resultant flux distribution with magnets and demagnetizing armature
reaction. The magnet (taxis is aligned with the axis of symmetry of the
armature ampere-conductor distribution, such that their MMFs are in
opposition
In Fig. 12.19 the dotted line shows the variation of flux density around
the airgap with the magnets acting alone. The solid line shows the flux
density variation when both magnets and armature current are present.
Note that both the cross-magnetizing and demagnetizing components of
armature-reaction MMF distort the airgap flux waveform and introduce
additional time-harmonics into the variation of the flux-density in the
teeth and yokes. This is the main cause of increased eddycurrent loss in
the core. The peak flux-density is also increased, and this contributes to
an increase in the hysteresis loss. It is difficult to estimate the magnitude
of these effects by simple formulations, but the finite element method
quickly brings the effects to light and provides an accurate means for
estimating them with a high degree of confidence.
12-27
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Fig. 12.19 Airgap flux-density variation under one pole with strong demagnetizing
armature reaction. Dotted line : magnets alone. Solid line ; resultant.
References
1. Fouad FA, Nehl TW and Dcraerdash NA [1981] Magneticfield modelling ofpermanent
magnet type electronically operated synchronous machine* using finite elementi, IEEE
Transaction], Vol. PAS-100, No.9, pp. 4125-4135
2. Reece ABJ : Electrical machine* and electromagnetics - computer aids to design, CJEC
Review, Vol.5, No.l, 1989, 34-41.
3. Hamdi ES, Licariao-Nogueira AF and Silvester PP [1993] Torque computation
mean and difference potential':, IEE Proceedings-A, Vol.140, No,2, 151-154.
4. Lowther DA and Silvester PP [1986] Computer-aided detign in magnetics, Springer-
Verlag.
5. Opera-2d Reference and User Guide, Vector Heidi Ltd., Oxford
6. Fitzgerald AE, Kingsley G and Umam SD [1990] Electric Machinery, fifth edition,
McGraw-Hill
12-28
13. EXAMPLES CALCULATED BY HAND
13,1 Introduction
The use and proliferation of brushless permanent-magnet motors over
the past ten years or so has been largely application-specific without any
standardization. For example, the motors used in computer hard disc
storage drives have been designed to keep pace with developments in the
disc drive. In a short period the data storage capacity of Winchester disc
drives increased 100-fold: the access time decreased by a factor of 10, and
tht! drive envelope decreased by a factor or 3 or 4. Needless to say, the
bmshless drive motors used in these drives have evolved at a comparable
Tiiie-
Another example of an application-specific brushless motor family is the
higli performance servo motor used to drive specific loads without the
use of gearing or clutches and brakes in order to achieve elegant
programmable motion. The configuration of these designs is driven by
high torque to inertia and ease of cooling the stator. Based on a casual
inspection of most vendor offerings it would appear that there are some
similarities, but their differences are more significant. It would seem that
among the various designs of similar motors each designer is able to
achieve acceptable performance for a particular physical size using
different magnet grades, number of poles and stator coils. There is also
a wide variety of feedback sensors in use. The author assumes that these
differences in design details from one vendor to another are attributed
principally to economic issues relative to each manufacturing operation.
The other possible reason would be that each designer achieves
acceptable results using design parameters which are within his or her
scope of understanding and experience.
Other motor products such as AG induction motors seem to all be alike.
If you disassemble them it is difficult to discern one from the other. DC
brush type motors are somewhat the same in their configuration. Most
companies which have developed brushless servo motors have been
known for their DC motors not AC motors. The large US induction
motor manufacturers were the last ones to enter the brushless AC or DC
servo business with new products so their design approaches are
somewhat different from those of the DC motor companies.
Most recently there have been several significant developments of
13-1
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
13-3
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
The laminations, stack lengths, stator ID and winding area are fixed.
Since the brushless motor must be low in cost to be competitive in the
adjustable-speed market, the use of the highest grade Ferrite magnet in
terms of remanence must be employed. The coercivity is less important
because the low-cost magnet is best utilized with extra thickness to
prevent demagnetization. The inverter drive will provide ultimate
protection because the drive transistors will be protected with a current-
limit circuit which also protects the magnets from demagnetization. The
highest possible flux/pole is then the main objective.
The Allen-Bradley/TDK material known as FB4B is easily selected for its
properties given in Table 13.2:
4000 G
3200 Oc
c, 3300 Oe
Temp. coeiTt. of Br -o.i8 % r c
T able 13.2 P roperties o f A l l e n -Bradley /T D K fb4b m agnet
A B /H curve from the vendor catalogue is shown in Fig. 13.2 complete
with the load-line due to the magnetic circuit airgap and the load-line
resulting from the stator current
The general practice of using mechanical airgaps of 0.030" nominal with
Ferrite permanent magnets in DC commutator motors is applied to this
brushless motor design. Since the speed is not intended to exceed 4000
rev/min, the only magnet retention will be a 3-M structural adhesive
between the rotor lamination stack and the magnet arc inside radius.
To achieve a maximum flux at +60 C rotor operating temperature, and
to prevent demagnetization at the peak current at starting, an
approximate permeance coefficient B/H of 10 is selected (see Chapter
4). This translates to a magnet thickness of 0.300":
B IH - iM - 10;
g (13.1)
= 10 * 0.030 = 0.300in.
13-4
13. E x a m pl e s c a l c u l a t e d By h a n d
]GBj M
Pig- 13.2
13-5
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
r rev/min poles
= 6 60 2 (13.2)
rev/min * poles
20
13-6
13. E x a m pl es c a l c u l a t e d by h a n d
excessive due to the 12-slot winding pitch. The choice could be either a
4-polc rotor or an 8-pole rotor. In either case a double-layer lap winding
could be used with 24 coils or 8 coils per phase. The lap winding
requires hand insertion. The most practical choice for automatic
insertion is a single-layer winding pattern of 12 coils with 4 coils per
phase, i.e. a concentric consequent-pole winding. If this pattern were
used with a four pole rotor, there would be 2 concentric coils per pole
per phase, which would probably require coil insertions of a single phase
at a time. With the use of the &-pole rotor, the concentric winding has
only one coil per pole per phase, permitting automatic insertion of all 12
coils into the stator in one stroke of the machine, which certainly speeds
up production.
So far the design parameters can be summarized as follows:
Next to be determined are the pole arc and winding connections, wye or
delta. Reference can be made to the generic back-EMF wave shapes For
3 slots/pole, shown in Fig. 3.15a and b. The controller will either be a 6-
step squarewave drive energizing only two phases at a time, or a sinewave
drive with current in all three phases simultaneously. The 6-step drive is
much lower in cost for this size of motor than the sinewave drive and
probably more suitable for this product for the market it would serve. If
that is the case, the selection of a delta connection would be appropriate
with a magnet pole-arc of 2/5 of one pole-pitch or 30. If a full-pitch
magnet arc of 45 is chosen the wye connection should be used,
otherwise the third-harmonic circulating in the delta would be excessive.
13-8
13. E x a m ples c a l c u l a t e d by h a n d
half of the magnet thickness would be wasteful, due to leakage from pole
to pole at the overhang. The resulting rotor lengths are determined by
adding the magnet thickness to the stack length
Short rotor length Lrl = 1.25 + 0.31 = 1.56 in. (min);
(13.3)
Long rotor length= 2.50 + 0.31 = 2.81 in. (min).
The magnet pole area is calculated as follows:
poles (13.4)
n *_2.3j * 1.56 _ j 42 in 2 for short stack
8
and
Anp = n g = 2.56 in 2 for long stack. (13.5)
With the magnet flux-density at 60 C equal to 3300 G (Fig. 13.2),
$ = BmAm * 2.542
m m (13.6)
= 3300 * 1.42 * 2.542 = 30,234 lines for short stack
and
$ = 3300 x 2.56 * 2.542 = 54,506 lines for long stack. (13.7)
In Wb, = 3.023 x 10 "4 for the short stack and 5.451 x 10 ~4 for the
long stack. The magnet poles should be tooled using the minimum
number of lengths to provide the two stack lengths. One possibility for
this motor would be two lengths, 0.70" long and 0.86" long. Sixteen arcs
0.70" would yield the 2.81" rotor magnet and four 0.70" arcs plus four
0.86 long arcs would yield the 1.56" long rotor magnet in a staggered
configuration so that the slot openings between them do not line up.
The spaces caused by the plus zero to minus 0.5 tolerances on the 90
arc angle would cancel.
13-10
13. E x a m pl es c a l c u ij \ t e d by h a n d
The other possibility is to tool the correct length for each stack length
of 1.42" and 2.56" to eliminate the extra labour of the rotor assembly
when handling so many arcs. Even though the number of arcs to be
tooled is the same as for the shorter lengths, the longer arcs do not offer
the flexibility of adding other rotor lengths without tooling another arc.
The next step is to estimate of the number of turns per coil. One way to
do this is via the EMF constant Sincc the maximum operating speed
is to be 4000 rev/min, a good rule of thumb for a Ferrite motor is to
begin with the rated speed at 80% of the no-load speed, giving
and
<*>nl = ^ = 524 rad/s. (13.9)
(For rare-earth magnets 90% would be a good place to start.) The
inverter will be powered from 115V AC single phase, full-wave rectified
to provide a 160V DC bus. A rough calculation of the EMF constant
and torque constant kj. can be determined by setting the back-EMF at the
no-load speed equal to the DC bus voltage, neglecting losses. Thus
[ L - D\1vVsloLs
Tooth area = wT-----------
= 0.230 * I f-I 4 ~ 3 I- x
(13.14)
-------------- * 24
Z'f
2
= 3.15 in2.
The nearest wire gauge is AWG #19 with a maximum diameter over
insulation of .0386, a bare wire diameter of 0.0359", a resistance at 20C
of 8.0293/1000ft, and a weight of 64.04 oz/lOOOft.
The winding resistance can be calculated after the mean length of turn
(MLT) is determined as twice the slot pitch to the average centre of the
slot opening plus twice the stack length plus two times the allowance for
end turn height on the automatic insertion machines: for the short
machine
MLT = 2 x (1.25 + 0.375) + 2 * 1.785 = 6.82 in. (13.17)
For the long machine MLT = 9.32". The resistance per coil is therefore
j _ ^RMS
Bare wire area
8 74 (13J9)
------ ------ = 8,634 A/in2.
-4 x 0.03592
13-13
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
t = i i X ( M f X 266 + l i , ( M Y X f M 6 ?
R 2 U-Oj 60 2 ^ 1.0 J { 60 ) (13.20)
= 1.08 + 3.89 = 5.0 W/lb.
From the stator dimensions calculated earlier the iron volume is
approximately 16 in3 and if the density is 0.28 lb/in 8 the core weight is
16 x 0.28 = 4.6 lb. Therefore the corc losses are approximately 5.0 x 4.6
a 23 W- If bearing and friction losses at 5 W are added, the total losses
at 4-4 A are 38 + 23 + 5 = 66 W, for an efficiency of 554/ (554 + 66) x
jftf) = 89.3%. At the 8.8 A operating point the total losses are 153 + 23
f 5 = 181 W and the efficiency is 1107/(1107 + 181) x 100 = 86.0%. An
obvious improvement would be to build the motor with thinner
laminations or to use a higher grade of core steel, but these efficiency
figures are considerably better than what could be achieved by the
induction motor in the same lamination, which would probably have
twice the losses at a comparable operating point
With no current-limit in the inverter the locked-rotor current could be
as high as 160/1.97 = 81 A, assuming no impedance or voltage-drop in
the supply.
In Fig. 13.2, a load-line was drawn on the vendor B /H curve for the FB4B
rotor magnets at the maximum rotor operating temperature of 60C.
The maximum allowable demagnetization field Hmax can be taken from
the plot at 20 C as -3200 Oersteds. The demagnetization current with
wye connection can be calculated from equation (3.6) using this Hmax
value, assuming a = 1 parallel path through the stator. With two phases
on, the number of conductors carrying current is z = 54 turns/coil x 4
coils/phase x 2 conductors/turn x 2 phases = 864: thus
1000 x 4 x l x 4 x (0.30Q 4 0.Q30) x 320Q
13-15
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
13-16
13. E x a m pl es c a l c u l a t e d by h a n d
13-17
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
Motor-in-hub requirement*
Exterior-rotor motor
Very little space available
Minimum cost
Long life
Low noise
Constant ambient temperature
Low power density
T able 13.6 G enera l r e q u ir e m e n t s o f c o m pu t e r d isc drive
These motors produce very litde starting or running torque which means
that the cogging or detent torque must be kept to an extremely low level.
This will also help to reduce the audible noise. To accomplish this, the
rotor poles or the stator should be skewed. In addition, the stator teeth
tips should be as thick at their root as they are long, extending from the
tooth, to prevent tooth tip saturation.
This also reduces cogging and audible noise. The stator slot openings
should be very small, just enough for the magnet wire to enter. Ihe use
of needle winders for interior stators is not recommended because too
much air space is required for the needle. 'Ihe winder of choice is known
as a "fly winder" with winding jaws or guides to feed the wire into the slot
openings.
13-18
13. E x a m ples c a l c u l a t e d by h a n d
13-19
D e s ic n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o to rs
1.0 B/H = 4
14
B (kG)
12
10
8
6
4.9 kG
4
13-20
13. E x a m pl es c a l c u l a t e d by h a n d
= ir/feA x 4 y
p 8 45'
ir x 0.695 x 0.370 wX 43 (13.22)
8 45
= 0.097 in2.
Consequently the flux/pole is
> - ^ A p *2.54 2
(13.23)
= 4900 x 0.097 x 2.54* = 3066 lines
or 30.7|iWb/pole. The next step is to check the flux density in the 0.050"
thick rotor yoke. The flux 4> for each of the 8 poles is split into two
paths in the rotor yoke, giving
B = ---------- 59^6/2---------- = 12 g4 kG (13.24)
v 0.050 x 0.370 x 2.542
or 1.57 T. This value is acceptable as the soft iron of the magnet return
path material is saturated at 18 kG using low-carbon steel. If a six-pole
magnet ring were used, the flux/pole would be 33% higher but the same
yoke thickness could be used. A summary of rotor dimensions which have
been determined so far is given below.
13-21
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
The stator outside diameter equals the rotor inside diameter minus twice
the airgap:
Ds Dn ' (13.25)
= 0.695 - 0.020 = 0.675 in
or 17.1 mm. For an 8-pole motor there are very few practical choices for
the number of slots for such a small compact design as is being
attempted here with the rotor on the outside. 6, 9 or 12 are probably the
only possibilides. The 6-slot stator would be easy to wind, but with so few
coils the end turns would be too large to fit into the space. The 12-slot
stator would work very well in a large enough diameter motor to have
enough circumference on the stator lamination for 12 slot openings.
The best selection might well be the 9-slot stator with 8 rotor poles in
terms of end-turn height and slot openings. The other significant
advantage is that only 1 out of 8 pole edges would line up with a slot
opening at any time during rotation. This results in a low cogging
torque. The disadvantage of the 8-pole, 9-slot design is that both known
winding patterns can cause unbalanced magnetic radial loading which is
said to cause noise problems, (cf. Fig. 3.12). If that is the case, perhaps
a 6-pole rotor should be considered with a 9-slot rotor. However, if space
permits the 8-pole 12-slot design would yield a good motor with low
cogging and quiet running.
Continuing with the 8-pole, 9-slot design, the lamination stack length
must be selected before the tooth thickness can be determined. The rule
of experience used from the interior-rotor example was that the magnet
should overhang the stack by about 1/2 its thickness for full-pitch poles.
The magnet length in the axial direction is 0.370" and the thickness is
0.040" so the stack length Lstk should be about 0.330 max. If .018" thick
laminations are used of M-19 annealed stock, about 18 laminations would
be required, which would figure out to 0.324" nominal, plus or minus
some tolerance. It is possible that 0.014" thick laminations should be
used for lower losses.
With an allowance of 18 kG in the stator teeth, and based on the
assumption that each of the 9 teeth will collect the flux from a single
pole, the tooth width can be determined as follows, allowing for 3
leakage factor (gap flux/magnet flux) of 0.9:
13-22
13. E x a m pl es c a l c u l a t e d by h a n d
9 BjL<k * 2.S42
* (13.26)
0 9 * 8 * 3066' 9 = 0.0652 in.
18,000 0.324 x 2.542
The lamination cross section can be drawn to scale, preferably on a GAD
system so that the winding area can be determined by the computer. The
slot openings are maintained at 0.040" 0.001" with a careful tooth tip
shape using tapered teeth and a 0.030" radius in the comers of the tip
so that tip saturation will not cause cogging.
The CAD system reveals a total slot area of 0.0132 in 2 or 8.52 mm2,
allowing for 0.005" build-up of epoxy insulation, i.e. 0.0066 in 2 for each
coilside in a double-layer winding. The mean turn length is easily
calculated as before using twice the stack length plus twice the tooth
thickness plus insulation and four times the coil thickness which is
estimated as 0.04": thus
13-23
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
vary from motor to motor. The method of holding the stack can be best
implemented by one of three ways listed below:
Press laminations on to a knurled shaft; epoxy coat; and wind
Clamp the lamination slack in alignment fixture; epoxy spray coat; wind;
then press on to shaft
Have the stamping die fabricated to provide cleatcd or dimpled stacks from the
punching operation; Insulate and wind
T able 1 S.l 1 M eth o d s o f fabricating stator
The actual choice depends on the production system of the motor
vendor plus the details of the mechanical design of the motor such as
how the starts and finishes of the phase windings will emerge from the
wound stack, under the ball bearings and out to the driver board.
The next step is to determine the number of turns per coil and the wire
gauge which will fit into this small lamination slot with a terminal
resistance acceptable to the design. With reference to Fig. 3.12b, a delta
connection with full-pitch magnet arcs would have excessive third-
harmonic in the phase EMF and this would cause circulating current in
the delta. This could be avoided by magnetizing the magnets in such a
way as to get 120 magnet arcs. Alternatively a wye connection could be
used. If the wye connection is used with full magnet arcs and one slot-
pitch of skew, the Fourier series analysis shows that the commutation
zone average back-EMF is 65.6% of the formula value. The specification
for is 1.5 V/krpm = 0.0143 V-s/rad so that Aj- = 0.0143 Nm/A or 2.03
oz-in/A. Using equation (3.3) or (7.28), and again using the leakage
factor (gap flux/magnet flux) of 0.9,
7 - x k*n x 1 x 1
3
2 <bpy 0.656 0.9 ......
(13.28)
= 2 x 0-0143 x 7r x 1 x _ 1_ = 93Q
2 3,066 *10' x 4 0.656 0.9
13-25
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
0.0066 in 2 and the MLT to be 1.05". Therefore, the winding gauge and
the terminal resistance can be determined using the same method as in
the previous example:
^slot 'slot
\ N (13.29)
0.0132 x 0.6 0.0087 in.
2 * 52
No. 32 AWG wire is 0.094 over insulation with a bare wire diameter of
0.0080" nominal. The resistance per 1000 ft. is 162.0 Q at 20 C and its
weight is 3.28 oz/1000 ft. The resistance per coil is determined as follows:
With three coils per phase the phase resistance is 3 x 0.737 = 2.2 Q and
with wye connection the line-line resistance is 2 x 2.2 = 4.4 Q at 20C or
5.35 Q at 75C.
The specification called for 1 oz-in of torque at speed, requiring a
current of 1/2.03 = 0.5 A. At 75C winding temperature the copper
losses would be 0.5 2 x 5.35 = 1.34 W. The RMS current in each phase is
0.5 x 7(2/3) = 0.408 A, so the RMS current density is 0.408/(k /4 x
0.0082) = 8120 A /in2.
13.4 Summary
The basic process of manual calculation of a design is the same for all
brushless motor designs including servo motors. The requirement,
packaging, cost and production methods help the designer select the
magnet grade, interior vs. exterior rotor, number of slots, poles and
winding method. The performance goals are laid out, the flux per pole
is calculated, then the turns per coil and finally the wire gauge and line
to line resistance and the losses.
This process can be reproduced on the computer using either
spreadsheet formulations of the basic design formulas, or powerful
13-26
13. E x a m pl es c a l c u l a t e d by h a n d
13-27
14. CONTROL SYSTEMS PERFORMANCE
14.1 Introduction
Brushless permanent-magnet motors have a linear torque/current
characteristic, low torque ripple, and fast response. This makes them
highly suitable for controlling speed, position or torque, either in a
single-quadrant variable control mode, or as four-quadrant servomotors
with reverse speed capability and dynamic braking.
This chapter describes the brushless permanent-magnet motor and its
controller as a control system. It includes a review of the simplified
mathematical models that describe the motor and controller, followed by
the main types of control system. Control system design is described in
relation to closed-loop operation, frequency response, step response,
stability, steady-state error, root loci, lead/lag compensation, pole
placement, and robustness. The design and tuning of PID controllers is
discussed in both linear (analog) and digital forms. Z-transform methods
are described for discrete digital systems. The chapter concludes with a
review of modern control methods including adaptive control, optimal
control, and observers.
14-1
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
14-2
14. C o n t r o l systems perfo rm a n ce
JW *U)
unit impulse S (<) I l
unit step 2 z
s z- 1
1 z
O '" s*a z - e~ T
cos co0/ s 2{z~ cos 0l> T)
S2 * 0)02 z 2 -2 z cos (J T* 1
<>0 z sin u T
sin ai0t z 2 - 2z cosu>T+ 1
4-Z + 0>02
s+a X / e 'sTcos(i) 7)
e~* cos Ci)</ (s + a)2 + (002 z 2 - 2ze~aTcos a) T+ e'2aT
e 'at sin G)0/ o ze~Brsm<i>r
(s + a)2 + co02 z 2 - 2 ze'aTcosu> T + e 2fl3"
Table 14.1 T able o f L aplace a n d z tra n sfo r m s
A t) = ~2irj [ T f i s ^ d s (14.3)
In many cases this contour integral does not need to be evaluated: instead,
the function F{s) that is to be inverse-transformed is expanded by partial
fractions into a collection of simpler expressions that are in a standard
table like Table 14.1. After inverse transformation of the partial fractions,
the resulting time functions are added together to get the overall time
function required.
