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K̂ξ
overall torque. Thus, after some manipulations, the torque can × ⎣ρν1 sin λξ sin(ξpϑb1 )
be rewritten as ξ
ξ
⎤
2π K̂ξ
μ0 D2 Lstk
τm = Ur (ϑr )Ks (ϑr ) dϑr . (9) + ρν2 × sin λξ [sin(ξpϑb2 ) − sin(ξpϑb1 )] ⎦
g 4 ξ
0 ξ
(13)
Since Ur (ϑr ) is a function of Ks (ϑr ), as discussed above,
it can be inferred that the motor torque exhibits an average where λν and λξ are given by (10) and
term, due to the fundamental harmonic of the electrical loading,
together with oscillating terms, due to the interaction between D3 Lstk 1
kτ = μ0 . (14)
the harmonics of the electrical loading of different orders. This g p2
will be clarified in the next section. Observing from (10) that λν and λξ depend on the harmonic
order (ν and ξ, respectively) and on the rotor position ϑm , it
III. R OTOR W ITH T WO F LUX B ARRIERS PER P OLE can be verified that the torque (13) is given by the sum of an
Let us consider the case of a rotor with two flux barriers average component (according to ν = ξ = 1) and other oscillat-
per pole, spanning angles 2ϑb1 and 2ϑb2 , as shown in Fig. 2. ing components (for any combination of ν and ξ different from
Letting the previous case). These latter components can be reduced by
means of a suitable design of the flux-barrier ends (i.e., of the
νπ
λν = + (ν − 1)pϑm − αie (10) angles ϑb1 and ϑb2 ).
2
the values of Ur (ϑr ) of the two rotor magnetic “islands” A. FE Comparison
become
With the aim of validating the analytical computation, a FE
K̂ν analysis is carried out, referring to the same geometry. The
Ur1 = −D ρν1 cos(λν ) (11) curve of the torque versus rotor position predicted analytically
ν
(νp)2
is compared with the same curve computed by means of FE
K̂ν
Ur2 = − D ρν2 cos(λν ) (12) method [13]. Two comparisons between the analytical and FE
ν
(νp)2 results are reported in Figs. 4 and 5.
924 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 45, NO. 3, MAY/JUNE 2009
Fig. 11. Photos of the “R and J” laminations. (a) R-type. (b) J-type.
Fig. 14. Insertion of the assisting PMs in the flux barriers of the “Machaon”
rotor.
C. IPM Rotor
In order to compare the performance of the “R and J” and
“Machaon” motors with the classical interior PM (IPM) motor,
Fig. 12. Photos of the “Machaon” lamination. (a) Actual waveform. a further rotor has been designed and built. For the sake of
(b) Average and fundamental waveforms.
comparison, the IPM rotor has two flux barriers per pole as
well. It is labeled IPM2B and is shown in Fig. 1(b). The flux-
barrier ends are uniformly distributed along the air gap, i.e.,
they are the same under each pole. Their position was obtained
by means of an optimization procedure so as to minimize the
torque ripple.
In addition, a two-step skewing has been adopted to cancel a
higher order torque harmonic.
D. Motor Tests
Fig. 15 shows the measured torque behaviors of the IPM2B,
“R and J,” and “Machaon” motors, referred to the nominal cur-
rent Iˆ = 2.64 A (peak value). The same scale of 0.1 N · m/div
is used, so that one can easily observe the effective reduction
of the torque ripple achieved by the proposed solutions. The
torque ripple of the “R and J” and “Machaon” motors is
about one third of the torque ripple of the classical IPM2B
motor.
Fig. 16 shows the measured torque behaviors referred to a
Fig. 13. Air-gap flux density distribution. current of Iˆ = 5.30 A (peak value). As mentioned earlier, both
innovative motor configurations exhibit a lower torque ripple.
In this case, the torque ripple becomes almost a half of that of
B. “Machaon” Rotor
the IPM2B motor.