14-3
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
*<8
Fig. 14,1 Step response associated with various pole positions in the complex plane
14-4
14. Control systems performance
14.2.2 Transfer functions
A transfer function represents the relationship between the driving
(input) signal and the response (output) of a dynamic system. It is
defined as the ratio of the Laplace transforms of the system output and
input, assuming zero initial conditions. With this definition, the transfer
function concentrates on the relationship between one output and one
input. If there are many inputs and many outputs, there will be a
different transfer function for every pair of input and output signals.
The roots of the denominator of the transfer function are known as the
system poles. (See also section 14.5.5). They are often plotted on the
complex plane as in Fig. 14.1. They describe the dynamic characteristics
of the system. If any pole has a positive real part a, it means that there
is an exponentially increasing element in the response and the system is
unstable. If the poles have non-zero imaginary parts, it means that the
response is partly oscillatory. This can be seen in Fig. 14.1. Negative real
poles indicate an exponentially decaying response. Complex poles always
come in pairs, with equal and opposite imaginary parts, i.e. conjugates.
14.2.3 Example of a DC or brushless DC motor
In Chapter 1 it was shown that the DC and brushless DC squarewave
motors can be represented by the same simple model in which V
represents supply voltage, /is armature current, / is armature resistance,
kE is the EMF constant, kj is the torque constant, Tc is the motor torque,
J/ is the rotor inertia, a is the rotational acceleration, and gjm _ is the
angular velocity. Armature inductance is assumed to be zero and any
mechanical shaft resonance is ignored.
We have seen in Chapter 1 and elsewhere that the speed is essentially
controlled by the voltage: in the steady state, assuming the load torque
is zero, the speed is given by equation (1.7) as
V= RI+ *E m; (15.4)
Tt = k , /; (14.6)
re = /a - (14.7)
and
(14.8)
dt
- a .
14-6
14. C o n t r o l system s p e r f o r m a n c e
14.3 Modelling drive components
In developing a controller for a servo system, it is necessary to create a
model of the "plant", which is that part of the system consisting of the
motor, the drive, the position and/or velocity transducers, the load, and
any mechanisms such as actuators or gear trains. Most control system
design methods require a linear plant model. This means that the
coefficients in the differential equations are constant: i.e., independent
of time and of speed, voltage, etc. If the plant model is not linear, it can
sometimes be linearised for small variations about an operating point
using "perturbation analysis.
14.3,1 Brushless PM motor model including inductance
The simple dynamic model of the brushless DC motor can be extended
to include the effects of inductance as follows. The electrical equivalent
circuit is shown in Fig. 14.2. E is the back-EMF, equal to The
electrical equation of the motor is
V =L ~ +R I + (14.12)
dt b m
We can assume that the magnetic field is constant and that the
electromagnetic torque T is proportional to current:
T =V - <14-13)
The mechanical properties of the motor are the inertia Jm and friction
torque Tf. Friction is often a nonlinear function of speed, and it is usual
to allow for a "viscous damping term" Dv>m, to represent at least that part
of the friction that is proportional to speed. The load can often be
Ia R La
14-7
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a c n e t m o t o r s
T = <V ~ (14.16)
Ls + R
Neither friction torque, 7} nor load torque TL affects the motor transfer
function, so they can be set to zero. The mechanical differential equation
(14.14) then transforms into
T = (/m * JL) s u m + (14.17)
(14.19)
\Xs) (L s * * )[(/ + f j s + D] * kEk ,
14-9
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
14.3.3 Transducers
When a motor is used as part of a control system, it is desirable to
measure some output variables of the system for comparison with the
desired values. Velocity and position are common examples. In position
servos, it is usual to have feedback of both position and velocity. One
solution is to measure position using an encoder and to use electronics
to calculate velocity from the encodcr output. Alternatively, resolvers may
be used with resolver-to-digital converters.
14.3.4 Load effects
The load affects the performance of the control system. For example, a
high load inertia JL slows the response, and a variable load torque can
cause unwanted speed variations. It is therefore important to account for
the load when modelling the system and to design the controller to be
sufficiently robust to allow for variations in the load.
14-11
D esign of brushless permanent-magnet motors
transfer function of the plant, and o rcf is the speed reference signal at
the input. The feedback loop tends to reduce the error between the
actual motor speed and the reference speed. Often the error signal is
amplified to increase the gain, as shown in Fig. 14.3. The amplification
may include "dynamics", such as the parallel addition of a term
proportional to the integral of the error signal. Accordingly the error
amplifier has its own transfer function C(j) as shown in Fig. 14.3. The
controller C(s) is designed to optimise certain system properties such as
robustness, stability and bandwidth, and it is sometimes known as a
compensator.
The transfer function of the closed loop system shown in Fig. 14.3 can
be derived easily as follows. If the error signal is represented as E(s) then
from Fig. 14.3
r(s) = 0 W{s) x B{s) and E{s) = U(s) - Y(s) ( 14-22)
so that by eliminating (j),
n s ) _ a s) m s) (1428)
U(s) 1 + a s ) W {S)'
This expression is written in terms of a general output variable Y(s) and
a general reference signal U(s). The denominator is significantly changed
by closing (he feedback loop, and so also is the gain. The system poles,
and therefore all its response characteristics, can be cxpected to be
significantly modified by loop closure, and later sections will examine
how these changes can be controlled.
14.4.2 Speed controls and servo systems
A speed controller that controls forward speed only, and is not capable
of producing a negative or braking torque, is known as single-quadrant
control, Fig. 14.4. It operates in only one quadrant of the spced/torque
plane. A true servo system operates in all four quadrants. That is, it can
produce motoring or braking torque when the motor is running in
either direction.
A control system alters a dynamic system to give more accurate control
of speed, position, etc., and it is often required to meet other
performance objectives such as robustness, stability, and rapid response.
14-12
14. Control systems performance
14-13
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
ERROR SIGNAL
Fig. 14.5 Block diagram of a hybrid position and velocity control system
* The dccibel i> defined as 20 !og]n((7), where G is the ordinary value of the gain. Some
normalization may be necessary to express the gain in dimensionless units or per-unit
before calculating the decibels.
14-16
14. CONTROL SYSTEMS PERFORMANCE
PHASE U G H
Fig. 14.6 Bode diagram of a first-order motor drive system with a single poic at
-*i.kt/RJ.
14-17
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a c n e t m o t o r s
14.5.2 Bandwidth
The bandwidth of a system is the frequency range over which the gain is
within 3 dB of the maximum gain. In servo drives the maximum gain is
usually the DC gain, reflecting the fact that slow variations in the demand
for velocity or position changes can be followed with high accuracy and
little phase shift. In order to follow rapid changes in the demand signal1
with high accuracy and minimal phase shift, the system requires a high
bandwidth. The bandwidth is generally different for different controller.
A torque control can generally have a much wider bandwidth than a
velocity controller, mainly because of the effect of inertia in slowing
down the rate at which speed changes can be made. A position controller
generally has a lower bandwidth. A very high velocity-loop bandwidth
requires low motor inertia, and the ultimate performance is achieved
with "moving coil" motors or ironless motors, which can have a
bandwidth of several thousand rad/s. Position loop bandwidth is
generally below 1000 rad/s.
A high bandwidth may imply a high power requirement if high torque
is to be repeatedly applied at high velocity. This directly affects the cost
of a servo drive. As the design bandwidth increases, so does the system's
susceptibility to noise and interference, requiring special measures in the
screening of transducer signals and the electronic circuit design.
14.5.3 Step response
It is often of interest to see the time-domain response of a dynamic
system to a step change in input signal. A step input contains information
at all frequencies, is often easy to apply experimentally, and gives an easy-
to-understand illustration of the how the system behaves. The response
can be calculated using the inverse Laplace transform (section 14.2.1).
For a first-order system such as the motor described in equation (14.11),
a step input is represented in the s-domain by the function V/s, and the
response is the speed as a function of time, given by
V Itffc
s (14.24)
1 + s--&RJ. J
14-18
14. CONTROL SYSTEMS PERFORMANCE
U sing partial fractions,
n ( ') = (14.25)
s + ^T-^E
RJ
From Table 14.1,
m<') - IT fi - '* ] (14.26)
w here
is the mechanical time constant. This time response can be seen in Fig.
14.7. It shows immediately how long it takes for the system to setde into
a new steady state. After one time constant (t = t ), the function 1 - e_1
* 0.632, so the speed is within 36.8% of its final value. Table 14.2 shows
the approach of the speed to its final value in these terms. After 5 time
constants, the speed is within 0.7% of its final value. This setding time
might be too long in many applications, and feedback controllers may be
designed to speed up the response.
NORMALISED OUTPUT
14-19
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a c n e t m o t o r s
/A 1 - e U'
0 0 1
l 0.632 0.368
2 0.865 0.135
3 0.950 0.050
5 0.993 0.007
1 + H is )
= 7 :--------------U.S)
(1 + G)
+ jr m
(14.29)
while the transfer function between the error signal and the input is
(14.29) this is
09) = (14.31)
\*G
Similarly for the error e{t), the limit as s - 0 of [ j x l / s x (.t)] is
* ' - > ) = 1 + Cr (H.32)
14-21
D e s ic n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
This result reveals an error in the final value of the system with respect
to the reference input. The steady-state error decreases as the forward gain
G of the system is increased, but to remove the steady-state error
completely, it would require infinite gain which is not practical. In
practice, increasing the gain generally produces instability sooner than
it reduces the steady-state error to an acceptable value.
14.5.6 Integral gain compensation
If the error amplifier has a transfer function C(.t) = 1/s, it is an integrator
rather than a plain amplifier, and the open-loop transfer function
acquires a pole at the origin (s = 0):
a s) ^ 5 ) = - -----(14.33)
* 0 + "m )
The effect of this on the steady-state output signal is that
yU ) = lim = 1. (14.34)
o sU + sr m) + G
Similarly
e (t >) = slim * ^m ) (14.35)
o j( l + ^rm) +G
Equations (14.34) and (14.35) show that the integrator removes the
steady-state error completely, A system whose open-loop transfer function
has a single pole at the origin is called a Type 1 system, and it has a zero
steady-state error. With no pole at the origin, the system is a Type 0
system and there is a finite steady-state error that depends on the gain.
14.5.7 Root locus
The characteristic equation of a system is the denominator of the transfer
function equated to zero. The roots of this equation are the system poles
and they reveal much about the system dynamics. In a closed-loop
feedback control system such as that illustrated in Fig. 14.3, the
characteristic equation is obtained from equation (14.23) as
1 + CW = 0. ( 14. 36)
14-22
14. C o n t r o l system s p e r f o r m a n c e
M the controller parameters are varied, the values of the poles change.
T hese poles can be plotted on the complex plane as a function of some
design parameter of the controller (e.g. the gain G), and the resulting
g raph shows the migration of the poles as this parameter is varied. The
set of graphs for all the system poles is called the root locus diagram.
A typical root locus for a third-order system is shown in Fig. 14.8. For the
sake of argument, assume that the variable control parameter is the
forw ard open-loop gain term G. We can tell the number of roots
immediately from the number and nature of the branches in the
diagram . The leftmost branch is associated with a single real pole that
starts at point E when the gain is low. As the gain increases this pole
migrates leftwards along the negative real axis. The right-hand root locus
begins with two negative-real poles at points A. As the gain is increased,
these poles approach one another until they merge at C. At higher values
of gain they separate into two conjugate poles with an imaginary part that
indicates that the system has an oscillatory component in its response.
Ihe system is stable provided the gain is not too large, as long as the
poles retain a negative real part. At higher values of gain the complex
poles migrate into the real half-plane and the system is then unstable. A
14-23
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
14-24
14. Control systems performance
ym a - 1 . . - t h / T ? < 1 4 4 0 >
14-25
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
and transient behaviour. The control system alters the plant dynamics to
match the specified closed-loop transfer function. The specified transfer
function must be robust to disturbances and plant parameter variations,
and of course the controller must be realisable and economical to
produce.
All of the above methods require a certain amount of judgement in their
execution. There is usually more than one possible solution and some
compromises may be required, even including a certain degree of
arbitrariness. As control design techniques become more sophisticated,
however, this arbitrariness decreases. More complicated techniques are
often based around optimising some quantitative performance index or
'cost function'. This cost function could be the mean squared error
between system output and a desired response for example. It could also
be subject to constraints on steady-state error, rise-time or overshoot.
Such control design methods produce high-performance, robust
controllers which often require accurately measured system variables for
feedback and high bandwidth controllers. Both facilities are expensive.
14,6.1 Lead-lag compensation
Lead and lag compensators are among the simplest of controller designs.
They work by altering the phase of the plant. A transfer function of such
a compensator is given by
His) = 1 + sl* . (14.41)
1 + s/aa
For a>l the equation represents a lead compensator, and for a<l it
represents a lag compensator.
The Bode diagrams of a lead and a lag compensator are shown in Figs.
14.9 and 14.10. Lead compensators increase the bandwidth by increasing
gain at higher frequency, and they increase the stability by increasing the
gain and phase margins. Lag compensators can be used to decrease the
bandwidth or alter the phase and gain margin to a specification. They
can generally be implemented using R-C circuits. Design of lead and lag
compensators normally involves specifying closed-loop parameters such
as gain and phase margin and then using root locus, Bode diagram or
Nichols chart techniques (among others) to design a controller within
practical constraints such as not having any poles too near the origin and
ensuring that o in equation (14.41) is not too large.
14-26
14. CONTROL SYSTEMS PERFORMANCE
GAIN (dB)
PH A SE LAG O
LOGFREQUENCY
LOGFREQUENCY
Fig. 14.10 Bode diagram of a typical lag compensator
14-27
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
Fig. 14.11 Block diagram showing DC or brujhlcss DC motor with velocity and
position feedback
14-28
14. C o n t r o l system s pe r f o r m a n c e
As in section 14.5.8, the transfer function can be written in the generic
form for a second-order system:
iKs) = -^ (14.44)
.r2 + 2 C<on^ + o>n2
The normalized step response can be calculated using the inverse
Laplace transform (equation (14.3)) as
To find the timeto first peak, equate dy{t)/dt to zero: the result is
^ = -----------T = - (14-46)
These values are then substituted into equation (14.44) which is equated
with equation (14.43) to give values for the control gains:
velocity gain Gv - 0.017 A/iad-s'1
position gain G - 1.89 A/rad
14-29
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
The poles are located a t.? = -67 j 78.3 and the closed-loop system step
response looks like Fig. 14.12.
14.6.3 Robustness
Lead-lag compensation and pole placement are examples of good
classical control design techniques. One drawback is that they are
strongly based on the dynamics of the system being controlled and not
very robust to changes in the plant or to external disturbances. Dynamic
system parameters can change due to operating conditions and also due
to component ageing over the lifetime of the system. The load can also
vary, and sometimes one controller must be able to handle a variety of
different loads. The ability of a controller to cope with changes in plant
and load as well as with external disturbances is called robustness. More
robust controllers can cope with changes in plant dynamics and can
therefore be thought of as more general-purpose controllers. A well-
known and widely used robust control design is PID
con tTo\proportional/integral/denvatwe control.
14-30
14. C o n t r o l system s p e r f o r m a n c e
14-32
14. C o n t r o l system s p e r f o r m a n c e
Fig. 14.13 Step response of third-order system showing Ziegler-Nichols PID design
technique
7J = I B (14.50)
rd = 0.55 (14.51)
where the PID controller is represented by
a s) = ^(1 + 1!T{s + 7dj). (14-52)
The engineer would implement the controller with these gains and then
"adjust on test" to achieve a satisfactory closed-loop response.
14.7.3 Auto-tuning
It is possible to tune PID controllers automatically. An auto-tuner applies
certain inputs to the closed-loop system and records the output. From
this data, it calculates the parameters for the PIDcontroller. A potential
problem is that the input may exceed the plants limits of safe operation.
An alternative is adaptive control This means that the parameters are
continuously varied while the system is in operation.
14-33
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
TIME (SECONDS)
fig 14.14 Example analog signal with digital sampled signal and a zero- order hold
(ZOH)
14-35
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
14.8.2 Z transforms
Whereas the Laplace transform is used for continuous system analysis, the
z transform is used for discrete systems. It works by replacing a
continuous signal by a sequence of equally spaced impulses. The equal
spacing is determined by the system clock rate or sampling rate, which
applies throughout the system. The z transform is defined as
00
/=H = f[nT )z'a (14.54)
ZbO
G (s ) = I - e-sT \ (14.55)
s+a
D(s)D(z) G(s)G(z)
14-36
14. C o n t r o l system s p e r f o r m a n c e
Then
m = iA* a*)
=
Zf
1-^-11
\ s + a\
-
s (14.56)
= u m - z->)
Using partial fractions,
(14.57)
r(z) = (1 - z - l) U tf
ZHl-Zfcf
From Table 14.1,
Y(z) _ 1 - e -aT (14.58)
V{) z - e H i'
The controller equation is
U() = Uz ' 1 + AqE(z) (14.59)
C/jz) g V (14.60)
2?(2} z- 1
(4 = >w (14.61)
n $ - W A G te (14.63)
R(z) 1+D(z)G(z)
Equation (14.63) is analogous to the continuous time expression for a
closed loop system in the s domain (equation (14.23)).
14-37
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
SPEED
ii
1.0- J t K * * X X X X
0.8 -
0. 6 -
0.4.
0 .2 .
Fig. 14.16 Deadbeat step response of a discrete speed control system with sampling
time 7' 0.012 seconds
14-39
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
(14.70)
z- 1
so the discrete transfer function of the complete system is
na _ DiAGiA _ i {147l)
R(z) 1 + D(2>)G($ z
1 4 -4 0
14. C o n tr o l systems pe r f o r m a n c e
Ap, kt and ftd are the proportional, integral and derivative gains
respectively. e(n) is the error signal or controller input at sampling
interval n and u(n) is the controller output.
The controller is protected against integral wind-up by having a limit
The integral sum is not allowed to exceed this value. Problems due to the
differentiation of noise are avoided by having a longer sampling interval
for the derivative term. The sampling interval means that the signals with
a frequency content higher than T J'i are ignored (where T is the
sampling interval). In this way, the derivative term has filtering action.
This type of digital PID controller typically comes in one integrated
circuit which can also include a summing junction and a digital-to-analog
converter for the controller output. It is normally programmed as if it
were an analog PID controller and the gains were analog PID gains.
14.8.8 PID control example
A nonlinear simulation program, PC-BDC [2] is used here to illustrate the
effect of a three-term PID controller on a 4-pole brushless DC motor with
surface-mounted permanent magnets. The motor is running at 2000 rpm
and is then forced with a step demand of a 200 rpm increase. After 0.04
seconds, the load torque increases from 0 to 0.45 Nm. Position is
measured by a 16-pulse encoder and the controller sampling rate is 2
kHz.
Fig. 14.17 shows the response of the system with no integral or derivative
termpurely proportional gain. The response to the step increase in load
torque shows a slight overshoot and a steady-state error of about 225 rpm
or about 10 % on the new set-point value of 2200 rpm.
Fig. 14.18 shows the effect of increasing the proportional gain. The
steady-state error is reduced but the overshoot is increased and the
response is slighdy more oscillatory.
14-41
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
14-42
14. C o n t r o l system s p e r f o r m a n c e
Fig. 14.19 shows the system with a PI controller. The steady-state error is
reducing but the overshoots are large, leading to concern about the
stability of the system.
The output with a complete PID controller is shown in Fig. 14.20. The
derivative term stabilises the system by adding damping. The output of
each of the three stages in the PID controller is shown in Fig. 14.21 and
illustrates the effect of each of the components.
14.9 Advanced control techniques
PI and PID control are widely used in industry for motor control because
they are robust and give good performance at low cost. However, control
theory has advanced considerably beyond three-term controllers and
many new techniques have been developed which can be applied to
motor control. Most motor control system design is done using classical
techniques based on transfer function descriptions of the plant and
described elsewhere in this chapter. More advanced techniques are
available.
14.9.1 Adaptive control
Control systems are designed specifically for one plant and one
performance specification. Robustness can be designed in to allow for
variations in the plant, but only to a limited extenL Also, the model on
which the control system design is based must usually be linear.
Nonlinear models must be linearised at some operating point and this
also compromises the performance of the final system because the motor
is expected to operate beyond the range of validity of the linear model.
One solution is to design a controller which changes or adapts as the
operating conditions change, that is, adaptive control The controllers are
constandy changing and are often nonlinear. This makes it more difficult
to ensure that the system remains stable in all cases. Three common
examples of adaptive control are self-tuning regulators, model reference
adaptive control (MRAC), and sliding-mode controllers.
Self-tuning regulators are based on conventional controllers such as PI
but the controller parameters or gains are constandy varied according to
the performance of the closed-loop system.
14-43
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
14-44
14. C o n t r o l system s p e r f o r m a n c e
............. U3J...T. t ... I.Bem.__ ruTQC7.Bnc........... .
1.00
a.00 i
a.4Q 0.60 D.6D i.oa
...................EHTJEEBG&JREEIr..
cr n I rrzi ruYflw.m
.. li ftt-i.MSiLArf.fl.n
L.90
0*90
1.20
Capcorsdil *
1.00
fig. 14,21 Output of each of the three terms of a PID controller for a PID controlled
BDC motor
Model reference adaptive control involves feeding the input signals of the
actual controller into a dynamic model of the system that is simulated
continuously in real time on a computer. The input signals are
simultaneously fed to the real system, and the output signals from the
computer model are compared with the output signals from the real
system. The error or difference between these signals is used to adapt the
parameters of the controller continuously so that the closed-loop system
response is as close as possible to that of the specified dynamic model.
In sliding mode control, the state of the system (a vector defining the
velocity, position, etc) is constrained to move or slide along a predeter
mined trajectory in "state-space". This trajectory could be a curve on a
velocity/position plot, for example. The controller adapts as the point
representing the system state crosses and re-crosses the prescribed
trajectory, so that the system always approaches the prescribed trajectory
in a stable manner even if the system is actually unstable at points. It is
analogous to a bang-bang controller or to a hysteresis current-regulator.
14-45
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
14-46
15. COOLING
15.1 Introduction
Heat transfer is as important as electromagnetic and mechanical design.