The “Machaon” rotor is formed by laminations that are Table I reports a numerical comparison between average
chemically eroded, shown in Fig. 12. Small PMs have been torque (Tavg ) and torque ripple (ΔT ), at various currents. It
again added in the center of the flux barrier. The PM width is worth noticing that the proposed solutions yield always an
and thickness are the same of those used in the “R and J” appreciable reduction of the torque ripple. A reduction of the
rotor. Fig. 13 shows the air-gap flux density distribu- average torque of about 8% is not negligible in the “R and J”
tion and the average value, together with the fundamental motor. On the contrary, the average torque appears slightly
waveform. higher in the “Machaon” motor.
BIANCHI et al.: ROTOR FLUX-BARRIER DESIGN FOR TORQUE RIPPLE REDUCTION IN MOTORS 927
TABLE I
TORQUE COMPARISON AT DIFFERENT CURRENTS AMONG IPM2B,
R AND J, AND “MACHAON” MOTORS
TABLE II
TORQUE HARMONIC COMPARISON
E. Torque Harmonics
Table II shows the torque harmonics computed from the
Fig. 15. Measured torque comparison (current amplitude Iˆ = 2.64 A).
(a) IPM2B motor. (b) “R and J” motor. (c) “Machaon” motor. torque behaviors of Fig. 15 (Iˆ = 2.64 A). In the same table,
the measured torque harmonics are compared with the torque
harmonics predicted by means of simulations. The good agree-
ment between the measures and the predictions highlights again
the effectiveness of the models used in the study.
From Table II, it is interesting to observe that higher torque
harmonics are achieved, corresponding to the slot harmonics
(i.e., of 12th and 24th orders). In addition, Table II shows
that the main reduction of the torque ripple is achieved in
the torque harmonic of 12th order: It decreases from 5.36%
in IPM2B motor to 1.35% in “R and J” motor and to 1.61%
in “Machaon” motor. Other significative reductions are of the
torque harmonics of 24th and 36th orders.
VIII. C ONCLUSION
An analytical model has been developed to study the depen-
dence of the torque harmonics on the rotor geometry. It is the
key tool in selecting the combinations of flux-barrier shapes,
yielding a significative torque harmonic reduction.
An effective torque ripple reduction is achieved by designing
flux barriers of different geometries, both adopting different
laminations forming the same rotor and a single lamination with
flux barriers of different geometries.
The results can be applied to synchronous reluctance
machines, as well as to PM-assisted reluctance machines
(as realized by the authors).
Fig. 16. Measured torque comparison (current amplitude Iˆ = 5.30 A).
(a) IPM2B motor. (b) “R and J” motor. (c) “Machaon” motor.
Two motor prototypes have been manufactured and tested.
The experimental results come up to the theoretical expecta-
The reason of the average torque decrease can be imputed tions: adopting the proposed solutions yields a sensible reduc-
to the higher saturation of the central rotor path of the J-type tion of the torque ripple. At nominal current, the torque ripple
lamination (see Fig. 9) and to the leakage flux among the rotor becomes about one-third of that exhibited by the classical rotor
islands of two different laminations. design.
928 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 45, NO. 3, MAY/JUNE 2009
R EFERENCES
[1] A. Fratta, A. Vagati, and F. Villata, “Permanent magnet assisted synchro- Silverio Bolognani (M’98) received the Laurea de-
nous reluctance drive for constant-power application: Drive power limit,” gree in electrical engineering from the University of
in Proc. Intell. Motion Eur. Conf. (PCIM), Nürnberg, Germany, Apr. 1992, Padova, Padova, Italy, in 1976.
pp. 196–203. In 1976, he joined the Department of Electrical
[2] N. Bianchi, M. Dai Pré, and S. Bolognani, “Design of a fault-tolerant IPM Engineering, University of Padova, where he is cur-
motor for electric power steering,” IEEE Trans. Veh. Technol., vol. 55, rently a Full Professor of electrical drives and is en-
no. 4, pp. 1102–1111, Jul. 2006. gaged in research on advanced control techniques for
[3] B. A. Welchko, T. M. Jahns, W. L. Soong, and J. M. Nagashima, “IPM motor drives and on the design of ac electrical motors
synchronous machine drive response to symmetrical and asymmetrical for variable-speed applications. He is the author of
short circuit faults,” IEEE Trans. Energy Convers., vol. 18, no. 2, pp. 291– more than 100 papers on electrical machines and
298, Jun. 2003. drives.