The analysis of heat transfer and fluid flow in motors is actually more
complex, more nonlinear, and more difficult than the electromagnetic
behaviour. It is often dealt with by means of simplified equivalent
circuits, and rarely receives the detailed analysis lavished on electromag
netic aspects.
Perhaps there is some justification for using approximate methods for
heat transfer, when exact methods are pursued for electromagnetic
design. The electromagnetic design determines the geometry of
laminations which are cut to fine tolerances. Their geometry and
thickness, together with their material properties and the design of the
windings, determine whether or not the motor will deliver the required
torque. They also determine the precise voltages and currents that will
be experienced by the power semiconductors in the controller. All of
these items critically affect the manufacturing cost. By contrast, as long
as the temperature rise does not exceed a nominal or specified value, the
actual thermal condition of the motor mainly influences how long the
motor will last, and has only a marginal influence on whether the torque
can be delivered. Furthermore, the motor designer often has little
control over the ultimate thermal environment of the motor, so there
may be little point in attempting exact thermal analysis.
There are two major aspects to the thermal problem: heat removal, and
temperature distribution within the motor.
In most motors heat is removed by a mixture of air convection,
conduction to the frame mountings, and radiation. In highly-rated
machines direct cooling by oil mist or even liquid coolants can be used
to achieve high power density. In "hermetic" motors used in refrigerator
compressors, the motor losses are usually transferred to the refrigerant
which may pass right through the motor.
The temperature distribution within the motor is essentially a diffusion
problem. It is difficult to analyze precisely, because of three-dimensional
' effects and "imponderable" parameters such as the thermal contact
resistance between, say, a bunch of copper conductors and a slot liner.
15-1
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a c n e t m o t o r s
Empirical rules are available, to be used with care. The most important
aspect of the temperature distribution problem is finding the hottest
temperature in the motor, given a certain distribution of losses and a
known rate of heat removal. The steady-state temperature distribution
can be very different from the transient distribution, and different
methods of analysis may be needed for the two cases.
The main reasons for limiting the temperature rise of the windings and
frame of a motor are:
1 to preserve the life of the insulation and bearings;
2 to prevent excessive heating of the surroundings; and
3 to prevent injury caused by touching hot surfaces.
The "life" of electrical insulation can be predicted only by statistical
methods, but in broad terms the life is inversely related to the
temperature, and the relationship is exponential, so that a sustained
10 C increase in temperature reduces the insulation life by approxi
mately 50%. Intermittent periods at higher-than-normal temperature can
be tolerated repeatedly, depending on their duration and the actual
temperatures reached. A spectacular example of this is the FUMEX
motor , which is used to extract fumes via the ventilation systems of
public buildings and concourses in the event of fire; these motors can
operate in an ambient temperature of 300 C for a limited period of 30
minutes. (After that the insulation life is well-and-truly used up). Similar
considerations apply to bearings. Grease-lubricated bearings maybe filled
with high-temperature grease for hot-running applications, but in
aerospace machines the bearings are usually lubricated by separately-
cooled oil or oil mist.
Heating of the surroundings is obviously undesirable especially if the
motor is heating the equipment it is driving. For this reason it is
important to minimize rotor losses, which are difficult to remove and are
conducted along the shaft. PM motors have cooler rotors than DC or
induction motors.
15-4
15. C o o l in g
plate is 1C/W, then with 40W flowing though it the temperature
difference across the interface would be 40 C.
The contact resistance between metallic surfaces held tighdy together
depends on the surface finish. For a 120pin milled finish the heat
transfer coefficient can be estimated as 0.7W/in 2/C , corresponding to
a thermal resistance of about 1.4C/W for an area of lin 2. A lapped
surface (5pin) might have a value of half this. Thermal grease can be
used to improve the heat transfer and lower the contact resistance by a
factor of approximately 2 by replacing the voids which otherwise would
be filled with air. The problem with thermal grease is that it tends to
migrate. An alternative is to use a gasket which may be made of
aluminium or copper foil, or special matrix materials impregnated with
graphite or silicone.
When conduction through the stator stack is the main path for heat
removal from the windings, it is advantageous to have a large number of
small slots in order to maximize the contact area between the core steel
and the windings and minimize the diffusion path length through the
slots for heat generated in the copper.
15-5
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
15.2.3 Radiation
Radiation is described by the Stefan-Boltzmann equation
S = e o i T f - T * ) W/in 2 (15.4)
A
where a is the Stefan-Boltzmann constant, 5.67 x 10 ~8 W /m^/K 4 or 3.66
x 10"11 W /in2/K for a black body. A black, body is a perfect radiator (no
reflection). Real surfaces are imperfect radiators and their effectiveness
relative to that of a black body is called the emissivity e. A black lacquered
surface can achieve an emissivity as high as 0.98, but a more practical
rule of thumb is to take 0.9 for black-painted or lacquered surfaces.
The temperature Tx is the absolute temperature of the radiating surface,
and T2 is the absolute temperature of the surroundings radiating back
to the motor .2 For example, a surface with an emissivity of 0.9 that is
50 C above the surroundings at 50 G, has a net heat transfer rate of
0.9 * 3.66x 10' 11 * ((50+50+273) - (50+273)4) (15-5)
which is 0.28 W /in2. A surface 30 C above the surroundings at 20G has
a rate of 0.12W/in 2 - quite a useful component of the heat-removal
capability of the frame.
15.2.4 Convection
Heat removal by convection is governed by Newtons Law.
-Q = Ji A T W/in2 (15.6)
A
where AT is the temperature difference between the cooling medium
and the surface being cooled, and h is the heat-transfer coefficient. The
units of h are W /in2/C [or W /m 2/C ]. The value of h depends on the
viscosity, thermal conductivity, specific heat, and other properties of the
coolant, and also on its velocity. In natural convection the flow of coolant
is not assisted by fans, blowers, pumps etc. In forced convection the flow is
assisted by one of these external means.
2 The absolute temperature in degrees Kelvin (K) is the temperature in C plus 273.
15-6
15. COOUNG
15-2.5 Natural convection
The heat transfer coefficient for natural convection around a
horizontally-mounted unfinned cylindrical motor can be roughly
estimated as
h (15.7)
For example, for an unfinned cylinder of diameter 4 in and a tempera
ture rise of 50 C, the natural-convection heat-transfer coefficient is
calculated as 0.0040 W /in 2/ 0C. For a A T of 30 C the heat transfer rate
is then 0.12W/in2. As a first approximation this value can be applied to
the whole surface including the ends, but if the motor is flange-mounted
then only one end is available for convective cooling.
15.2.6 Forced convection
Forced convection, with "air-over" cooling from a shaft-mounted or
external fan, increases the heat-transfer coefficient by as much as 5-6
times, depending on the air velocity. The increase in heat-transfer
coefficient is approximately proportional to the square-root of the air
velocity. An approximate formula for the forced-convection heat-transfer
coefficient is
h - 11.2 * 10^ (15.8)
where V is the air velocity [ft/min] and L is the frame length [in]
(assumed parallel to the direction of airflow). For a motor of length 3.7
in, if the air velocity is 800 ft/min, this formula predicts h = 0.0165
W/in 2/C . This is 4 times higher than for natural convection.
The air velocity V is the actual air velocity, not the so-called "no-load"
value.The no-load flow through a fan is usually specified in cubic
feet/min (CFM), and the no-load velocity is given by the no-load CFM
dividedby the fan inlet area (in ft2). The actual air velocity is determined
from the intersection of the curve of static pressure vs. flow rate for the
fan,and the pressure/flow curve for the air path over the motor. This
calculation requires the use of fluid-dynamics, but a rough guide is to
takeV as one-half the no-load value:
15-7
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
where Qis the total rate of heat removal and A is the temperature-
rise of the air passing over the motor. Normally A T^t should be limited
to about 15C for an ambient temperature of 50 C. For example, if 100
W is to be removed with a A Tair of 15C, the actual CFM of the fan must
be 11.7 CFM. To allow for static pressure drop, a no-load fan of 25-30
CFM should be considered.
15.2.7 Some rules of thumb for "calibration"
Holman [1] gives an interesting example of a water-immersed wire 1 m
long, 1 mm diameter, in which a power loss of 22 W (0.56 W per inch
length) is sufFicient to boil the water at the wire surface. The wire surface
temperature is 114C and the heat transfer coefficient (see below) is
5000 W /m 2/C or 3.23 W /in 2/C . The heat flow at the wire surface is
45 W /in 2 (0.07 W /mm2) and the current-density in the wire is
approximately 35 A/mm2.
In normal motors, the rate at which heat can be abstracted is nothing like
as high as this. Correspondingly, current-densities as high as 35 A/mm 2
are achievable only for very short bursts. This current density is sufficient
to fuse a copper wire in free air.
The maximum rate at which heat can be removed from a surface by
natural convection and radiation (with 40 C rise) is only about 0.5
W /in2. With forced air convection the rate increases to about 2 W /in2j
and with direct liquid cooling about 4 W /in2. Motors that generate more
heat than can be removed at these rates have to absorb the heat
internally in their thermal mass, which is an acceptable way of increasing
the output power for a short time.
These rates limit the heat generated per unit volume to about 0.2 W/in
for natural convection, 5 W /in 3 for4 metallic conduction, 7 W /in 3 for
forced-air convection, and 10 W /in for direct liquid cooling.
15-8
15. C o o l in g
If rated torque is required at very low speed, a shaft-mounted fan may not
provide enough coolant flow to keep the motor cool. DC motors often
have separate AC-driven fans, because they have to work for prolonged
periods at low speed with high torque. Since most of the heat in a DC
motor is generated on the rotor (in the armature windings and the
commutator), a good internal airflow is essential for cooling. In DC
motors the external fan is usually mounted to one side of the motor,
where it is easily accessible, and does not increase the overall length. A
similar problem arises with AC induction motors, especially vector-
controlled motors. A common practice is to mount the fan in line with
die motor at the non-drive end, and arrange it to blow air over the
outside of the finned frame. The fan may increase the overall length by
as much as 60%. Brushless motors do not have this problem to the same
degree, because most of the heat at low speed is generated in the stator
windings, where all three forms of cooling (conduction, radiation and
convection) are more effective.
15-9
D e s ig n o f b r u sh l e s s pe r m a n e n t -m a g n e t m o t o r s
= J L m 2/s (15.13)
pc
n
is the dijfustvity in SI units. (English units are in /s). In SI units, k is the
thermal conductivity in W/mC; cis the specific heat in kJ/kgC, and p
is the density in kg/m 3. In a structure as complex as an electric motor
the heat conduction equation is a complex boundary-value problem that
is best solved by computer-based numerical methods such as the finite-
element method.
In electric motors the internal convection and radiation processes may
be as important as the conduction process, and when the differential
equation is extended to include them, matters become very complicated.
15.3.2 Thermal equivalent circuit
For most practical purposes it is sufficient to use a thermal equivalent circuit
of the interior of the motor, Fig. 15.1. The thermal equivalent circuit is
an analogy of an electric circuit, in which heat is generated by "current
sources" and temperature is analogous to voltage. The rate of generation
of heat in a source is measured in Watts. The heat flow rate, which is also
measured in Watts, is analogous to current. Resistance is measured in
C/W. The copper losses, core losses, and windage 8c friction losses are
represented by individual current sources, and the thermal resistances of
the laminations, insulation, frame, etc. are represented as resistances. In
the simplest possible model, all the losses are represented together as
one total source, i.e. the individual sources are taken as being in parallel.
Heat source W inding H ot Spot
(losses) T S
15-10
15. C o o l in g
The thermal equivalent circuit is really a lumped-parameter model of all
the heat-flow processes within the motor as well as the heat removal
processes discussed in section 15.2.
Pd
0
The thermal equivalent circuit shown in Fig. 15.4 includes provision for
direct cooling of the winding conductors, ("cad" = eonductors-to-
a m b ie n t/ direct); and for direct cooling of the rotor shaft ("had" =
staft-to- ambient direct). It also includes the thermal mass or capacity of
the winding , and the thermal capacities of the rotor and stator
laminations, and The other internal thermal resistances are
essentially self-explanatory.
The heat removal routes by conduction, radiation, and convection are
also represented by thermal resistances. For convection the appropriate
resistance is given by
15-11
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
^
= J - -C/W (15.14)
hA
where A is the appropriate surface area for convective heat-transfer and
the subscript "v" stands for convection. If A is a function of the
temperature-difference, the equivalent circuit becomes non-linear and
requires an iterative solution. For radiation the equivalent thermal
resistance is the ratio of the temperature difference 1\ - T2 to the
radiation heat exchange rate Q in equation (15.4). Clearly this is non
linear. However, the non-linearity is often neglected and a fixed value of
Rf is calculated assuming that the final temperature of the case is known.
15.3.3 Current Density
The current-density cannot be directly related to the temperature rise of
the winding by a simple general equation, because the heat transfer rate
depends on the shape of the conductors. For example, 1 in3 of copper
can be made into a stubby cylinder of 1 in diameter and 1.27 in length,
or a long wire of 0.5 mm diameter and 83 m length. If only the
cylindrical surface area is available for cooling, the short cylinder has a
surface area of 4 in2 while the lone wire has a surface area of .2039in2.
The loss density in W /in o in copper conductor is J n p where yis in A/in
and p is in p-in. At 20 C the resistivity of copper is approximately 0.68
pQ-in, but at 100 C it is about 1.16 p2-in. If 1 W can be dissipated from
every in2 of surface at 100C, this suggests that in the short stubby
cylinder the permissible current density is 2,115 A /in2 (3.3 A/mm 2) and
in the long wire, 15,076 A /in2 (23.4 A/mm 2).
With this reservation, it is still possible to quote typical values of current
densities used in motors cooled by different methods:
15-12
15. C o o l in g
Material Emissivity
Polished aluminium 0.04
Polished copper 0.025
Mild steel 0.2-0.3
Grey iron 0.3
Stainless steel 0.5-0.6
Black lacquer 0.9-0.95
Aluminium paint 0.5
T a b le 15.4 Selected e m issiv it ies
15.4.1 Duty-cycle
The duty-cycle d is defined as
d = . (15.16)
'e y ' o n + 'o f f
The most efficient use of the thermal capability of the motor will be
9
This section is an expanded analysis based on ideas originally published in the paper
"Dynamic thermal model for a three-phase sinusoidal Ag brushless servomotor" by Richard
Welch and George Kaufman of Reliance Motion Control.
15-14
15. C o o l in g
made if the maximum winding temperature T just reaches the rated
value Tt at the end of each on-time. Because the power dissipation is
interrupted with cool-down intervals (OFF, the power that can be
dissipated during the on-times may exceed the steady-state continuous
dissipation rating of the motor PT, and therefore the motor may be
permitted to exceed its steady-state output power rating during the on-
times. The simplified thermal equivalent circuit model in Fig. 15.1 makes
it possible to calculate the permissible overload factor as a function of
the on-time <ON and duty-cycle d for a given motor.
The thermal equivalent circuit is a parallel combination of thermal
resistance R and thermal capacitance C. R represents the steady-state
thermal resistance between the winding and the surroundings in C/W.
C represents the thermal capacity of the entire motor in J/C . The
thermal time-constant t is given by
r = RC (15-17)
in [s].
The analysis is based on equating the temperature rise during the on-
time with the temperature fall during the off-time. To do this we need
the equations for the temperature rise and the temperature fall.
15.4.2 Temperature rise during ON-time
During the on-time (qN> the power dissipation in the motor is Pd and the
temperature rises according to the equation
T - T0 = RPd( 1 - e-fr) + (Tc - T0)e -tlT. (15.18)
15-15
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Overload fa c to r k
15-17
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
15.4.4 Steady-state : Equating the temperature rise and the temperature fall
First, multiply equation (11) by e rN/r:
( Tc - T J e '0H'T = ( Tr - T Je<to* * W)/r. (15.26)
The left-hand side of equation (15.26) is identical to the right-hand side
of equation (15.23), so the right-hand side of equation (15.26) can be
equated to the left-hand side of equation (15.23). With suitable
rearrangement, the result can be expressed in different ways, all of which
are useful for different purposes.
15.4.5 Maximum overbad factor
First, we get a solution for the dissipation overload factor A2 in terms of
the on-time and the duty-cycle: writing <q N/<2 instead of <q N + i.e.,
instead of t^, the expression is
P = 1" g - (15.27)
1 -
For example, if the duty-cycle is 25% (d = 0.25) and <ON = 0.2 x t, the
dissipation overload factor is
k2 = L l = 3.04, (15.28)
1-
which means that the dissipation can be increased to 304% of its rated
steady-state value for a period of /qN = 0.2t in every cycle of length t^ =
<QN/d = (0.2/0.25)t = 0.8t. A s a concrete example, if t = 40 min, then
the dissipation can be raised to 304% for 8 minutes followed by a cool
down period of 24 minutes.
In the above example, increasing the dissipation to 304% of the rated
value corresponds to an increase in current and torque to ^3.04 =
1.74 times iheir rated values, or 174%.
If t t, then equation (15.27) simplifies so that
k 2 = -i. (15.29)
d
15-18
15. C o o l in g
This means that when the on/off cycles are very short compared with the
thermal time-constant of the motor, the mean dissipation will be equal
to Pr when the peak dissipation i j = f?Pr is equal to Pr/d . This simple
result, is intuitive.
15.4.6 Maximum overload for a single pulse
Equation (15.27) can also be used to calculate the maximum dissipation
overload factor fora single pulse, for which d = 0. In this case
Jc2 = -1 ~. (15.30)
1 - e 'W
toti = r In (15.33)
15-20
15. COOLING
15-21
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
Thermal Units
capacitance kJ/C
Thermal Units
resistance C/W
Heat Units
source W
RcsisUnee: from to by
Frame Ambient conVeclion
Conductor! conduction
Rotor conVection
Si at or Radiation
lHafl Direct
Ambient Total
Fig. 15.5 Key for Fig. 15.4
Eg. 15.6 Simple apparatus Tor measuring heat transfer of conductors in slots
In these cases experimental data is essential, and Fig. 15.6 shows an
example of a special test fixture for measuring the heat transfer between
a conductor in a slot, and the surrounding stator. The block is made of
Aluminium, which has a high thermal conductivity so that it can be
assumed to be at a uniform temperature throughout its cross-section.
(This is verified by test). The block used in the SPEED Laboratory is a
15-23
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a c n e t m o t o r s
3-inch cube with a slot width of 10mm and a slot depth of 30mm.
Thermocouples are let into the block and into the compression yoke at
the locations shown in Fig. 15.6 by small circles.
The slot can be lined with various slot-liner materials, and then a copper
coil is laid in the slot. The coil is wound on a former sized such that its
length overhangs the ends of the slot by the minimum manageable
am ount Typically 75% of the copper lies within the slot and 25%
outside. The coil may be varnished or potted, and it can be compressed
to a predetermined and repeatable pressure by a weight on top of the
compression yoke. The yoke is insulated from the coil by an insulating
shoe. Coils of varying depth/width ratio can be laid in the slot, and a
thermocouple is laid in the middle of the coil to meaure the hot-spot
temperature.
The coil is excited by DC to raise its temperature, and transient
temperature curves are plotted for all the thermocouples. By varying the
shape and size of the coil, the slot liner material and thickness, and the
degree of compression, it is possible to build up an extensive database of
heat-transfer data which can be used in the thermal model of Fig. 15.4.
It is possible to study the diffusion of heat through the coil by laying two
or more coils on top of each other, and exciting only one of them.
Thermocouples are provided in the middle of each coil.
The heat source in Watts is easily calculated by measuring the DC voltage
and current, and then multiplying the power by the fraction of copper
(by weight) that is in the slot- This fraction is accurately determined by
cutting off the end windings at the end of the experiment, and weighing
the bits.
The heat transfer block can be used to measure the thermal conductivity
and specific heat of insulating materials. In this case a suitable thickness
(e.g. multiple layers) of an insulating material is laid at the bottom of the
slot, and an Aluminium shoe with an embedded thermocouple is laid on
top. The heating coil is laid on top of the shoe. This provides a regular
rectangular geometry from which the thermal conductivity and specific
heat can be extracted following the thermal experiments.
Reference
1. Holman JP [1989] Heat Transfer, McGraw-Hill ISBN 0-07-100487-4
15-24
16. MAGNETIC MATERIALS
16.1 Introduction
This chapter reviews the material properties of permanent magnets,
electrical steel and insulated wire.
There is still widespread use of c.g.s. units in the magnet industry,
whereas motors are usually designed in metric (SI) units in Europe and
Japan, and in metric or mixed units in the USA. The most important
magnetic conversion factors are given in Chapter 4.
16-2
16. M a g n e t ic m a teria ls
16-3
D e s ig n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
C depends upon the shape of the magnet and the working permeance
of the circuit it is supplying and can be calculated using a load line*
technique (Chapter 4). The 2nd quadrant of the major B-H loop is
referred to as the "demagnetization curve". If the applied magnetizing
force is insufficient to magnetize the magnet fully, it will work on a
minor loop inside the major loop.
The working point may be driven further down the B-H curve by
applying an external demagnetizing field (//M < 0). As long as the
working point is not driven below the knee D, the reduction in B ^ is
reversible: i.e., when the external field is removed, the working point will
retrace the demagnetization characteristic back to point C. If, on the
other hand, the working point is driven below D, say to point E, then
when the external field is removed the working point does not retrace
the demagnetization curve, but follows a recoil line at a lower level of
flux-density. The recoil line may be considered a straight line (E-F), of
constant slope equal to the recoil permeability (-Lo*J-rcc
If the working point is driven below the knee D, the magnet will be
partially irreversibly demagnetized. Having been exposed to this sequence
of operations, the magnet is stabilised against further irreversible
demagnetization by external fields smaller than the maximum negative
value of Hm.
16.2.2 Permanent magnet materials
Much of the recent progress in the development of permanent magnet
brushless motors can be attributed to remarkable improvements in the
properties of magnet materials. Fig. 16.3 shows that since 1900 the
historical development in maximum energy product of commercial
permanent magnets has been nearly exponential. Fig. 16.4 compares
typical B /H characteristics of the major magnet material types. A brief
summary of magnet properties is also given in Table 16.1. More detail
can be obtained from suppliers data sheets.
The metal alloy materials are seldom used in motors where the magnet
is placed adjacent to the airgap, since their highly non-linear
demagnetization characteristics and low coercivities give them a low
resistance to demagnetization. However, the essentially linear
demagnetization characteristics and relatively high coercivities of ferrite
and rare-earth magnets make them ideally suited to motor applications.
16-4
16. M a g n e t ic m a teria ls
YEAR
Fig, 16.3 Improvement! in (BH)mll since 1900
16-5
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
16-6
16. M a g n e t ic m a t er ia l s
1.40
-900
k i
-800 -700
--i
-600
,/T T i M
-300 -400 -300 -200 -100 0
0
H (kAAn)
Fig. lfi.4 Typical B/II curves
A new generation of rare-earth Neodymium-Iron-Boron (Nd-Fe-B)
materials emerged in the mid 1980s. Nd-Fe-B has a larger energy-density
than Sm-Co and is made from less expensive materials. However, Nd-Fe-B
is by no means as thermally stable as Sm-Co and suffers from corrosion
problems. Nd-Fe-B was pioneered by Sumitomo in Japan and General
Motors in the USA. Both use similar compositions, but use fundamentally
different processing techniques for production. The initial predictions
that Nd-Fc-B materials would displace Ferrite in many applications has
not yet materialised. This is mainly due to the fact that Nd-Fe-B is more
costly than ferrite and that current grades of Nd-Fe-B have a limited
operating temperature range and are relatively susceptible to corrosion.
These factors have probably helped ferrite to remain the magnet of
choice for most automotive applications, and rare-earth Sm-Co for most
aerospace applications and high-performance servomotors. However, Nd-
Fe-B is making good progress and is now used in many motor products.
The corrosion can be controlled by suitable coatings (or in some cases
by encapsulation or even the use of hermetic canisters as in the
celebrated GM cranking motor). Considerable research worldwide is
devoted to advancing the technical capabilities and application of Nd-Fe-
B materials.
16-7
D e s ic n o f b r u s h l e s s pe r m a n e n t -m a g n e t m o t o r s
16-8
16. M a g n e t ic m a t er ia l s
Table 16.1 gives typical values of Curie temperature and maximum
recommended working temperature for sintered magnet materials. The
maximum recommended working temperature for all the materials is
sufficiently high for most practical motors. However, if the magnets are
in their bonded forms, there is an upper temperature limit due to the
properties of the polymer binder material. This is an area in which there
has been much recent research and the latest bonded materials have a
temperature limit of around 180 C.
16.2.4 Magnet energy product
It is shown in Chapter 4 that for a given airgap volume magnetized to a
certain flux-density, the required magnet volume is inversely proportional
to the energy product, i.e., the product B ^H ^. Contours of constant energy
product are rectangular hyperbolas, frequently drawn on property data
sheets provided by magnet suppliers. The maximum energy product or
(BH)m3X of a given magnet occurs where the demagnetization
characteristic is tangent to the BH hyperbola. If the recoil permeability
is unity, this occurs for a permeance coefficient of unity, provided that
there is no externally applied field from windings or other magnets.
In static magnetic circuit designs where there is no demagnetizing MMF
from electric currents, the magnet length and pole area can be
proportioned relative to the length and area of the airspace, so as to
cause the magnet to work at (BH)m3X. In motors this principle must not
be followed because the armature current produces demagnetizing
ampere-turns that may be very great under fault conditions (Chapter 12).
To reduce the risk of demagnetization, motors are designed so that on
open-circuit or no-load, the magnet operates at a high permeance
coefficient (corresponding to a small airgap length) with adequate
margin of coercive force to resist the maximum demagnetizing
ampere-turns expected under load or fault conditions. Some designs rely
on the current-limit in the controller to guard agains demagnetization.
The B fly product is sometimes preferred over (BH)m as a figure of
merit of magnet materials for motors, especially when the magnets are
exposed to potentially large demagnetizing fields, as in surface PM
motors. The /?r//k product is simply the value of remanence (Br)
multiplied by the knee value of magnetizing force (i/k). This product is
a combined measure of the flux-producing capacity with the resistance
to demagnetization under the influence of external MMF.
16-9
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
16.2.5 Magnetization
The value of magnetizing force H required to "saturate" a magnet varies
with the type of material. The saturation magnetizing force can be taken
approximately as a multiple k of the intrinsic coercivity, where k is about
3 for anisotropic and 5 for isotropic materials. If a lower value of A is
used, the magnetization will be less than the saturation magnetization,
which is the maximum magnetization achievable that produces the
maximum remanence.
Table 16.1 lists typical values of magnetizing force requirement for some
common magnets. High-energy magnets require such a high magnetizing
force as to need special fixtures and power supplies, and this is one
reason why high-energy magnets are usually magnetized before shipping.
Even then, the ampere-tums requirement is usually beyond the
steady-state thermal capability of copper coils. Therefore, pulse
techniques are used, or in some cases superconducting coils.
Ceramic (ferrite) and Alnico magnets can sometimes be magnetized in
situ in the final assembly, but this is seldom possible with high-energy
magnets, particularly in motors because of the airgap, the slotting, the
circular geometry (which increases "leakage" flux during magnetization),
the limited conductor cross-section, and the generally inappropriate
disposition of conducting coils. Finite-element analysis is often useful for
designing the magnetizing fixture and to determine the magnitude of the
applied field required to give complete magnetization. In some cases is
it impossible to achieve complete magnetization: the demagnetization
characteristic can then be inferior to the major characteristic [8,10] and
this must be taken into account in the motor design.
In some applications bonded magnets are preferred over sintered
magnets because it is relatively easy to form the magnets into complex
shapes which can then be magnetized with any pole configuration.
16.2.6 Mechanical properties and handling
Magnets are often brittle and prone to chipping, but proper handling
procedures are straightforward enough as long as the rules are followed.
Modern high-energy magnets are usually shipped in the magnetized
condition, and care must be taken in handling to avoid injuryfor
16-10
16. M a g n e t ic m a teria ls
Steel guide
Rotor
1 This method waa invented by D.W. Jones of CE. Once inside the steel guide, even
the strongest magnets become completely docile and can be pushed around at willl
16-11
D e s ig n o f b r u sh l e s s p e r m a n e n t - m a g n e t m o t o r s
16-12
16. M a g n e t ic m a t er ia l s
common are arcs and sometimes rectangles. Tolerances in the
magnetized direction can be held very close, ^/-O.lmm even for standard
magnets. But if the design permits a relaxation of the required tolerance,
particularly in the dimensions perpendicular to the magnetic axis, this
should be exploited because it reduces the cost of the finished magnets.
Thermal expansion of magnets is usually different in the directions
parallel and perpendicular to the magnetic axis. The coefficients in Table
16.1 are for the direction of magnetization, i.e. along the magnetic axis.
Most magnets have a high compressive strength but should never be used
in tension or bending.
16.2.7 The latest trends in magnet technology
There is still much research into new methods of producing Nd-Fe-B
materials especially with regard to corrosion resistance. There is also
work on new materials such as Br-Fe-B (Br = 12.8kG, Hci = 11.5kOe,
(BH)m*x = 38MGOe) and Sm-Fe-N (r = 19kG, //d = 9kOe, (BH)max =
20MGOe).
There has been a 10-14% growth rate per year for bonded materials over
the last 5 years. A 180C operating temperature bonding material is also
now available. Mitsubishi have developed the HDDR process for making
anisotropic Nd-Fe-B materials (this was developed at the end of 1993).
This is believed by many to be the most important development for
bonded magnets in the last 10 years. The HDDR process makes it
possible to manufacture 20MGOe bonded magnets. There is also a cross-
licensing agreement for the HDDR process with Sumitomo and General
Motors. Activity in magnet research is well reported in IEEE and
specialist conference proceedings.
16-13
DESIGN OF BRUSHLESS PERMANENl'-MACNET MOTORS
cost. Table 16.2 lists the main properties of some of the more common
materials used in brushless motors in the USA. Table 16.3 presents
equivalent information for materials used in Europe.
16.3.1 The DC magnetization curve
In order to calculate the airgap flux and particularly the MMF
requirement of an electric motor it is necessary to know the dc
magnetization curve (or initial magnetization curve) of the soft magnetic
material used in the magnetic circuit. The dc magnetization curve is in
effect the average value of B versus H of the major hysteresis loop. It is
noted that typical elcctrical steels have very narrow hysteresis loops
compared with permanent magnet materials. Fig. 16.6 compares the dc
magnetization curves of a number of common electrical steels.
Grade Saturation Core Low (W/lb)
Induction 15kG and 60Hz (lW/lig - 0.454 W/lb)
(Cauu) 0.014" 0.0185" 0.025"
29 Gauge 2fi Gauge 24 Gauge
M-I5 19,900 1.45 1.68 NA
M-19 19,900 1.58 1.74 2.08
M-36 20,200 1.90 2.05 2.40
M-43 20,400 2.00 2.30 2.70
T able 16.2: L am ination materials (USA)
The intercepts Z)j, Z)2 and for the three values of are substituted
into the logarithm of Equation (16.6), giving three simultaneous linear
algebraic equations for C^, a and b of the form:
The most convenient data format is tables or graphs of total core loss vereus frequency
for different fixed values of Bp.
16-17
D e s ig n o f b r u sh l e s s p e r m a n e n t -m a g n e t m o t o r s
These are solved for log a and tr, is then obtained from log
Three values of C are obtained from the gradients of the three graphs
of P /fy s. / (Equation (16.5)). The average or the highest value can be
taken for Cc. Finally:
Europe and Japan this is not the case and typically fully processed
materials are used with without annealing after punching. The reason for
this is that most American motor companies (at least the small ones) do
not punch their own laminations but buy them from large stamping
houses who specialize in punching electrical steel motor and transformer
laminations. In Europe and Japan many motor companies have their own
punching presses and make their own laminations. Under certain
circumstances this may suit just-in-time delivery practices, but the motors
must be designed such that they can handle the increased losses.
16.3.5 Special steels
Special cobalt-iron alloys such as Vanadium Permendur offer saturation
capabilities of up to 2.4T (24kG). This permits a smaller cross section of
iron in the stator and therefore a smaller and lighter machine. However,
these materials are very expensive and are only used in applications that
require high power to weight ratios, e.g. aerospace motors and
generators. To obtain the high powers, high speeds are also used, thus
the steel is usually used in very thin gauges, sometimes with
interlamination insulators to reduce core losses.
16-19
D e s ig n o f b r u s h l e s s p e r m a n e n t -m a g n e t m o t o r s
Reference
1. Parker RJ [1990] Advances in Permanent Magnetism, John Wiley &
Sons, N.Y., ISBN (M71-82293-0.
16-21
Index
AC 1.1-1.4, 1.12, 1.24, 2.2, 2.6, 2.7, 2.20, 2.38-2.40, 2.46, 2.47, 2.49, S.2, 3.3. 3.5, S.12,
3.14, S.29-3.31, 3.33, 3.35, 4.18, 5.9, 5.18, 5.31, 5.63, 6.1-6.4, 6.9, 6.12,
6.13, 6.29, 6.40, 6.47, 7.1, 7.7, 7.8, 7.13, 7.15, 9.1, 11.6, 11.14,11.16,
12.2, 12.3, 13.1-13,3, 13.6. 13.7, 13.11. 13.14, 15.9, 16.14
AC induction motor 1.1
see induction motor
AC servomotor 1.2
Accuracy 1.21, 1.25, 2.47, 3.24, 4.26, 10.32, 12.14, 14.13, 14.18
Adaptive control 14.1, 14.31, 14.33, 14.43, 14.45
Air cooling 12.5
Airflow 15.7, 15.9
Air-over 12.5, 13.14, 15.7
Airgap 1.1,1.19, 2-5, 2.6, 2.11,2.12, 3.1, 3.8, 3.19, 3.20, 3.21,3.23, 3.24.3.25. 3.26,3.51,
3.71, 4.2, 4.5, 4.7, 4.8, 4.10, 4.12-4.16, 4.23, 4.25, 4.28, 4.30, 4.32, 5.1,
5.12, 5.19, 5.21, 5.35, 5.42-5.55, 5.61,6.1, 6.3-65, 6.12, 6.13, 6.17, 6.24,
6.25,6.28-6.33, 6.37, 6.46, 7.3. 7.12, 8.4-8.10, 8.12, 8.13,8.16, 9.2,10.2,
12.2-12.4,12.6,12.12,12.15-12.17,12.19-12.23,12.25-12.28, 13.4,13.6,
13.9, 13.-11, 13.14, 13.19-13.22, 16.4, 16.7, 16,8, 16.11, 16.12, 16.14
Airgap flux 2.5, 3.24, 4.2, 4.10,4.14, 4.16. 4.30, 4.32, 5.1, 5.12, 5.21, 5.35, 5.43. 6.4, 6.5,
6.12, 6.25, 6.28, 6.3M.33, 6.46, 7.12, 8.&4.10, 8.13, 9.2, 12.12,
12.19-12.21, 12.25-12.28, 16.12, 16.14
Airgap length 3.24, 4.2, 4.13-4.15, 4.25, 4.28. 5.61, 6.3, 13.9, 16.8
Airgap shear stress 12.2, 12.4, 12.6
Alger 5.58, 5,66
Aliasing 14.35
Alnico 2.19, 3.23, 4.5, 16.7, 16.8
Ampere 1.1-1.3, 1.17, 2.15, 2.20, 2.46. 3.4, 3.6, 3.26, 4.9, 4.19, 4.20, 4.22, 5.18-5.21,
5.25, 5.28, 5.31, 5.36, 5.56, 6.4-6.7. 6.1M.13, 6.16, 6.20, 6.23, 6.24,
6.28, 6.31,6.35,6.39,6.42-6.44, 7.1, 7.14,7.15,11.2,12.21-12.23,12.26,
12.27, 16.7, 16.8
Ampere-conductors 3.6, 4.19, 4.20, 4.22, 5.18, 5.19, 5.21, 5.25, 5.31, 6.4, 6.6, 6.7, 6.10.
6.16, 6.20, 6.28, 12.22, 12.23
Amplifier 2.43, 2.44, 6.43, 14.11, 14.12, 14.22
Analog converter 14.34, 14.41
Annealing 13.22-13.24, 16.15, 16.16
Anti-windup 14,32, 14,34
Applications 1;1, 1.3, 1.23, 1.25, 2.1, 2.5-2 6, 2.9-2.11, 2.13, 2.18, 2 20. 2.39, 2.43, 2.45,
2.47, 2.49, 3.1-3.3, 3.5, 3.9, 3.25-3.28. 3.33, 3.71, 3.76, 4.33, 5.18, 5.32,
6.47, 6.48, 8.3, 8.19, 8.20, 9.9, 10.35, 11.1, 12.5, 12.14, 12.18, 13.1,
13.19, 14.1, 14.9, 14.13, 14.14, 14.19, 14.21, 14.46, 15,2, 15.14, 15.22,
16.4, 16.6-16.8, 16.11, 16.16
Arc 2.3, 3.8, 3.12, 3.19-3.21. 3.25, 3.33, 3.45, 3.47, 3.50, 3.51, 4.12, 4.24, 4.25, 5.1, 5.5,
5.8, 5.14, 5.19-5.21, 5.24-5.26, 5.28-5.32, 5.35,5.60, 5.65, 6.3, 6.29,7.12,
8.1, 8.2, 8.5-8.7, 8.11, 8.12, 8.15, 9.5, 9.6, 10.15, 13,4, 13
Arc magnets 3.25
Armature 1.4, 2.8, 3.3. 5.20, 3.23, 3.35, 4.12,4.18, 5.39, 5.40, 5.46, 5.55, 5.63, 6.3, 6.12,
6.13, 6.23, 6.24, 6.28, 6.90-6.34, 6.38, 6.40, 7.S-7.5, 8.20, 11.2, 11.9,
12.20-12.28, 14.5, 15.9, 16.2. 16.8, 16.11
Armature reaction 3.20, 4.18, 5,39,5.40, 5.46, 5.55, 5.63, 6.3, 6.12, 6.13, 6.23-6.24, 6.28,
6.30-6.34, 6,40. 7.4, 7.5, 11.2, 11.9, 12.20-12.22, 12.24-12.28, 16.2
Armature-reaction flux 5.55, 6.23, 6.24, 6.33, 6.34
Augmentation of stator teeth 9.6, 9.7
Auto-tuning 14.33
Axial gap 1.4
Axially laminated motor 18.1 IT
Axis 1.7, 2.46, 3.21, S.42, 3.43, 3.45, 4.6-4.8, 4.23, 5.1-5.3, 5.5, 5.35, 5.47. 5.63. 6.2, 6.3,
6.8-6.10. 6.17, 6.18,6.20,6.22-6.25, 6.2M .38,6.40,6.42-6.44.6.46, 7.15,
8.5, 8.9,8.16, 11.4,12.21, 12.25-12.27, 13.19, 14.16, 14.23-14.25.14.32,
16.10,16.11, 16.14
Back-EMF1.2,1.7-1.9,1.13,1.14,1.23, 2.14, 2.15, 2,17, 2.22, 2.23, 2.30, 2.33, 2.34, 2.43,
2.44, 2.46-2.48, 3.6, 3.15, 3.16, 3.18, 3.19, 3.33, 3.38, 3.45-3.47,
3.49-3.51, 3.71, 3.74, 4.18, 4.28, 5.3, 5.5, 5.8, 5.9, 5.12, 5.21, 5.25, 5.35,
5.36, 5.40-5.42. 5.63, 5.65, 6.2, 6.4, 6.36, 6.42, 6.46, 7.1-7.5, 7.7, 8.1-8.3,
8.11-8.13, 8.20, 9.2, 9.9, 10.1, 10.28-10.32, 11.2,11.3,11.9, 12.9,12.12,
12.20, 13.8, 13.9, 13.11, 13.13, 13.19, 13.25, 14.7
Back-EMF constant 3.18, 3.19, 5.12, 5.42, 7.1, 7.3, 8.1, 10.1, 10.30, 13.19
Back-iron 2.11, 3.6, 3.25, 3.34, 4.2
Bandwidth 1.19, 2.22, 2.47, 3.2, 11.12, 14.12, 14.15, 14.18, 14.26, 14.32, 14.35
Bare wire 13.13, 13.26
Base interval 2.31-2.33, 10.1, 10.2, 10.4, 10.13, 10.20, 10.22, 10.24
Base speed 1.12
Bearings 1;17,1.20, 1.22, 2.2, 2.6, 2.8, 3.8,3.17,4.33, 5.39, 11.6,13.2,13.15,13.25.15.1,
15.2
Bekey-Robinson 2.5
Bifilar-wound 3.4
Bifurcated teeth 4.27, 4.28, 8.14
B1L 3.16
BJT 2.20
Blocking 2.18, 2.19, 3.35
Black body 15.5
BLV 5.19, 5.36, 8.3^.5, 8.9-S.ll
Bode diagram 14.16, 14.17, 14.21, 14.26, 14.27
Bonded ferrite 2.3
Bonded ring magnet 2.3, 2.8, 3.8
Bonding 3.28, 3.29, 16.10, 16.11
Boules 5.64, 5.66, 8.3, 8.19, 8.20
Boundaryelemcnt method 5.38, 5.42, 5.61, 5.66, 8.2
Brake 11.6, 11.9
Braking 2.17, 2.44, 2.45, 3.2, 6.47, 14.1, 14.12
Brushes 1.1
C 14.34
Carbon steel 2.2, 3.25, 13.21, 15.13
Carter coefficient 3.21, 4.13, 5.44, 8.12
Centrifugal blower 2.9
xviii
I n d ex
Centrifugal loading 4.28
Centrifugal pump 1.12
Centrifuges 1.17
Ceramic 4.5, 15.13, 16.8
Ceramic magnets 4.5
Chamfer 3.8, 4.28
Characteristic equation 14.22
Charge 2,17
Chemicals S.2, 3,32, 16,10
Chopping 1.17, 1.19, 2.15, 2.21, 2.23, 2.24, 2.26, 2.27, 2.30, 2.32-2.35, 2.37, 2.41, 2.43,
3.25,4,18,5.32, 5.39,5.41,7.5.8.1,10.7-10.14,10.16-10.18,10.22-10.24,
10.26-10.28, 16.13
Chording 3.36, 5.29, 5.30, 6.3, 6.14, 6.16, 6.18, 6.19
Circle diagram 17,11 et waj.
Circuit 1.10, 1.14, 1.19, 1.24, 1.25, 2.1, 2.9-2.11, 2.15-2.17, 2.22-2.28, 2.30, 2.31, 2.41,
2.45, 2.47, 2.48, 3.4,3.14, 3.15, 3.17, 3.20,3.21,3.23, 3.29,3.S0,4.S4.9,
4.11-1.16, 4.19, 4.254.27, 4.32, 5.14, 5.21. 5.32, 5.33, 5.38, 5.40, 5.41,
5.43, 5.58, 5.61, 6.3,6.12, 6.22, 6.24, 6.25, 6.3W.35, 6.45.6.47, 7.4, 7.8,
8.2. 8.4, 9.2, 10.2, 10.3, 10.7, 10.8, 10.10, 10.12-10.15. 10.20, 10.21.