[4] A. Fratta, G. P. Troglia, A. Vagati, and F. Villata, “Evaluation of torque Prof. Bolognani is the President of the IEEE Industry Applications
ripple in high performance synchronous reluctance machines,” in Conf. Society–Industrial Electronics Society–Power Electronics Society North Italy
Rec. IEEE IAS Annu. Meeting, Toronto, ON, Canada, Oct. 1993, vol. I, Joint Chapter.
pp. 163–170.
[5] A. Vagati, M. Pastorelli, G. Franceschini, and S. C. Petrache, “Design
of low-torque-ripple synchronous reluctance motors,” IEEE Trans. Ind.
Appl., vol. 34, no. 4, pp. 758–765, Jul./Aug. 1998. Diego Bon was born in Vicenza, Italy, in 1977. He
[6] T. M. Jahns and W. L. Soong, “Pulsating torque minimization techniques received the Laurea degree in electrical engineering
for permanent magnet ac motor drives—A review,” IEEE Trans. Ind. from the Department of Electrical Engineering, Uni-
Electron., vol. 43, no. 2, pp. 321–330, Apr. 1996. versity of Padova, Padova, Italy, in 2002, where he is
[7] S. Y. Jung and H. K. Jung, “Reduction of force ripples in permanent currently working toward the Ph.D. degree.
magnet linear synchronous motor,” in Proc. ICEM, Brugges, Belgium, He is involved in the design of low-cost electric
Aug. 2002. CD-ROM. drives for the rural community.
[8] N. Bianchi and S. Bolognani, “Reducing torque ripple in PM synchronous
motors by pole-shifting,” in Proc. ICEM, Helsinki, Finland, Aug. 2000,
pp. 1222–1226.
[9] M. Sanada, K. Hiramoto, S. Morimoto, and Y. Takeda, “Torque ripple
improvement for synchronous reluctance motor using asymmetric flux
barrier arrangement,” in Proc. IEEE Ind. Appl. Soc. Annu. Meeting,
Oct. 12–16, 2003, pp. 250–255.
[10] T. Li and G. Slemon, “Reduction of cogging torque in permanent magnet Michele Dai Pré (S’06) was born in Verona, Italy,
motors,” IEEE Trans. Magn., vol. 24, no. 6, pp. 2901–2903, Nov. 1988. in 1979. He received the Laurea degree in electrical
[11] N. Bianchi, “Analysis of the IPM motor—Part I. Analytical approach in engineering from the University of Padova, Padova,
design, analysis, and control of interior PM synchronous machines,” in Italy, in 2004, where he is currently working toward
Conf. Rec. IEEE IAS Annu. Meeting, N. Bianchi and T. M. Jahns, Eds. the Ph.D. degree in the Department of Electrical
Seattle, WA, Oct. 3, 2005, pp. 3.1–3.33. IEEE IAS Tutorial Course Notes, Engineering and is involved in the design of innov-
CLEUP (info@cleup.it). ative electrical motors for automotive and aerospace
[12] M. Liwschitz-Garik and C. C. Whipple, Electric Machinery, vol. II. applications, with special attention to fault-tolerant
New York: Van Nostrand, 1960. configurations.
[13] N. Bianchi, Electrical Machine Analysis Using Finite Elements, In 2004, he received a bursary scheme at the Lab-
ser. Power Electronics and Applications Series. Boca Raton, FL: CRC oratory of Electric Drives, Department of Electrical
Press, 2005. Engineering, University of Padova.