10.23, 10.24, 10.27, 10.28, 11.2, 11.5, 11.9, 12.21, 12.22, 12.26, 13.3,
13.4, 13.16, 14.1, 14.7, 14.9, 14.11, 14.14, 14.18, 14.34, 14.41,
15.10-15.12, 15.15, 15.21-15.23, 16.1, 16.4, 16.8, 16.10, 16.12
Cleat 3.29. 13.25
Closed-loop control 3.2, 14.10, 14.15, 14.20
Closed-loop transfer function 14.25, 14.26
Cobalt 3.8, 3.28, 4.3, 4.9, 6.47, 6.48, 15.13, 16.4, 16.16
Cobali-Sainarium 4.3, 4.9
Coefficient2.3,3.17,3.19-3.21,3.23,3.24,3.27,4.8-4.11,4.13-4.15,4.24,4.25, 5.1S, 5.44,
5.55-5.59, 6.9, 6.34, 8.12, 12.2, 13.4, 15.2, 15.5-15.8, 16.7, 16.8, 16.17
Coenergy 3.17, 4.27, 5.36, 5.37
Coercive force 16.8
Coercivity 3.23, 3.25, 3.27, 4.6, 4.8, 4.9, 4.15, 4.16, 4.18, 5.64, 6.12, 12.22, 13.4, 16.2,
16.3, 16.7, 16.8, 16.11
Cogging 1.19, 2.1, 2.3, 2.11, 2.13, 2.47, 3.3, 3.7, 3.8, 3.10, 3.12, 3.13, 3.24, 3.34, 3.51,
3.74.4.26-4.28,4.33,5.57,5.62,6.21,8.10,8.19,12.14,13.7,13.9,13.18,
13.22, 13.23
Coil 1.7,1.9,1.10,1.14, 2.1,2.6, 2.10-2.12, 3.1, 3.5, 3.10,3.12, 3.14-3.15,3.20, 3.23,3.28,
3.30, 3.31-3.36, 3.39-3.51, 3.70, 3.71, 4.1, 4.5, 4.10, 4.20, 4.21, 5.2, 5.3,
5.5, 5.6, 5.8, 5.9, 5.11-5.14, 5.20, 5.21, 5.29, 5.30, 5.35, 5.36, 5.43-5.49,
5.51-5.55, 5.59, 5.60, 5.64, 5.65, 6.1, 6.3, 6.5-fi.8, 6.13-6.21, 6.25. 7.11,
7.12, 8.1, 8.2, 8.4, 8.5, 8.9-8.11, 8.17, 9.7,10.15,11.12, 12.9,13.1, 15.2,
13.6, 13.8, 13.11-15.13, 13.15, 13.16, 13.22, 13.23,13.25, 13.26, 14.18,
15.4, 15.5, 15.24, 16.8, 16.15
Coil pitch 5.3. 5.9, 5.20, 5.29, 8.1, 8.4, 10,15
Coil span 3.14, 3.35. 3.36, 3.39, 3.41, 3.42, 3.49, 3.51, 5.20, 6.16, 8,2
Coil winding 5.9
Coils per phase 3.36, 3.42, 3.44, 5.12, 5.60, 13.8, 13.13, 13.26
xix
Coils per pole 3.36, 3.39, 3.49, 6.13, 6.17, 6.25, 13.8
Combinatorial logic 2.45
Commutation 1.2, 1.5,1.12,1.18-1.23, 2.15, 2.19, 2.20, 2.32-2.35. 2.42, 2.43, 2.45, 2.47,
3.1, 3.4, 3.6.3.32, 3.50,3.51, 3.71,5.5, 5.15,5.17, 5.19,5.31, 5,32. 6.41,
7.2, 7.6, 8.1,10.1,10.2, 10.4,10.7-10.9, 10.13-10.17,10.20,10.23,10.24,
10.28, 10.30,10.31, 10.33,11.1,11.2, 11.6.11.7, 11.9,11.11,13.6,13.7,
13.11, 13.16, 13.25, 16.13
Comparator 2.22
Compensator 14.11, 14.12, 14.25-14.27
Complex frequency 14.2
Compressors 1.12, 15.1, 15.2
Computer disc 3.71, 3.73, 3.74, 13.16, 13,18
Concencrated winding 6.18, 7.14
Concentric winding 3.39, 3.40, 5.9, 6.17, 13.8
Conduction 1.13,1.19,2.13, 2.17-2.19.2.24,2.25. 2.32,2.33, 2.35,2.38, 2.41,2.44, 3.32,
4.22, 5.5, 5.17-5.19, 5.24. 5.25, 5.41, 7.2, 10.9, 10.16, 10.24, 10.27,
10.28, 10.30, 11.9, 15.1, 15.2, 15.4, 15.5, 15.8-15.11
Conductivity 3.15, 15.3-15.6, 15.10, 15.11, 15.23, 15.24, 16.17
Conductor 1.1-1.4,1.7,1.17, 2.12,2.13, 2.15,2.46,3.1,3 4-3.6,3.16-3.18, 3.21,3.26,3.27,
3.30,3.32, 3.33,3.38,3.70,4.2,4.19,4.20,4.22, 5.5, 5.9, 5.18-5-21,5.25,
5.28, 5.31, 5.35, 5.36, 5.39, 5.43, 5.44, 5.46, 5.48, 5.49, 5.51, 5.53-5.65,
6;1, 6.M.7, 6.10-6.13, 6.15, 6.16, 6.20. 6.23-6.25, 6.28, 6.31, 6.35, 6.44,
7.11, 7.12, 7.14, 7.15, 8;4, 8.9, 8.10, 12.6, 12.15, 12.22, 12.23, 12.26,
12.27, 13.11, 13.13, 13.15, 13.25, 15.1, 15.4, 15;5, 15.11, 15.12, 15.23,
16.8, 16.16
Consequent-pole 2.3, 3.24, 3.36, 4.21, 5.11-5.13, 13.8
Constant power operation 1.12, 2.3, 6.4, 6.46, 17.1 et seq.
Constant-power speed range
see CPSR
Contact resistance 15.1, 15.4, 15.5
Continuous 1.16, 1.17, 2.10, 3.2. 3.21, 3.31, 3.76, 5.18, 5.31, 5.32, 6.42, 6.47, 7.2,11.7,
13.13, 13.14, 14.34, 14.36-14.38, 14.40, 15.15, 15.17, 16
Control 1.1, 1.2, 1.5, 1.11, 1.12, 1.18, 1.23, 1.25, 2.9, 2.11, 2.14, 2.15, 2.19, 2.23, 2.24,
2.30-2.36, 2.38-2.47, 2.49, 3.2, 3.4, 3.5, 3.25, 3.31, 3.76, 5.18, 6.2, 6.3,
6.11, 6.12, 6.43, 6.48, 7.1, 7.3, 8.1, 10.10, 10.28, 11.6, 11.7, 11.9, 12.7,
12.10, 13.16, 14.1, 14.7, 14.9-14.16, 14.18, 14.20, 14.22, 14.23, 14.25,
14.26, 14.28-14.36, 14.38-14.43, 14.45, 14.46, 15.1, 15.14, 16.11, 16.15
Convection 12.5, 15.1, 15.2, 15.6-15.12
Converter 1.19, 1.25, 2.43, 6.38, 6.43, 10.16, 10.18, 10.28, 14.34, 14.41
Conveyors 1.12
Cooling 1.17, 2.2, 2.13, 3.3, 3.33, 4.32, 11.1, 11.8, 12.4-12.6, 13.1, 13.14, 15.1-15.2,
15.5-15.9, 15.11, 15.12, 16,7, 16.16
Copper 1.17,1.20, 2.12, 2.47, 3.5, 3.15-3.17, 3.28. 3.32, 3.70, 4.31,5.11, 5.12, 5.21, 5.31,
5.39, 5.61, 5.63, 6.3, 9.1. 13.13, 13.14, 13.17, 13.26, 15.1, 15.4, 15.5,
15.8, 15.10, 15.12-15.14, 15.23, 15.24, 16.8, 16.16, 16.17
Copper losses 2.12, 3.32, 5.31, 5.39, 9.1, 13.14, 13.26, 15.10
Core 1.17, 2.1, 2.1S, 3.25, 3.28, 3.33, 3.34, 3.71, 3.73, 4,1. 4.2, 4.33, 5.60, 8.3. 8.4, 8.10,
8.20, 9.1-9.3, 9.6-9.9,11.4,12.15,12.20, 12.21,12.27, 13.3, 1S.7,13.14,
13.15, 13.23, 13.24, 15.4, 15,5, 15.10, 16.11-16.16
XX
Index
Core losses 1.17, 2.1, 3.28, 3.35, 3.34, 4.2, 4.33, B.3-8.4, 8.10, 8.20, 9.1, 9.2, 9.7. 9.9,
12.20, 12.21, 13.3, 13.7, 13.14, 13.15, 13.23, 13.24, 15.10, 16.12-16.14,
16.16
Core plate 3.28, 3.33, 16.15
Core steel 15.15, 15.5, 16.11
CPSR 17.2 et seq., 18.7 tt *eq.
Critical damping 14.24
Cross-inagnetizing 6.33, 12.24, 12.25, 12.27
Cuffs 3.29
Current 1.1, 1.2, 1.4, 1.8, 1.9, 1.11-1.16, 1.18, 1.19, 1.22, 2.3, 2.6, 2.11, 2.12, 2.14-2.27,
2.29-2.35, 2.37-2.48, 3.1, 3.4, 3.6, 3.8, 3.15-3.17, 3.19, 3.20, 3.23,
3.25-3.27, 3.32, 3.33, 3,50, 3.71, 4.M.4, 4.7-4.9, 4.12, 4.1&4.20, 4.22,
4.26-4.29, 4.31,4.33, 5,4,5.5, 5.9, 5.12,5.17, 5.18, 5.21, 5.23-5.27,5.29,
5.31-5.34,5.36-5.41,5.43,5.44,5.46,5.47, 5.54,5.61,5.63-5.65,6.1,6.4,
6.8, 6.12, 6.14, 6.16, 6.28, 6.30, 6.32, 6.36^.44, 6.46, 6.47, 7.1-7.4,
7.6-7.10,7.12,7.13,7.15,7.16, 8.1-8.3, 8.11, 8.16, 8.19, 8.20,9.1,9.5-9.7.
10.1,10.2,10.4,10.7-10.11,10.13-10.16,10.18,10.21-10.25,10.27-10.35,
11.1, 11.2, 11.5, 11.6, 11.8, 11.9, 11.12-11.14, 12.2-12.5, 12.12, 12.15,
12.18-12.21, 12.23, 12.25-12.27, 13.4, 13.8, 1S.13-1S.16, 13.19, 13.25,
13.26,14.1,14.5, 14.7,14.14,14.31,14.45,15.2,15.4,15.8-15.10,15.12,
15.17,15.18, 15.24, 16.6, 16.8, 16.13
Current density 3.1, S.32,4.31, 5.61, 5.63,5.64. 6.4,12.2,12.4, 12.5,12.19, 12.23, 13.13,
13.14, 1S.26, 15.4, 15.8, 15.9, 15.12
Current regulator 2.15, 2.38, 2.46
Current transducer 2.22, 11.6
Current-regulated 2.43
Curve 1.12,1.13, 1.15-1.18, 2.47, 3.20, 3.21, 3.23, 3.25-3.27, 3.51, 3.71, 4.16, 4.17, 4.33,
5.35, 11.1, 11.2, 11.5, 11.7,12.17, 12.20,13.4-1S.6, 13.14, 13.15, 13.19,
13.20, 14.45, 15.7, 16.1-16.4, 16.12, 16.16
Cutting 3.28, 5.36, 14.14, 15.24
Cycle 2.15, 2.17, 2.21, 2.22, 2.24, 2.26, 2.27, 2.34, 2.37, 2.43-2.45, 3.18, 4.31, 5.5, 6.43,
9.1, 9.3, 10.11, 10.13, 10.18, 10.22, 10.27, 10.28, 10.32, 10.33, 14.24,
15.14-15.16, 15.18-15.20, 15.22
d-axis 5.1-5.3, 5.35, 6.23-6.25, 6.28-6.30, 6.33-6.38, 6.40, 6.44, 6.46. 12.21, 12.25, 12.27
Damping 10.24, 14.7, 14.9, 14.13, 14.24, 14.25, 14.38, 14.43
dB 8.7,9.2, 9.3, 9.6, 14.16, 14.18, 14.21
DC 1.1-1.12, 1.14-1.20, 1.25, 2.6, 2.8, 2.10, 2.15, 2.19, 2.23, 2.27, 2.30, 2.32, 2.33, 2.35,
2.38-2.41, 2.44, 3.1-3.6, 3.19, 3.26, 3.29, 3.33, 3.35, 3.71-3.76, 4.4, 4.5,
4.18,4.22, 4.24, 4.33,5.1, 5.2,5.6,5.18, 5.25-5.27,5.32, 5.33, 5.36,5.39,
5.40, 5.57, 5.66, 6.12, 6.41, 6.47, 7.1-7.11, 8.1, 8.19, 8.20, 9.1,9.2, 9.9,
10.1, 10.2, 10.13, 10.14, 10.20-10.22. 10.26,10.28, 10.30, 10.34,10.35.
11.1,11.2, 11.4-11.7,12.17, 12.20,12.21, 1S.1,13.3,13.4,13.11,13.14,
13.19, 14.5, 14.7, 14.16-14.18, 14.28, 14.31, 14.41, 14.42, 14.46, 15.2,
15.9, 15.24, 16.11, 16.12, 16.16
DC commutator motor 1.2-1.9, 5.18, 7.3, 7.7
Deadbeat response 14.40
Decibcl 14.16
xxi
Demag current 3.26, 3.27
Demagnetization 1.16, 1.17, 1.18, 2.3, 3.1, 3.23-3.27, 3.74, 4.54.9, 4.12, 4.14-4.16, 4.1&.
4.20, 4.22, 4.27, 4.28, 5.3&-5.40. 5.62, 5.64, 6.33, 16.4, 16.7,6.37-6.38,
6.40,6.44,6.47,11.4,11.5,12.20,12.21,18.25,12.27,12.28.13.4,13.15,
13.16, 13.19, 16.1, 16.2, 16.3, 16.4, 16.7, 16.8
Demand signal 10.28, 14.10, 14.11, 14.14, 14.18, 14.20, 14.21, 14.31
Design 1.2, 1.3, 1.5. 2.1-2.3, 2.5, 2.6, 2.9, 2.11, 2.13, 2.47, 3.1, 3.3. 3.7, 3.8, 3.10, 3.14,
3.17-3.21, 3.23-3.26, 5.28, 3.32, 3.34, 3.36,3.71, 4.1, 4.2, 4.9, 4.15, 4.22,
4.29, 4.30, 5.1, 5.13, 5.33, 5.38, 5.39, 5.42, 5.58, 5.63, 5.66, 6.21, 6.33,
6.42, 6.47, 7.1, 8.1-8.S, 8.20, 9.3, 11.1, 12.1, 12.2, 12.6-12.10, 12.13,
12.14,12.19,12.20,12.28,13.1-13.4,13.6-13.9,13.14,13.16-13.19.13.22,
13.23, 13.25-13.27, 14.1, 14.7, 14.9, 14.10, 14.16, 14.18, 14.23-14.26,
14.30, 14.31, 14.33, 14.34, 14.38-14.40, 14.43, 14.46, 15.1, 15.23, 16.8.
16.10. 16.16
Detent torque 3.34, 13.7, 13.18
Dielcctric strength 3.32. 15.13
Digital control 1.23, 2.19. 14.11, 14.34, 14.38
Digi(a 1-to-analog converter 14.41
Digital PID 14.34, 14.40, 14.41
Dimpled staclu 13.25
Diode 2.16, 2.17, 2.19, 2.21, 2.23, 2.26, 2.27, 2.30, 2.33-2.38, 6.41, 10.7, 10.8, 10.10,
10.15
Direct axis
see d-axis
Direct conductor cooling 12.6
Disc drive 3.73, 3.74. 11.7, 13.1, 13.16, 15.18, 13.19
Dissipation 6.42, 15.15, 15.17-15.20
Distribution factor 3.45, 6.18, 6.19
Dominant poles 14.24
Double-layer winding 3.36, 5.9, 5.21, 5.30, 13.23
Drive 1.2, 1.3, 1.11, 1.12,1.17, 1.20, 1.24, 2.1, 2.5, 2.9, 2.10, 2.19, 2.20, 2.23, 2.26, 2.27,
2.35, 2.37, 2.39, 2.40, 2.42, 2.43, 2.452.47, 2.49, 3.2, S.4-3.6, 3.15, 3.24,
3.26, 3.27, 3.46, 3.47, 3.49, 3.50, 3.71, 3.73. 3.74. 4.2, 4.8, 4.26-4.28,
4.33, 5.32, 7.4, 7.16, 9.1, 10.14, 10.22, 11.1, 11.2, 11.4, 11.5, 11.7.
11.11-11.14, 12.9, 13.1,13.4, 13.8, 13.9, 13.16, 13.18, 13.19. 14.1, 14.7,
14.9, 14.11, 14.17-14.19, 14.32, 15.9, 16.3
Driver 2.19, 13.25, 14.14
Dummy slots 4.27
see bifurcated teeth
Dust 1.23, 3.2, 3.32
Duty-cycle 2.15, 2.21, 2.22, 2.26, 2-27, 2.34, 2.37, 2.43, 2.44, 4.31, 6.43, 10.11, 10.13,
10.18.10.22,10.27,10,28, 10.32,10.33,15.14-15.16,15.1
Dynamic braking 2.17, 2.44, 2.45, 14.1
Dynamics 14.9, 14.12, 14.22. 14.26, 14.30, 15.7
Dynamometer 1.13, 4.33, 7.4, 11.2, 11.6, 11.7, 11,9, 11.12-11.16
ECM 2.6
Eddy current losses 16.13
Eddy-currents 1.4. 1.17. 2.6. 2.11, 2.12, 3.25. 3.33, 4.2, 5.61. 9.1, 9.5-9.7, 11.6, 12.27,
13.14
XXll
I n d ex
EDM 3.28
Effective airgap 3.21. 5.52. 5.61, 6.30, 8.10, 8.12
Efficiency 1.1, 2.6, 2.9, 2.45, 3.28, 5.31, 5.32, 5.39, 8.2,10.1-10.2,11.7,11.12,12.1,12.3,
12.5, 13.15, 14.46, 15.2, 15.14
Electric 1.12, 2.6, 2.12, 3.6, 3.14, 3.15, 3.17, 4.3, 5.36, 5.40, 5.61, 7.1, 10.34, 12.2-12.5,
12.28, 14.14, 14.40, 15.5, 15.10, 15.21, 16.8, 16.12
Electric loading 2.12, 3.6, 5.61, 12.2-12.5
Electric vehicles 1.12, 14.14
Electrical degrees 2.15, 2.17, 2.30, 2.45, 3.4, 3.18, 3.43, 3.48, 3.50, 3.51, 3.71, 4.12, 5.6,
5.11, 5.20, 5.28, 5.32, 5.46, 6.16, 6.21, 6.22, 6.31, 7.6, 7.12, 7.15, 8.13,
10.1, 10.3, 12.26
Electrical radians 3.18, 4.12, 5.65, 6.3, 6.4, 6.6, 6.&6.10, 6.17, 6.20, 8.5. 8.10, 8.12, 9.7
Electrical steel 9.1, 12.10, 16.1, 16.11-16.13, 16.15, 16.16
Electro-discharge 3.28
Electromagnetic 1.1
Electronic 1.20, 1.22, 1.23, 1.25, 2.9, 2.14-2.16, 2.18-2.20. 2.27, 2.39-2.41, 3.15, 3.19,
3.26, 5.1, 10.1, 10.2, 11.13, 11.14, 14.5, 14.18, 16.9
Electronic wattmeter 11.14
Electronically commutated motor 2.6
Ellipse diagram 17.11 et v.q.
Embedded 2.5, 3.3, 3.7, 3.8, 3.24, 15.24
EMC 3.2, 12.1
EMF 1.2.1.7-1.9,1.11,1.13,1.14,1.22,1.23, 2.14,2.15, 2.17, 2.22, 2.23, 2.30, 2.33. 2.34,
2.43, 2.44, 2.46-2.48,3.6, 3.15-3.20, 3.33,3.38,3.45-3.51,3.71, 3.74, 4.1,
4.18, 4.28, 5.1, 5.S-5.9, 5.12-5.21, 5.24-5.26. 5.28-5.30, 5.32, 5.34-5.36,
5.38, 5.40-5.42, 5.63, 5.65, 6.1-6.4, 6.9, 6.12,6.13, 6.16, 6.19, 6.22, 6.36,
6.42, 6.46,7.1-7.5,7.7,7.10-7.13, 7.15, 7.16, 8.1-8.6, 8.9-8.17, 8.19, 8.20,
9.1-9.3, 9.6, 9.7, 9.9, 10,1, 10.2, 10.12, 10.15, 10.22, 10.25-10.33, 11.2,
11.3,11.9,11.12,12-3,12.9,12.10,12.12,12.20,13.8,13.9,13.11,13.13,
13.19, 13.25, 14.5, 14.7
EMF constant 1.2, 1.13, 3.18, 3.19, 5.12, 5.35, 5.38, 5.42, 7.1, 7.3, 8.1, 10.1, 10.30,
13.11, 13.19, 14.5
EMI 2.39
Encapsulation 15.5, 16.6
Encoder 1.19, 1.21, 1.22, 1.24, 1.25, 2.45, 6.11, 11.5, 11.7, 14.10, 14.13, 14.14, 14,34,
14.41
End turns 3.12, 3.32, 3.35, 13.6, 13.22
End-windings 2.12, 5.9, 5.11, 5.60, 6.3, 15.24
Energy product 3.23-3.25, 4.15, 16.1, 16.4, 16.7
Epoxy 2.8, 3.28-3.31, 11.7, 12.6, 13.6, 13.19, 13.23, 13.25, 15.13
Error amplifier 2.43, 14.11, 14.12, 14.22
Error signal 2.41-2.43, 14.12, 14.20, 14.21, 14.31, 14.41
Exterior rotor 1.3, 1.4, 2.1, 2.2, 2.8-2.10, 3.1, 3.3, 3.6, 3.10, 3.25, 3.35, 3.73, 3.74, 5.21,
12.6, 15.2, 13.16, 13.18, 13.26
Faraday 3.15
Fault 2.41, 3.2, 3.36, 10.2, 11.12, 16.8
Feedback 1.1, 1.18-1.20, 1.24, 2.22, 2.30, 2.43, 2.47, 6.11, 11.6, 11.7, 11.9, 13.1,
xxiii
14.10-14.14,14.19,14.20,14.22,14.23,14.26,14.28,14.31,14.32,14.36.
14.46
Fertile 2.3, 2.5, 2.6, 2.8, 2.10, 2.13, 3.3, 3.8, 3.23, 3.24, 3.26, 3.27, 3.74, 4.3, 4.9, 4.16,
11.7, 12.4, 12.9, 12.22, 13.2, 13.4, 13.11, 16.4, 16.6-16.8
Fiberglass 3.35
Field-oriented control 1.12, 2.46, 6.2, 6.11
Field-weakening 6.46, 17.1 ft vq., 18.1 ft vq.
Finite element method 8.17, 8.20, 12.13, 12.14, 12.27, 12.28
Finite maximum speed 17.11
Finned 1.17, 15.9
Firmware 14.34
First-order hold 14.35
Floppy disc 2.1, 13.16
Flux 1.7-1.9, 1.11, 1.13, 1.17, 1.22, 2.5, 2.6, 2.11-2.14, 2.46, 3.1, 3.3, 3.7, 3.8, 3.15-3.21,
3.25-3.26,3.33, 3.34, 3.71,3.74,4.1-4.17,4.19,4.23-1.33,5.1-5.4,5.6-5.9,
5.12, 5.13, 5.19, 5.21, 5.28, 5.29, 5.31, 5.32, 5.35-5.37, 5.39, 5.42-5.56,
5.61-5.63,5.65,5.66, 6.1-6.10, 6.12-6.17, 6.19, 6.22-6.25,6.28-6.34, 6.37,
6.38, 6.40, 6.42, 6.46, 7.11-7.15, 8.2-8.11, 8.13-8.20, 9.1-9.3, 9.5-9 7,
10.28.11.2, 11.9,11.12, 12.3-12.5,12.12,12.13,12.18-12.28,13,2, 13.4,
13.6,13.9-13.11,15.14, 13.19-13.23, 13.25,13.26,15.9, 16.1,16.2,16.4,
16.7, 16.8, 16.10-16.14
Flux concentration 2.5
Flux distribution 5.1, 5.4, 5.19, 5.21, 5.28. 5.29, 5.35, 5.46, 5.47, 5.49, 5.50, 5.54, 5.62,
6.2, 6.13-6.16, 6.22, 6.24, 6.25, 6.31. 7.15, 8.5, 8.7, 9.2. 12.
12.20-12.23, 12.25-12.27, 13.11
Flux linked 3.15, 5.8, 6.6
Flux-linkage 1.7-1.9, 1.11, 1.13, 3.15, 3.15, 3.17, 3.18, 5.3, 5.4, 5.6-5.9, 5.35-5.37, 5,43,
5.44, 5.46, 5.47, 5.51, 5.52, 5.54-5.56, 5.65, 5.66, 6.1, 6.2, 6.4, 6.6.9,
6.16, 6.17, 6.22, 6.23, 6.31, 6.32, 8.4, 8.9, 12.19, 12.20
Flux-weakening 17.2 ft seq.
Fly winder 13.18
Forced cooling 1.17, 11.8
Four-quadrant 2.17, 14.1
Fracdonal-slot 3.10, 3.12, 5.34, 3.40, 3.41, 3.44, 3.48, 6.17, 6.19, 12.9
Frequency 1.1,1.19,1.21, 2.15, 2.18, 2.20-2.23, 2.34, 2.38,2.43, 2.45, 2.47,3.2, 3.6, 3.33,
3.51, 4.27,5.5,5.9,6.11, 6.42,6.43,6.4M.47, 9.1,9.2,9.5,10.11,10.28,
11.4, 13.6, 13.7, 13.14, 14.1-14.3, 14.6, 14.8, 14.15-14.18, 14.20, 14.21,
14.24-14.26, 14.32, 14.35, 14.3&44.41, 15.9, 16.11, 16.14
Frequency response 14,1, 14.15, 14.16, 14.20
Friction brake 11.6
Full-bridge 2.16, 2.23-2.27, 2.39, 3.4, 5.32
Function 1.10, 1.12, 2.41, 2.46, 4.2, 4.10, 4.27, 4.33, 5.1, 5.3, 5.32, 5.64. 5.65, 6.2, 7.1,
8.5, 8.6, 8.9, 8.12, 8.15, 9,3, 11.8, 12.14, 12.18, 14.2, 14.3, 14.5-14.10,
14.12,14.14,14.16,14.18-14.26,14.28,14.29,14.35,14.36,14.40,14.43,
14.46, 15.4, 15.12, 15.15, 15.19, 16.1, 16.7, 16.11, 16.14
Fundamental 1.5,1.11, 2.1, 2 22, 2.38, 2.46, 3.14, 3.17, 3.33,3.45, 5.1, 5.5.5.8, 5.9, 5.18,
5.24, 5,33. 5.36, 5.61, 5.62, 6.1-6.3, 6.9, 6.10, 6.13, 6.1
6.21-6.24, 6.3^6.32, 6.46, 7.2, 7.13-7.16, 8.9, 9.1, 9.2, 9.5, 12.3, 12.24
Fundamental ampere-conductor distribution 2.46
xxiv
I n d ex
Fundamental winding factor 6.22
Gain 1.12, 1.19, 2.41-2.43, 2.47, 7.1, 10.12, 14.6, 14.9-14.12, 14.16-14.18, 14.20-14.26,
14.28, 14.29, 14.31, 14.32, 14.41, 14.42
Gain margin 14.20, 14.21, 14.26
Gap 1.4,1.7, 1.19, 2.1, 2.6,2.10-2.13, 3.1,3.3, 3.6, 3.10, 3.20, 3.25, 3.74, 4.16, 5.44. 5.61,
5.62, 6.27, 6.28, 8.10, 9.5, 13.6, 13.16, 13.22, 13.25
Gauss 3.23, 4.7, 4.8, 13.19, 16.12
Cear 3.5, 14.7, 14.14
Geaimotor 11.2, 11.10
Generator 3.15, 3.71, 4.18, 6.39-6.41, 6.47, 7.4, 7.5, 7.7, 10.34, 14.17
Glassfibre 3.71, 4.28
"Go" coilside 3.42
Gramme 2.12, 5.65
Hague 5.64-5.66, 8.3, 8.20
Hall 1.19, 1.22, 1.24, 1.25, 2.45, 3.4, 3.16, 3.17, 3.30, 7.2, 11.7, 11.11, 11.12, 13.16
Hall effect 1.22, 3.16
Hall switch 1.22, 1.25, 3.4
Hard chopping 2.21
Hard disc 13.1
"Hard magnet 3.20
Hanmonic 1.11, 2.13, 2.23, 2.38-2.39, 3.2, 3.4, 3.45, 3.51,4.26, 4.27, 4.33, 5.8, 5.9, 5.26,
5.28-5.30, 5.33, 5.55, 5.61-5.65, 6.1-6.2, 6.9-6.10, 6.16-6.22, 7.13, 7.14,
8.2, 9.2, 11.13-11.14, 12.10, 12.24, 12;27, 13.8, 13.25
Heat 1.1, 1.17, 2,9, 2.13, 2.40, 3.28, S.32, 3.33, 3.73, 5.61, 6.42, 11.7, 11.8, 12.5, 12.6,
15.1, 15.2, 15.4-15.13, 15.22-15.24
Heat transfer 3.73, 12.5, 15.1. 15,5-15,8. 15.12, 15.22-15.24
Heat treatment 3.33
Henry 3.15
Hi-pot 3.31
High-energy magnet 2.3, 2.5, 5.61
Hoists 1.12
Hub 1.4, 4.2, 13.16, 13.18, 13.24
Hysteresis 1.17, 2.17, 2.22, 2.23, 3.25, 3.33, 4.2, 4.6, 4.7, 9.1. 10.13, 10.15, 10.21, 11.6,
12.27, 13.14, 14.14, 14.45, 16.1-16.3, 16.11-16.13, 16.16
Hysteresis brake 11.6
Hysteresis losses 3.25, 9.1, 12.27, 13.14, 16.11
IC 1.23, 2.30, 2.32, 2.46, 5.14, 5.24, 6.42, 6.44-6.46, 10.4, 10.16
Ideal drive 17.2
Identification 14.16
IEEE488 3.2, 11.15
IGBT 2.19, 2.20
Incremental encoder 1.22, 2.45
Incremental motion control 14.14, 14.15
Incremental permeability 4.2
Induced current 4.29
Inductance 1.17, 2.13, 2.16, 2.22, 2.32, 2.34, 2.43, 3.1, 3.6, 3.15-3.17, 3.33, 3.51, 3.71,
4.30, 5.13, 5.14, 5.25, 5.39-5.46, 5.48-5.51, 5.53-5.60, 5.62, 5.64. 5.65,
XXV
6.3, 6.4, 6.6-6.9, 6.13, 6.23, 10.9, 10.24, 10.25, 11.2-11.4, 11.6, 11.9,
12.19, 12.20, 12.23, 12.24, 13.2, 14.5, 14.7
Induction motor 1.1,1.2, 1.4, 1.12, 2-2, 2.6, 2.20, 2.46, 3.14, 5.29, 3.31, 3.35, 5.55, 5.58,
9.2, 13.1-13.3, 13.6, 13.7, 13.14, 13.15, 17.3
Inertia 1.4,1.19, 2.1, 2.2, 2.5, 3.2, 3.3, 3.6, 3.73, 6.46,11.2,13.1.13.2, 13.16, 14.5, 14.7,
14.8, 14.10, 14.14, 14.18
Infinite maximum speed 17.11
Inset 2.3
Inside rotor
see interior rotor
Instantaneous 1.9, 2.23, 2.34, 2.35, 2.46, 5.24, 5.32, 7.10, 7.12, 10.2
Insulation 1.16, 3.2, 3.28, 3.31, 3.32, 3.35, 3.70, 4.2,13.13,13,23,13.26,15.1,15.1,15.5,
15.10, 15.13, 16.15, 16,17
Integral gain 2.43, 14.22, 14.31
Integral slot 3.40
Integral-slot 3.10, 3.12, 3.34, 3.40, 3.48, 13.7
Interconnections 3.31
Interference 1.23, 2.39, 14.18, 14.32
Interior permanent-magnet motor
see IPM
Interior rotor 3.1, 3.3
Interior-rotor motor 1.4, 2.1, 2.2, 2.12, 4.11, 13.2
Interphase fault 3.36
Intrinsic 3.26, 3.27, 16.1, 16.2, 16.7, 16.8
Intrinsic coercivity 3.27, 16.2, 16.7, 16.8
Intrinsic demagnetization curve 3.26, 3.27
Inverter 1.10, 1.19, 2.39-2.41, 3.4, 4-33, 5.32, 7.2, 11.1, 11.6, 11.10, 15.4, 13.11, 13.15,
13.16, 16.13
Inverter utilization 17.2
IPM 17.8 et <*q., 18.1 et teq.
IPM parameter plane 17.16 et vq.
Iron 1.1, 1.17,1.20,1.22, 2.2, 2.3, 2.5,2.8, 2.11, 2.13,2.47, 3.4-S.6, 3.16, 3.24, 3.25, 3.28,
3.34, 4.2-4.5, 4.9, 4.18, 5.61, 5.66, 6.3, 8.3. 8,20, 9.3, 9.9, 13.15, 13.17,
13.21, 13,24, 15.13, 15.14, 16.6, 16.11, 16.13, 16.15, 16.1
Iron losses 2.13, 3.6, 8,3, 8.20, 9.9, 16.16
Kalman filter 14.46
Kapton 15.13
kE 1.13, 1.14, 3.18-3.20, 3.23, 5.12, 5.35, 5.36, 5.38, 5.39, 5.42, 7.1-7.10, 7.12-7.16, 8.1,
10.30, 10.33, 13.11, 13.13, 13.19, 13.25, 14.5-14.7, 14.9,
Keeper 4.4, 4.5, 16.1, 16.9
Kelvin 11.15, 15.6
Kevlar 1.4, 2.3, 13.6, 16.10
loj. 1.13, 1.14, 1.17, 3.19, 3.20. 3.22, 3.23, 5.12, 5.36, 5.38, 5.42, 6.39, 6.42, 7.1-7.10,
7.12, 7.13, 7.15, 7.16, 8.1, 11.8, 11.9, 12.21, 13.11, 13-25, 14.5
Lacing 3.35
Lamination 1.17, 2.2-2.S, 2.5-2.6, 2.8, 2.12, 3.1, 3.3, S.4-3.5, 3.9-3.10, 3.12, 3.24,
3.28-3.35, 3.50, 3.70, 4.2, 5.62, 8.11, 9.1, 9.6, 12;1. 12.6, 12.15, 12.16,
13.2-13.4, 13.7,13.9,13.15, 13.19,13.20,13.22-13.25,15,1,15.5, 15;10-
15.11, 16.11-16.12, 16.13, 16.15-16.16
xxvi
INDEX
Lamination stack
bond 3.26
Lap winding 3.10, 3.31, 3.35, 3.39, 3.40, 3.43, 5.9, 5.10, 6.3, 6.17, 6.19, 12.9, 1S.6, 13.8
Laplace operator 14.2
Laplace transform 14.1-14.3, 14.8, 14.18, 14.29, 14.36, 14.38
Laser S.28, 3.73, 13.23
Lead/lag 14.1, 14.25
Leakage 1.22. 2.3, 2.6, 2.11, 2.18, 3.8, 3.18, 5.21, 3.71. 4.3, 4.104.12, 4.14, 4.16, 4.2S,
4.25, 5.14. 5.25, 5.42, 5.43, 5.55, 5.57-5.59, 5.62, 6.13, 6.23, 6.29,
6.31-6.34. 6.41, 8.16, 12.18, 12,19, 13.9, 13.22, 13.25, 16.8
Leakage flux 1.22, 3.71, 4.10, 4.14, 4.16. 4.23, 5.43, 5.55, 8.16, 12.18, 12.19
Leakage inductance 5.14, 5.25, 5.55, 5.57, 5.62, 6.13, 6.23
Leakage permeance 4.3, 4.11, 4.12, 4.23, 4.25, 6.29, 6.33, 6.34
Leakage reactance 5.58, 6.23, 6.31, 6.32, 6.41
Line 1.3, 1.15, 1.18, 2.26, 2.27 , 2.29-2.35, 2.37-2.40, 2.45, 2.46,3.12,3.21.3.23,3.2
3.27, 3.29, 3.33, 3.45-3.48, 3.71, 4.7, 4.8, 4.22-4.24,4.26, 5.5,5.B, 5.14,
5.17-5.21, 5.24, 5.25, 5.29, 5.30, 5.32, 5.35, 5.37, 5.38, 5.43, 5.44, 6.4,
6.16, 6.29, 6.39, 6.41, 6.47, 7.2, 7.S-7.7, 7.9, 7.10, 7.13, 7.16. 8.1, 8.13,
10.2, 10.4. 10.7-10.11, 10.13, 10.15, 10.16, 10.18, 10.21, 10.22. 10.27,
10.28, 10.30, 10.31, 11.2, 11.4, 11.6, 11.9, 11.10, 11.14, 12.10, 12.25,
12.27,12.28,13.2,13.4,13.10,13.13,13.15. 13.19,13.22,13.26, 14.1
14.14, 14.31, 14.32, 15.9, 16.4
Line-line 2.31-2.33,2.38, 2.39,3.45-3.48, 3.71,5.14,5.17-5.21,5.24,5.30,5.35, 6.16, 6.41,
7.5, 7.7, 7.10, 7.13, 7.16, 8.1, 10.10, 10.27, 10.30, 11,4, 12.10, 13.13,
13.26
Linear 1.2, 1.11, 1.12, 1.15. 2.15, 2.38. 2.39, 4.16, 4.17, 4.19, 5.18, 5.36, 6.42, 8.5, 11.6,
12.2. 12.13, 12.14, 12.17, 12.19, 12.21, 14.1, 14.7, 14.16, 14.20, 14.34,
14.43, 15.12, 16.3, 16.4, 16.7, 16.14
Linearity 1.11, 2.41, 3.74, 5.38, 11.2, 11.8-11.10, 15.12
Liquid cooling 1.17, 2.13, 3.33, 15.8
Load 1.12, 1.14-1.16, 1.18, 1.19, 2.1, 2.6, 2.16, 2.17, 2.20-2.26, 2.39, 2.44, 3.15, 3.21,
3.23, 3.27, 3.33, 4.1, 4.7, 4.8, 4.18, 4.22, 4.33, 5.39, 5.66, 6.36, 6.41,
6.46. 7.4, 8.19, 10.1, 10.27, 10.28. 10.30-10.35. 11.2, 11.5-11.7, 11.9,
12.20, 12.21, 13.4, 13.11, 13.15, 13.19, 14.1, 14.5, 14.7-14.10, 14.14.
14.30, 14.31, 14.41, 15.7, 15.8, 15.17, 15.20, 16.8, 16.10,
Load line 3.21, 3.23, 3.27, 4.7, 4.8, 13.4, 13;15, 13.19
Locked rotor 1,14-1.16, 4.18-4,22. 11.7, 12.26, 13.15
Locate 2.8, 3.28, 3.29, 16,10
Lorentz 3.16, 3.17, 12.20
Losses 1.1, 1.4, 1.9, 1.17, 2.1, 2.6, 2.9, 2.11-2.13, 2.18, 2.19, S.5-3.6, 3.10, 3.25, 3.28,
3.32-3.34,4.2, 4;8. 4.284.33, 5.25, 5.26, 5.31, 5.39, 5.61, 6.41,6.46, 7.2,
8.3-8.4, 8.10, 8.20, 9.1-9.S. 9.5-9.9, 10.22, 10.30, 10.31. 10.34, 11.7,
11.12,12.20,12.21,12;27,13.7,1S.11,13.14,13.15,13.19, 13.22,13;2S,
13.24, 13.26, 14; 20, 15.1, 15.2, 15.4, 15.8, 15.9, 15.10, 15.12, 15.17,
16.11, 16.12-16.16
Low<arbon steel 2.2, 13.21
Machine tools 1.11, 1.12, 3.3, 3.76, 14.14
xxvii
Magnequench 13.19, 13.20
Magnet 1.1, 1.2, 1.4, 1.7, 1.9, 1.11, 1.16-1.17, 1.20, 1.22, 1.23, 1.25, 2.1-2.8, 2.10-2.15,
2.19-2.20, 2.40, 2.41, 2.46, 2.47, S.l-3.8, 3.15, 3.16-3.21, 3.23-3.27,
3.30-3.35,3.47, 3.50,3.51, 3.71,3.73-3.74,3.76,4.1-4.20,4.22,4.25-4.29,
4.32, 4.33, 5.1, 5.3-S.5, 5.8, 5.11-5.14, 5.17, 5.19-5.21, 5.24-5.26,
5.28-5.32, 5.35, 5.38-5.39, 5.44, 5.52, 5.55, 5.61-5.66, 6.1-6.4, 6.9, 6.10,
6.12, 6.16. 6.21, 6.22, 6.24, 6.26, 6.28. 6.29. 6.31, 6.33-6.35, 6.37-6.40,
6.42-6.44, 6.46-6.48, 7.10-7.16, 8.2-8.13, 8.15, 8.16, 8.19, 8.20, 9.5, 9.9,
10.15,11.4,11.5,11.7-11.9,11.11,11.12,11.16,12.6,12.9-12.10, 12;15,
12.17, 12.18, 12.20-12.28, 13.1, 13.2, 13.4-13.11, 13.15-13.22, 13.25-
13.26, 14.1, 14.41, 15.13-15.14, 16.1-16.12, 16.16, 16.17
bonded ring 3.8
embedded slab 3.8
ferrite 3.24
Magnet length 3.21, 4.12, 4.14, 8.2, 8.6, 13.22, 16.8
Magnet thickness 3.24-3.26,4.18,12.6,12.22,13.4,13.6,13.9,13.10,13.16,13.19.13.20
Magnet wire 3.30-3.32, 13.18, 16.17
Magnetic 1.1,1.2,1.4,1.6,1.7,1.14,1.17,1.19,1.22, 2.1, 2.3, 2.6, 2.11-2.13, 3.1, 3.6, 3.8,
3.15, 3.16-3.18, 3.21, 3.26, 3.29, 3.32, 3.33, 4.1-4.6, 4.8, 4.9, 4.11-4.13.
4.15-4.18, 4.23-4.29, 4.32, 5.1, 5.32, 5.36, 5.38, 5.39, 5.42-5.44, 5.52,
5.61, 5.63-5.65, 6.9, 6.12. 6.24, 6.25, 6.28, 6.34, 6.36, 8.2-8.4, 8.9, 8.16,
8.20,9.1, 9.2,10.2,10.34,11.6,11.9,12.2-12.4,12.6, 12.13,12.19-12.21.
12.28, 13.3, 13.4, 13.6, 13.17, 13.19, 15.22, 14.7, 14.9, 16.1, 16.8-16.13,
16.15, 16.16
Magnetic loading 2.12, 3.1, 12.2-12.4, 12.6
Magnetic short circuit 16.1
Magnetization 3.20, 3.21, 3.25, 4.6, 4.9, 4.12, 4.28, 6.2, 6.3, 11.11, 11.12, 12.18, 12.21,
12.25, 13.7, 13.9, 16.1, 16.3, 16.7. 16.8. 16.11, 16.12, 16.
Magnetizing fixture 3.8, 4.5, 13.9, 16.8
Maximum energy product 4.15, 16.4, 16.7
Maxwells equations 12.13
Mean length of turn 5.60, 13.13
MGOe 5.23, 4.8, 4.15
Micro-controller 14.11
MLT 3.70, 5.60, 13.13, 13.26
Model reference adaptive control 14.43, 14.45
Modulation 1.17, 2.15, 2.21, 2.22, 2.38, 2.39, 2.44, 6.2, 9.1
Moisture 3.32
MOSFET 2.19, 2.20
Motion control 3.76, 14.14, 14.15, 15.14
Motor 1.1-1.25, 2.1-2.3, 2.5, 2.6-2.20, 2.22, 2.23, 2.27, 2.28, 2.30, 2.32, 2.34, 2.37-2.47,
5.1-3.6, 3.8-3.19, 3.21, 3.23, 3.24, 3.26-3.36, 3.39-3.48, 3.50, 3.51,
3.71-3.76, 4.1-4.5, 4.9-4.11, 4.1M.16, 4.1&4.20, 4.22, 4.23, 4.26, 4.28-
4.29, 4.32, 4.33, 5.1-5.4, 5.6-5.12, 5.14-5.16, 5.18-5.26, 5.28-5.33,
5.35-5.41,5.43, 5.44,5.52, 5.55, 5.57, 5.58, 5.60-5.63, 5.66, 6.1-6.4, 6.11,
6.12, 6.16, 6.23, 6.25, 6.29, 6.35, 6.37, 6.39, 6.40, 6.42-6.44, 6.46, 6.46,
6.47, 7.1-7.16, 8.1-8.3, 8.5, 8.6, 8.10. 8.12, 8.19, 8.20, 9.1, 9.2, 9.9,
10.1-10.6, 10.9, 10.16, 10.18, 10.20, 10.22, 10.27, 10.28, 10.30-10.33,
10.35, 11.1, 11.2,11.4-11.14, 11.16,12.1, 12.2-12.9, 12.13-12.21, 12.24,
xxviii
I n d ex
13.1-13.4,13.6-13.11,13.14-13.16,13.18,13.19,13.22,13.24-13.26,14.1,
14.5, 14.7-14.10, 14.12-14.19, 14.28, 14.31, 14.32, 14.34, 14.40-14.46,
15.1, 15.2, 15.4, 15.5, 15.7-15.17, 15.19, 15.21-15.22, 16.1, 16.4,
16.6-16.16
AC induction 1.1
AC servo 1.2
stepping 1.1
velocity servo 11.9
Motor-in-hub 18.16, 13.18, 13.24
Motoring 2.44, 3.2, 3.15, 6.37, 10.1, 10.34, 10.35, 14.12
Muitiple-strand 3.32, 16.16
Mutual inductance 3.15, 3.71, 5.13, 5.42-5.44, 5.46, 5.48-5.51, 5.53-5.55, 5.57-5.59, 5.65,
6.8, 6.9, 11.4, 12.23
NdFeB
see Neodymium Iron Boron
Needle 3.12, 3.31, 5.21, 11.12, 13.18
Negative feedback 14.11, 14.31
Neodymium-Iron-Boron 3.24, 3.27, 4.3, 4.5, 4.9, 11.7, 12.4, 13.19, 15.13, 16.6
Nested 3.29, 3.70, 14.32
Noise 1.1,1.19,1.22,1.25,3.2, 3.34,12.1,13.18,13.22,14.18,14.31,14.32,14.34,14.41,
14.46
audible 1.19
Nomex 15.13
Nonlinear 2.37, 4.16, 4.25, 8.16, 11.8, 12.19, 14.7, 14.20, 14.41, 14.43, 15.1
Non-salient 17.6
Nyquisi 14.35
Observer 6.12, 6.23, 14.46
OD 2.3, 3.35, 6.44, 12.5, 12.6, 13.3, 13.6, 13.9, 13.20, 13.21
Oflset 3.5, 3.48, 6.42
Op-amp 2.43, 14.11
Open-circuit 3.15, 3.20, 3.21, 3.23, 4.5, 4.7, 4.8, 4.12, 4.14-4.16, 4.19, 6.3, 6.12, 6.22,
6.33, 6.35, 6.45, 7.4, 11.5, 12.21, 12.22, 12.26, 16.8
Open-loop transfer function 14.21, 14.22
Operating region 1.16, 1.18
Optical interrupter 1.25
Optimal control 14.1, 14.46
Oscilloscope 3.19, 7.7, 11.2, 11.5, 11.11, 11.14
Output 1.17,1.19, 2.16, 2.39, 3.3, 3.5, 3.51,4.18,6.41,11.1,11.2,11.7,11.11,12.2,12.5,
12.7, 12.10, 12.13, 12.19, 13.14, 13.19, 14.2, 14.5, 14.10-14.13, 14.16,
14.20-14.22,14.26,14.31,14.33,14.34,14.36,14.40,14.41,14.43,14.45,
14.46, 15.8, 15.15
Output coefficient 12.2
Output equation 12.2, 14.36
Outside rotor 3.25
see exterior rotor
Overcurrent 2.16, 2.30, 2.41, 3.2, 4.28, 5.38, 6.46, 6.47
Overload factor 15.15-15.20
x xix
Overtemperature S.2, 4.28, 5.38
Pack 3.28, 3.30, 3.31
Pancake motor 2.1, 2.10, 2.11
Pancake resolver 1.20
Parallel 2.19, 3.18, 3.26, 3.71. 4.3, 4.12, 4.204.22, 5.12. 5.24, 5.35, 5.39, 5.46, 5.47. 5.59,
5.60, 5.63, 5.64, 6.2, 6.7, 6.14, 6.28, 6.29, 6.33, 6.35, 7.12, 7.13, 7.15,
7.16,10.13, 10.15, 10.16,10.20,10.21,13.11, 13.15,14.12, 15.7,1
15.15, 16.10
Parallel paths 3.18, 3.26, 4.20, 4.21, 5.12, 5.35, 5.39, 5.46. 5.47, 5.59, 6.7, 6.14, 6.28,
7.12, 7.13, 7.15, 7.16, 13.11, 13.15
PC-BDC 5.13, 5.30, 5.51,5.59, 8.1, 8.3, 8.13.8.17, 9.2, 9.7,10.1,10.26,12.6-12.14,13.27,
14.41, 15.23
PC-SRD 9.2
Performance 1.2, 1.5, 1.12. 2.10, 2.11. 2.13, 2.20, 2.43, 3.1, 3.3, 3.17, 3.22, 3.28, 4.9,
5.33, 5.66, 6.1, 6.3, 6.42, 8.3, 8.20, 11.1, 11.2, 11.7, 12.1, 12.4,
12.7-12.10, 12.14, 13.1, 13.19, 13.23, 13.26, 14.1. 14.9, 14.10, 14.12,
14.18, 14.25, 14.26, 14.40, 14.43, 16.4, 16.6, 16.11, 16.15
Permanent magnets 1.1
Permeability 4.2, 4.6, 4.7, 4.18, 5.36, 8.6, 8.16, 11.4, 12.20, 12.22, 16.2, 16.4, 16.7, 16.11
Pcrmeance 2.3,3.20, 3.23. 3.24,4.3, 4.8,4.11, 4.12,4.14, 4.15,4.23-4.27, 5.13, 5.55-5.59,
6.24, 6.28, 6.29, 6.33, 6.34, 13.4, 16.4, 16.7, 16.8
Phase 1.2, 1.9-1.11, 1.13, 1.17-1.19, 1.21-1.23, 2.1, 2.2, 2.12, 2.14-2.17, 2.19, 2.23-2.31,
2.35-2.41,2.44-2.47, 3.1,3.3-S.5,3.9-3.13,3.18-3.20,3.26-3.28, 3.31-3.36.
3.38,3.41-3.51,3.70.3.71,4.1,4.5,4.7-4.10,4.12,4.15,4.184.22,5.1-5.3,
5.5, 5.6, 5.9, 5.11-5.14, 5.17-5.21, 5.23-5.26, 5.2&-5.30, 5.32-5.35,
5.38-5.41, 5.43, 5.44, 5.46-5.50, 5.54, 5.55, 5.58-5.60, 6.2-6.4, 6.7, 6.8,
6.11-6.14, 6.16, 6.19-6,23, 6.27, 6.28, 6.31, 6.32, 6.35, 6.38, 6.41. 6.43.
6.46, 6.47, 7.1, 7.4, 7.6-7.16, 8.1, 8.9, 8.10, 8.16, 8.17, 10.1, 10.3, 10.4,
10.8,10.12,10.15,10.16,10.22-10.26,10.28,11.2-11.7,11.9,11.14,12.3.
12.10, 12.13, 12.22, 12.24, 13.2, 13.6, 13.8, 13.11, 13.13-13.15, 13.25,
13.26, 14.9,14.16,14.18,14.20, 14.21,14.25,14.26,15.14
Phase displacement 3.42, 3.43, 3.45, 5.5
Phase margin 14.20, 14.21, 14.26
Phase sequence 10.4
Phaseleg 2.15-2.17, 2.26, 5.32
Phasor 2.38, 2.46, 6.3. 6.4. 6.22, 6.28, 6,30, 6.32, 6.35-6.37, 6.3M.46, 7.15, 11.4, 11.5,
12.24
Phasor diagram 2.38, 2.46, 6.3, 6.4, 6.22, 6.28, 6.30, 6.32, 6.35-6.37, 6.39-6.42, 6.44-6.46,
11.4, 11.5, 12.24
PID control 14.30, 14.31, 14.41, 14.43
Pitch 1.21, 3.10, 3.12, 3.14, 3.31, 3.35, 3.36, 3.40, 3.42, 3.45, 3.48. 3.50. 3.51, 4.12, 4.17,
4.30, 4.32, 5.2, 5.3, 5.5, 5.6, 5.8, 5.9, 5.11, 5.14, 5.20. 5.28-5.30, 5.35,
5.36, 5.44, 5.45, 5.53, 5.58, 6.1, 6.3. 6.6, 6.7, 6.1^6.17. 6.19-6.21. 7.11,
7.12, 7.14. 8.1, 8.4, 8.5, 8.9-8.12, 8.17. 10.15, 12.5, 12.16-12.18,
13.6-13.9, 13.13, 13.18, 13.20, 13.22, 13.25
Pitch factor 3.45, 5.29, 6.16, 6.17, 6.21
Plant 14.7, 14.11, 14.12, 14.14, 14.20, 14.26, 14.30. 14.31, 14.34, 14.36. 14.39, 14.40,
14.43
Platen 13.16
XXX
Index
Polarization 16.1, 16.2
Pole-pieces 2.5, 3;7, 3.24, 3.74, 4.23, 4.25, 6.3. 6.2W.29, 6.33
Poles 1.1, 1.2, 1.23, 2.3, 2.5, 2.6, 2.10, 3.1, 5.6-3.13, 3.20, 3.23, 3.25, 3.33-3.36, 3.41,
3.43-3.45, 3.48, 3.50,3.71,4.4,4.5,4.21.4.27.4.28,4.32, 5.5,5.12,5.17,
5.18, 5.21, 5.35, 5.46. 6.4, 6.7, 6.1S, 6.25, 8.6. 8.7, 8.16, 12.21, 13.1,
13.6-13.10, 13.18, 13.21, 13.22, 13.26, 14.5, 14.8, 14.12, 14.16,
14.22-14.26, 14.30, 14.38, 16.15
Position control 1.1, 1.11, 2.45, 14.13-14.15, 14.18, 14.28-14.30. 14.32
Power 1.2.1.9, 1.10,1.12, 1.15-1.17, 1.19, 1.25, 2.3, 2.5, 2.6, 2.11, 2.14-2.24, 2.27, 2.80,
2.39-2.42, 2.44, 2.45, 2.47, S.2-3.6, 3.15, 3.25, 3.26, 3.28, 3.32, 5.1, 5.5,
5.17.5.32, 5.33, 5.39, 6.4,6.38, 6.44, 6.46,6.47, 7.4,7.7-7.10, 7.15, 8.19,
9.1, 9.9, 10.1, 10.2, 10.30, 10.31, 10.34, 11.1, 11.2, 11.6. 11.7, 11.13.
11.14, 12.3, 13.13, 13.14, 13.18, 13.19, 14.2. 14.18. 14.46, 15.1, 15.5,
15.8, 15.15, 15.17, 15.24, 16.8, 16.16
Power density 2.6, 3.28, 13.18, 15.1, 15.5
Power factor 2.6, 2.20, 2.39, 6.38, 6.44, 6.46, 7.15
Power transistor 1.2, 1-10, 1.16, 1.19, 2.14, 2.15, 2.18, 2.19, 2.21, 2.23, 2.30, 2.41, 2.42,
3.4, 5.5, 5.17, 5.32, 5.33. 5.39. 10.1
PPR 14.13
Precision dynamometer 11.12-11.16
Prime mover 10.34, 16.10
Principle of virtual work 3.17
Progressive die 3.28
Properties 2.18, 4.6, 4.9, 4.12, 6.1, 6.4, 7.10, 13.4, 14.7, 14.12, 15.1, 15.6, 15.13, 16.1,
16.3-16.5, 16.7, 16.8, 16.11, 16.12, 16.15, 16.17
Proportional gain 2.42, 14.31, 14.41, 14.42
Pulse-width modulation 1.17, 2.15, 6.2, 9.1
Pulses per revolution (PPR) 14.13
Punch press 3.28
Punching 2.3, 3.28, 3.29, 4.27, 9.1, 9.2, 13.2, 13.23-13.25, 16.15, 16.16
PWM 2.21, 2.23, 2.30, 2.35, 2.38, 2.39, 2.41, 2.43-2.46, 3.25, 4.33, 5.32, 6.2, 6.43, 7.2,
10.10, 10.28, 10.33, 11.12, 14.34. 16.11, 16.13
q-axis 2.46, 4.23. 6.2, 6.3, 6.9, 6.22-6.24, 6.28, 6.29, 6.31-6.33. 6.35-6.38, 6.40, 6.42-6.44,
6.46, 7.15. 8.5, 11.4, 12.21. 12.26
Quadrant 2.17, 4.6-4.9, 4.16, 5.64, 6.38, 14.1, 14.12, 14.13, 16.3, 16.4
Quadrants 2.44, 14.12, 16.16
Radiation 15.1, 15.2, 15.5, 15.8-15.12
Rated currcnt 17.1 et xeq.
Rated speed 17.1 rt vq.
Rated torque 17.1 et vq.
Rated voltage 17.1 et vq.
Recoil line 4.8, 16.4
Recoil permeability 4.6, 4.7, 8.6, 8.16, 12.22, 16.2, 16.4, 16.7
Rectifier 2.17, 2.39, 2.40, 2.44, 6.41, 6.47, 7.5, 7.7, 10.28
Reference 1.7, 1.21, 1.25, 2.15, 2.22, 2.23, 2.38, 2.41, 2.43. 2.46, 2.47, 3.1, 3.19, 3.45,
4.32, 5.1, 5.2, 6.2, 6.10, 6.35, 7.2, 7.9, 7.10, 10.35, 12.28, 13.6, 13.8
13.25, 14.11-14.13, 14.22, 14.43, 14.45, 15.24, 16.16. 16.17
XXXI
Reference frame 2.23, 2.46, 7.10
Reference signal 2.43, 14.11-14.13
Regenerative 2.44, 2.45
Regenerative braking 2.44, 2.45
Regulation 2.20-2.2S, 2.S4. 2.39, 2.42, 2.43, 2.45. 5.32, 10.10, 10.18, 10.24, 10.28
Regulator 2.15, 2.23, 2.38, 2.46, 10.9, 10.13, 10.14, 10.18. 10.21, 10.23, 10.24. 10.27,
14.43,14.45
Reluctance 1.12, 1.19.1.25, 2.3, 2.13, 4.3, 4.12, 4.24, 5.55, 5.66, 6.29, 6.36, 6.38, 7.16,
8.2, 8.4, 8.16, 10.35, 12.22
Reluctance network 8.16
Remanence 3.23-3.25, 13.4, 16.1-16.3, 16.7, 16.8
Remanent 3.21, 4.S4.9, 4.13-4.15, 11.9, 11.12. 16.11
Remote sensing 1.23, 2.47, 13.18
Resistivity 1.4, 1.17, 3.33, 4.32, 15.2, 15.4, 15.12, 16.11. 16.17
Resistor 2.44, 2.45, 6.47, 10.24
Resolution 1.19, 1.21, 1.25. 11.13, 14.13, 14.14, 14.35
Resolver 1.19-1.22, 1.25, 2.45, 6.11, 14.10, 14.13, 14.34
Resolver-todigital converter 1.19, 1.25, 14.34
Resonance 1.11, 14.5, 14.9
Retaining can 1.4, 2.3, 4.28-4.30, 6.41
Retention 2.1-2.3, 2.8. 3.24, 13.4, 13.6
Retrogressive 3.42
"Return" coilside 3.42
Reversal 1.2, 5.17
Reverse 1.2, 2.17-2.19, 2.24, 2.25, 2.43, 2.44, 2.46, 3.2, 5.4, 4.8, 4.22, 5.3, 6.29, 10.9,
10.15, 10.27, 10.28, 14.1
Reverse commutation 2.43
Reverse recovery 10.9
Ripple 1.11, 1.17-1.19, 2.6, 2.13, 2.22, 2.23, 2.30, 2.46, 2.47, 2.49, 3.5, 3.6, 3.19, 3.50,
3.51, 4.26-4.28, 4.33, 5.19, 5.20, 5.25, 5.26, 5.29-5.31, 5,62, 5.63, 6.21,
11.2, 11.10, 11.11, 14.1
Robust 12.14, 14.10, 14.26, 14.30, 14.40, 14.43, 14.46
Robustness 14.1, 14.11, 14.12, 14.25, 14.30, 14.43, 14.46
Root locus 14.22-14.26, 14.38
Rotation 1.19, 2.3, 2.11, 2.43, 2.45, 3.4-3 6, 3.15, 3.31, 4.26, 4.27, 4.31. 5.32, 5.41, 6.2,
6.10, 6.11, 8.9, 8.11, 9.2, 11.7, 12.16. 13.7, 13.16, 13.22
Rotational voltage 3.15, 3.16
Rotor 1.1-1.7,1,9,1.14-1.16,1.19,1.20,1.22-1.24,2.1-2.6. 2.8-2.10, 2.12, 2.20, 2.30, 2.32,
2.41, 2.4S, 2.44, 2.46, 3.1, 3.3, 3.4, S.6-3.8, 3.10, 3.17, 3.18, 3.20,
3.24-3.26.3.28,3.33-3.36,3.51,3.71,3.73-3.75,4.2,4.11,4,12,4.17-4.23,
4.25-4.31,4.33,5.1-5.3,5.14.5.19,5.21,5.25,5.31,5.33, 5.
5.55,5.61,6.2,6.9-6.12,6.23, 6.25,6.28.6.29,6.33-6.35,6.41, 6.44,7.11,
7.12, 8.3, 8.4, 8.9, 8.11, 8.13, 8.15, 8.16, 9.2, 9.3, 9.6, 9.7, 10.2. 10.24,
11.1, 11.2, 11.4, 11.7, 11.9, 11.12, 12.2-12.7, 12.12, 12.15-12.17,
12.19-12.21, 12.23-12.26, 13,2, 13.4, 13.6-13.11, 13.15, 13.16,
13.18-13.23, 13.26, 14.5, 15.2, 15.9, 15.11, 16.9, 16.10. 16.13, 16,15
axial 3.6
inside 1.4, 3.6
outside 1.4, 3.6
In d ex
Roving 3.71, 4.28
Saliency ratio 18.4
S.I. Units 7.1
Samarium cobait 3.8
Sampling rate 14.35. 14.36, 14.41
Screening 14.18
Second-order system 14.24, 14.28, 14.29
Self-inductance 3.15, 3.71, 5.42-5.46, 5.48-5.51, 5.55. 5.59, 5.65, 6.7, 6.9, 11.4, 12.23
Self tuning regulators 14.43
Sensor 1.20, 1.22, 2.30, 2.33-2.35, 3.5, 3.71, 5.14, 6.11, 7.7, 11.2, 11.6, 11.7, 14.13
Sensorless control 1.23
Separately-excited DC motor 17.1
Sequence 1.22, 1.23, 1.25, 2.27, 2.32, 2.33, 2.35, 3.43, 3.44, 5.5, 5.14, 5.15, 5.21, 5.23,
5.26, 5.28-5.31, 10.2, 10.4, 10.13, 10.20, 10.24, 11.9, 14.36, 15.14, 16.4
Servo 1.2, 1.4, 1.11, 1.12, 1.24. 2.1, 2.5, 2.41, 2.44, 2.49, 3.3. 3.4, 3.32. 3.76, 4.33, 5.38,
7.1, 13.1, 13.2, 13.26, 14.7, 14.9, 14.12, 14.18, 14.46,
Servo motor 1.12, 3.71, 3.72, 3.76, 4.26. 5.38, 11.9, 13.1, 13.2, 15.14, 15.17
Servo system 14.7, 14.9, 14.12
Settling rime 14.19, 14.25, 14.28, 14.29, 14.39
Shaft coupling 14.9
Shaft flux 3.8
Shaft position transducer 1.19, 1.22, 1.23, 1.25
Short-pitching 3.36, 3.51, 6.3, 6.16
Short-time operation 1.16, 15.22
Shunt 1.22
SI Units 3.19, 4.6, 15.10
Signal 1.19-1.22, 1.25, 2.11. 2.19, 2.22, 2.30, 2.41-2.45, 3.32, 7.2, 10.28, 14.2, 14.5.
14.10-14.18, 14.20-14.22, 14.31, 14.32, 14.34-14.36. 14.40, 14.41
Silicon 2.19, 2.47, 3.4, 3.5, 3.33, 4.2, 5.33, 13.23, 15.13. 16.11
Silicon steel 3.33. 13.23. 15.13. 16.11
Simulation 5.26, 5.29.5.30,5.58, 8.1, 10.1,10.11,10.28,10.31, 10.33,12.1,12.10,12.24,
14.9, 14.34, 14.41, 15.22
Sine 1.19,2.38, 2.39,3.4,5.47, 6.1-6.10,6.13, 6.14, 6.19,6.21-6.25. 6.27, 7.2, 7.14,12.24,
14.34
Sinewave 1.2, 1.3, 2.5, 2.15, 2.28-2.30, 2.37, 2.38, 2.40, 2.45-2.47. 3.4, 3.5, 3.36, 3.39,
3.45, 3.48, 3.50, 3.74, 4.26,4.30, 4.31. 5.1, 5.3, 5.9,5.14,5.18,5
5.24, 5.31, 5.33, 5.36, 5.39,5.58, 5.62, 6.1-6.4, 6.35,6.37,6.40,6
6.44, 7.1, 7.2, 7.7-7.10, 7.13-7.16,8.1, 9.1, 9.3, 11.1, 11.4, 11.5, 12.9.
12.10, 12.24, 13.8, 13.9
Sinewave drive 2.5, 2.37, 2.40, 2.45, 2.46, 3.5, 3.50, 3.74, 11.1, 11.4, 11.5, 12.9, 13.8
Single phase 2.26, 3.4, 5.32, 13.8, 13.11
Single-quadrant 14.1, 14.12
Skew 3.34, 3.35, 3.50, 3.51, 4.27, 4.28, 5.9, 5.29, 5.63, 6.3, 6.21, 7.14, 8.2, 8.3, 8.7, 8.8,
8.11, 8.14, 13.9, 13.11, 13.25
Sliding mode 14.43, 14.45
Slip rings 1.1
Slot 2.3, 2.6, 2.13, 3.1, 3.4, 3.6, 3.9-3.14, B;16, 3.20, 3.21, 3.29-3.32, 3.34-3.36, 3.38-3.45,
xxxiii
5.4651, 5.70, 5.71, 4.2, 4.264.30, 4.32, 5.2, 5.3, 5.5, 5.6, 5.9, 5.11, 5.12,
5.14, 5.20, 5.21, 5.31, 5.36, 5.39, 5.42-5.44, 5.47-5.51, 5.55-5.59, 5.61-
5.62, 6.13, 6.16-6.19, 6.21, 6.31, 6.32, 8.1-8.3, 8.9-8.12, 8.15, 8.17, 8.19,
10.31,11.12,12.4-12.6,12.9,12.16,12.18,12.22,12.23,15.2,15.3,15.6
15.8, 15.10-15.13, 15.18, 15.22, 15.23, 15.25, 15.26, 15.1, 15.5, 15.23,
15.24
Slot fill 5.70, 12.4, 12.5
Slot liner 5.30, 5.70, 15.1, 15.24
Slot opening 5.34, 4.30, 4.32, 8.1, 8.2, 8.12, 15.3, 15.13, 13.22
Slot-fill 3.70, 5.39
Slotless 1.4, 2.1, 2.12-2.14, 3.16, 5.1, 5.61-5.63, 8.3
Slots/pole 3.10, 5.12, 5.14, 3.34, 5.40, 5.41, 5.44, 3.45, 3.50, 4.264.28, 5.2, 5.11, 5.36,
5.48, 5.50, 8.19, 12.18, 15.7, 15.8
Slotting 1.17, 1.19, 2.1, 5.28, 4.2, 4.13, 5.21, 5.28, 5.29, 5.44, 5.62, 6.21, 8.3, 8.5, 8.9,
12.22, 16.8
Soft chopping 2.21, 2.23
Space harmonic 5.61, 6.16
Space-harmonic 2.13, 3.4. 4.27, 5.55. 5.61, 5.63, 5.65, 6.9, 6.18, 7.14, 12.24
Span 5.12, 5.14, 3.33, 3.35. 3.36. 3.39, 3.41-5.43, 3.45, 3.49, 3.51, 4.19, 5.3, 5.8, 5.20,
5.53, 6.3. 6.6, 6.16, 6.17, 6.20, 8.2
Specific heat 15.6, 15.10, 15.24
Speed 1.1, 1.2, 1.4, 1.9, 1.11-1.19, 1.21, 1.23, 1.25, 2.1, 2.3, 2.6, 2,10, 2.11, 2,13-2.15,
2.19, 2.34. 2.41-2.47, 5.2. 5.3, 3.6, 3.14, 3.18, 3.28, 5.29, 3.32-3.34,3.71,
4.1, 4.4, 4.18, 4.26, 4.28, 4.31-4.33, 5.39-5.42, 6.4, 6.10, 6.12, 6.23,
6.42-6.44, 6.46, 6.47, 7.S-7.5, 8.19, 9.9, 10.1, 10.2, 10.4, 10.9, 10.14,
10.18,10.25,10.27,10.28,10.30-10.35,11.1,11.2,11.5-11.7,11.9,11.10,
11.12,12.6,12.9,15.2,13.4,15.11,13.14,13.16,13.19,13.26,14.1,14.2,
14.5-14.14, 14.17-14.19, 14.31, 14.32, 14.34, 14.39, 14.46, 15.9. 15.23
Speed reference 2.43, 14.11-14.13
Speed/torque 1.2, 1.12-1.18, 3.71, 4.1, 4.4, 4.33, 5.39, 5.42, 6.4, 6.42, 6.44, 6.46, 7.3,
11.6, 11.7, 13.14, 14.12
see also Chapters 17 and 18
Spindle motor 2.1, 17.3
Spoke-iype motor 5.74, 5.75, 6.25-6.26, 6.28, 12.18, 12.19
Squarewave 1.2, 1.3,1.5. 1,10-1.12, 2.26-2.31, 2.35-2.37, 2.39, 2.40, 2.42, 2.43, 2.45-2.47,
3.5, 5.6, 5.18, 5.19, 5.39, 5.46, 5.47, 5.49-5.51, 5.71, 4.19, 5.1, 5.3, 5.5,
5.8, 5.14-5.16, 5.18, 5.19, 5.21-5.23, 5.25, 5.28, 5.33, 5.355.37, 5.41,
5.43,5.47, 5.62, 6.1, 6.4,6.12,6.35, 7.1, 7.2, 7.4,7.7,7.8,7.10-7.13, 7.16,
8.1, 10.1, 10.28, 11.4, 12.9, 12.10, 12.21, 12.24, 13.8, 15.13, 14.5
Squarewave drive 2.26-2.28, 2.35, 2.36, 2.40, 2.42, 2.43, 2.45, 2.46, 3.5, 5.6, 3.46, 5.47,
3.49, 3.50, 3.71, 7.16. 11.4, 13.8
Stability 2.42, 14.1, 14.12. 14.13, 14.15, 14.16, 14.20, 14.26, 14.31, 14.32, 14.38, 14.43,
14.46, 16.7
Stack 2.2, 2.5, 2.8, 2.12, 3.12, 3.24, 3.28-3.30, 3.32-5.35, 5.50, 5.70, 4.12,4.28, 4.32, 5.35,
7.11, 8.4, 8.7,12.2,13.2-15.4,13.9-13.11,13.13,15.22-13.25,15.4,15.5,
15.11
Stall torque 1.14, 3.76
Stamping 3.29, 4.2, 5.57, 13.25, 16.13, 16.15, 16.16
Star-delta switching 17.5
xxxiv
Index
State observer 14.46
State-space 10.10, 10.11. 10.18, 10.25, 14.45
Stator 1.1, 1.4,1.11,1.17,1.19, 1.20, 1.22, 2.1-2.3, 2.6, 2.8, 2.10-2.13, 2.46, 3.1, S.3, 3.4,
3.6, 3.8-3.10,3.14,3.20,3.21, 3.24. 3.26-3.29,3.31-3.36, 3.39, 3.40, 3.43,
3.70, 3.73, 4.1, 4.2, 4.12, 4.164.19, 4.26, 4.28, 4.30, 4.33, 5.2, 5.3, 5.5,
5.12, 5.14, 5.18, 5.20, 5.21, 5.24, 5.26, 5.31, 5.35, 5.36, 5.38, 5.44-5.46,
5.51,5.53-5.55,5.60-5.63,5.65,6.1,6.3, 6.11, 6.12, 6.29,6.31,6.35,6.37,
6.39, 7.11, 7.13, 7.14,8.M.6, 8.9-8.11, 9.1, 9.2, 9.5, 9.6,11.1, 11.2,11.4,
11.7, 11.9, 12.3-12.6, 12.15-12.17, 12.21, 12.26, 13.1-13.4, 13.&-13.8,
13.15, 13.16, 13.18, 13.19, 13.22, 13.23, 13.25, 15.4, 15.5, 15.9, 15.11
15.23, 16.10, 16.13, 16.16
Steady-state error 14.1, 14.21, 14.22, 14.25, 14.26, 14.31, 14.32, 14.39, 14.41, 14.43
Steel 1.4, 1.22, 2.2, 2.3, 2.6, 2.8, 2.10, 2.11, 2.13, 3.17, 3.21, 3.25, 3.33, 3,73, 4.1, 4.2,
4.12, 4.16-4.18, 4.31, 4.32, 5.44, 5.55, 5.60-5.62, 9.1, 11.12, 12.3, 12.4,
12.15,12.17, 13.6, 13.14, 13.15, 13.21, 13.23, 15.5, 15.13, 15.14. 15.23,
16.1, 16.9-16.11, 16.13-16.16
Stepper 1.1, 1.2, 1,19
Stepping motor 1.1
Summing junction 14.11, 14,34, 14.41
Surfece-magnet rotor 2.5, 3.7, 3;21, 3.23-3.25,4.2, 4.11,4.13,4.14,4.18, 4.28,5.44, 5.52,
5.55, 6.4, 6.26, 6.35, 6.39, 6.42, 6.43, 6.46, 8.5, 8.10, 8.12, 11.4
Switchmode 2.15, 2.23, 2.41
Synchronous 1.1, 1.2, 2.2, 2.3, 2.6, 2.15, 2.20, 2.46, 3.6, 5.14, 5.18, 5.66, 6.2, 6.3, 6.9.
6.10, 6.12, 6.23, 6.24, 6.32, 6.35, 6.36, 6.40-6.43, 6.46, 6.47, 7.8, 7.9,
11.2, 11.4, 11.5, 11.9, 12.20, 12.24, 12.28
Synchronous reactance 3.6, 6.3, 6.12, 6.23, 6.24, 6.32, 6.36, 6.41, 6.42, 6.46, 6.47,11.4,
11.5, 12.24
Synchronous reluctance 2.3, 17.26
System identification 14.16
Teeth 1.1, 2.6, 2.12, 2.13, 3.16, 3.24, 3.29, 3.33, 3.34, 4.2, 4.17, 4.27, 4.28, 5.36, 5.38,
5.55, 5.61, 6.29, 8.9, 8.10, 8.14, 8.16, 8.18, 9.2, 9.3, 9.6, 9.8, 12.3, 12.4,
12.21, 12.26, 12.27, 13.2. 13.12, 13.18, 13.22, 13.23. 16.15
TEFC 15.13
TENV 15.12, 15.13
Test facilities 11.12
Thermal capacity 11.8, 15.15
Thermal conductivity 15.3-15.6, 15.10, 15.11, 15,23, 15.24
Thermal resistance 4.2, 11.2, 11.7, 11.8, 13.14, 15.4, 15.5, 15.12, 15.15, 15.23
Thermal time constant 11.1, 15.22
Thermistor 11.7
Thermocouple 15.24
Three-phase 1.10,1.22-1;23.2.2,2.16, 2.27-2.31,2.35-2.39, 2.44, 2.45, 2.47, 3.4, 3.5, 3.26,
3.27,3.35,3.41, 3.44, 3.46-3.48,3.50, 3.71, 5.1, 5.3,5.5, 5.14, 5.18, 5.20-
5.21, 5.32, 5.33, 5.43, 5.44, 5.58, 6.11, 6.13, 6.16, 6.47, 7.1, 7.4, 7.8, 7,9,
7.11, 7.15, 10.28, 11.4, 11.5, 12.10, 13.2, 13.6, 15.14
Throw 3.31, 5.3
see pitch, span
XXXV
TIG 3.29
Time constant 3.51, 3.71, 11.1, 11.4, 14.6, 14.9, 14.19, 14.21, 15.15-15.16, 15.19-15.20,
15.22
Time-ratio control 2.15
Tolerance 10.14, 10.23, 13.6, 13.9, 13.22, 14.29, 16.10
Tooth 1.1, 2.3, 3.33-3.S5, 4.27,4.28, 5.5, 5.57, 5.58, 6.21, 8.3, 8.7, 8.93.19, 9.3, 9.5-98.
10.28, 12.5, 12.12, 12.16, 12.23, 12.26, 13.3, 13.7, 13.18, 13.22, 13.23
Tooth span 3.33
Tooth rips 4.28, 13.7
Tooth width 8.11, 12.5, 12,16, 13.3, 13.22
Torque 1.1, 1.2, 1.8, 1.9, 1.11-1.19, 2.1-2.S, 2.11, 2.13-2.15, 2.30, 2.38, 2.43-2.47, 2.49.
3.2-3 6, 3.8, 3.10, 3.13, 3.17-3.20,3.26, 3.34, 3.36, 3.46, 3.47, 3.50, 3.51,
5.71, 3.74, 3.76, 4.1, 4.4, 4.9, 4.264.28, 4.33, 5.5, 5.8, 5.9, 5.12,
5.17-5.21.5.24-5.26,5.29-5.33,5.36-5.39,5.41,5.42,5.57,5.62,5.63, 6.1,
6.3, 6.4, 6.8, 6.10-6.12, 6.22, 6.36, 6.38, 6.39, 6.42-6.44, 6.46, 6.47, 7.1,
7.3, 7.4, 7.6, 7.7, 7.12, 7.14-7.16, 8.1. 8.10, 8.19, 10.2, 10.22, 10.24,
10.28, 10.3010.35, 11.1, 11.2, 11.5-11.12. 12.2-12.4, 12.12, 12.14,
12.19-12.21, 12.28, 13.1. 13.2. 13.7, 13.11, 13.13, 13.14, 13.16, 13.18,
13.19, 13.22, 13.26, 14.1, 14.5. 14.7-14.10, 14.12, 14.14, 14.18, 14.31,
14.41, 15.1, 15.9, 15.17, 15.18, 16.7
linearity 11.2
Torque constant 1.2, 1.13, 1.17, 3.19, 3.51, 4.9, 5.12, 5.36, 5.38, 5.39, 5.42, 6.42, 7.1,
7.3, 7.4, 7.6, 7.7, 7.12, 7.14, 13.11, 14.5
see krpkg
Torque linearity 3.74, 5.38, 11.2, 11.8-11.10
Torque per unit volume 16.7
Torque ripple 1.19, 2.13, 2.46, 2.47, 2.49,3.5, 3.6, 3.19, 3.50,4.264.28, 4.33. 5.19, 5.20.
5.25, 5.26, 5.29, 5.30, 5.62, 5.63, 11.2, 11.10. 11.11, 14.1
Torque/speed
see speed/torque
Torsional 14.9
Toraional resonance 14.9
Torsional stiffness 14.9
Traction 1.12
Transducer 1.10,1.19,1.22-1.25, 2.22,11.6,11.9-11.11,14.13,14.14, 14.18,14.32,14.34
Transfer function 14.5, 14.6, 14.8, 14.12, 14.16, 14.19-14.22, 14.24-14.26, 14.28, 14.29,
14.36, 14.40, 14.43
Transformer 3.15, 8.4, 16.16
Transformer EMF 3.15, 8.4
Transient heating 15.20
Transistor 1.10, 2.16,2.18-2,24, 2.26, 2.27, 2.30, 2.32-2.38, 2.43,2.47,5.5,5.18, 7.2,10.7,
10.9, 10.10, 10.12-10.14. 10.18, 10.22-10.24, 10.26-10.28, 10.30, 13,13
TRV 12.2-12.5
Tuning 14.1, 14.31-14.33, 14.43
Turns 1.7,2.23,2.32, 2.33,3.1, 3.4, 3.10, 3.12,3.15,3.18-3.20, 3.23,3.26, 3.27,3.31-3.33,
3.35, 3.36, 3.38, 3.43, 3.45, 3.47, 3.48, 3.51, 3.70, 3.71, 4.1, 4.194.22,
5.1, 5.3, 5,6, 5.8, 5.9, 5.21, 5.30, 5.35, 5.38, 5.39, 5.42, 5.44, 5.46, 5.47,
5.49-5.51, 5.59, 5.63, 6.4, 6.0.8, 6.13, 6.14, 6.17, 6.206.23, 6.25, 6.27,
6.28, 7.11, 7.14, 8.4, 8.10, 8.17, 10.9, 10.14, 10.18, 10.22, 10.24, 11.2,
xxxvi
I n d ex
11.7,12.3,12.7,13.2,13.6,13.7,13.11,13.12,13.15,13.16,13.22,13.25.
13.26, 16.8
Turns in series per phase 3.27, 4.21, 5.35, 5.S8, 5.39, 5.46, 6.7, 6,13, 6.14, 6.27. 6.28.
7.11, 12.3
Turns per coil 3.23, 3.70, 5.21, 5.59, 13.2, 13.11, 13.25, 13.26
Two-axis theory 2.46, 6.9
Two-phase 1.19, 2.17, 2.26, 2.27, 3.4, 3.27, 4.19,5.32, 5.33, 5.43, 6.31, 6.32, 7.1, 7.7-7.9,
7.13, 12.22, 13.14
Two-phase-on 4.19, 12.22, 13.14
Type 0 14.22, 14.31
Type 1 14.22
Unipolar 2.47, 3.5, 3.27, 5.32, 10.1, 10.4, 10.23-10.26
Vamish 3.32, 3.29, 3.32, 3.33, 3.35, 3.70, 12.5, 15.24
Vector 1.12, 2.46, 2.47, 2.49, 5.37, 5.43, 5.59, 5.60, 5.66, 6.1, 6.2, 6.11, 6.12, 6.18, 6.19.
12.13, 12.14, 12.19, 12.28, 14.34, 14.45, 15.9
Vector control 1.12, 2.46, 2.47, 2.49, 6.2, 6.11, 14.34
Vector potential 5.43, 5.60, 5.66, 12.13, 12.14, 12.19
Vector rotator 2.46
Velocity 1.9, 1.11, 1.15, 1.19, 1.23, 2.11, 2.47, S.2, 4.30, 5.36, 6.9, 6.11, 6.23, 7.3, 7.4,
7.11, 8.5, 8.11, 11.9, 14.1, 14.5, 14,7, 14.10, 14.13-14.15, 14.18, 14.28,
14.29, 14.32, 14.45, 15.6, 15,7
Voice coil actuator 13.16
Voltage 1.14-1.16, 1.18, 1.25, 2.15-2.18, 2.20, 2.21, 2.23-2.25, 2.30-2.35, 2.38-2.41,
2.43-2.45, 2.47, 3.2, 3.4, 3.14-3.17, 3.20, 3.25, 3.31, 3.32, 3.71, 4.1, 4.3,
4.4,4.18, 5.14, 5.17, 5.32, 5.39-5.41,6.1,6.12, 6.13,6.23,6.3(V6.32, 6.35,
6.36, 6.38,6.40-6.47, 7.S-7.7, 7.10,9.1,9.2,10.1, 10.4.10.8-10.12,10.14,
10.16,10.18,10.19,10.22,10.25-10.33,11.1,11.2,11.5-11.7,11.9-11.14,
13.11, 13.13, 13.15, 13.19, 14.2, 14.5-14.8, 14.10, 14.11, 14.17, 14.35,
15.10, 15.24. 16.10
constant 11.1
Voltage PWM 2.21. 2.30, 10.10
Volls 2.18, 2.20, 2.39, 3.18, 3.19, 5.36, 7.1, 7.4, 7.1], 14.35
Washing machine 2.45
Water brake 11.6
Wattmeter 11.14
Waveform 1.7,1.9,1.11,1.18, 1.21, 2.15, 2.23, 2.33-2.35, 2.38, 2.43, 3.6, 3.19, 3.45-3.47,
3.49, S.50, S.74, 4.28, 4.30, 5.3-5.5, 5.8, 5.9. 5.13, 5.14, 5.17-5.20, 5.26,
5.30, 5.32, 5.40, 5.41, 5.65, 7.2, 7.4-7.7, 7.12, 7.15, 7.16,8.1^8 5,8.8-8.10,
8.12-8.19, 9.2, 9.3, 9.5-9 9, 10.1, 10.2, 10.4. 10 28-10.33, 11.5, 11.14,
12.9, 12.14, 12,27, 13.11, 14.2
Wind-up 14.31, 14.32, 14.41
Winder 13.18
Winding 1.1. 1.4, 1.14, 1.16, 1.17, 2.1, 2.6, 2.8, 2.10, 2.12, 2.13, 2.15, 2.27, 2.43, 2.45,
3.1-S.3, 3.5, 5.10, 5.12, 3.14-3.16, 5.18-5.20, 3.24, 3.26, S.28-S.32,
3.34-3.36,3.39-3.51,3.70,3.71,3.734.1-4.2,4.7-4.8,4.10,4.12,4.1&4.21,
4.26.4.32.5.1-5.3,5.5, 5.6,5.9-5.14,5.17-5.21, 5.24-5.26,5.28-5.32,5.35,
5.38, 5.39, 5.41-5.44, 5.47-5.51, 5.54.5.57-5.66,6.1-6.13,6.14, 6.16-6.23,
xxxvii
6.25, 6.27, 6.28, 6.47, 7.5, 7.11-7.16,8.3.8.9, 8.11), 8.17,11.4,11.7,11.8.
12.5. 12.7-12.11, 12.18, 12.19-12.21, 12.23-12.24, 13.2, 13.4, 13.6-13.8,
13.11-13.13, 13.18. 13.22, 13.23, 13.25, 13.26, 15.1-15.2, 15.5, 15.9,
15.11, 15.12. 15.14, 15.15, 15.17, 15.24, 16.7, 16.17
delta 5.21
fly 5.21
integral slot 3,12, 3.34
single needle 5.21
Winding factor 3.34, 5.28-5.30, 5.49, 6.17, 6.19, 6.21, 6.22, 7.12, 7.13
Winding pitch 3.12, 3,14, 3.35, 5.14, 5.58, 13.6-13.8
Winding techniques 2.12, 5.29
Wire 2.30, 2.38,3.1,3.28, 3.30-3.33,3.70,5.11, 5.21, 5.31,11.14,12.6,12.7,13.12.13.13,
13.16, 13.18, 13.25, 13.26, 15.8, 15.12, 16.1, 16.16, 16.17
Wire diameter 3.70, 13.12, 13.13, 13.26
Wire size 3.1, 3.70, 12.7
Wire-EDM 3.28
Word 14.34, 14.35
Work hardening 16.15
Work-hardening 16,15
Wyc-della switching
see star-delta switching
Yoke 2.2, 2.3, 2.6, 2.11, 2.13, 3.6, 3.25, 3.34, 4.2, 4.16, 4.17, 5.31, 5.61, 5.62, 8.10, 8.16,
8.18, 8.19, 9.2,9.3,9.5-9.7,12.4.12.12,12.23.12.26,13.2,13.3,13.9,13.20,13.21.13.23,
15.24
Z-transform 14.1, 14.38
Zero-order hold 14.35, 14.36
Zero^olt loop 2-21, 2.23, 2.33
ZOH 14.85
xxxviii