Permanent Magnet

Synchronous Motor (PMSM)

Introduction

Permanent Magnet (PM) Motor

Characterized by permanent
magnets on rotor
Known for its simplicity and
low maintenance
No copper loss on rotor
High efficiency

Exploded View of a PM Motor

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

2nd Edition, p. 44, Motor Design Books LLC, 2010.

Inner Rotor Possibilities (1)

surface radial
magnet

surface parallel
magnet

breadloaf
magnet

ring
magnet

Inner Rotor Possibilities (2)

Toyota Prius

MS-TECH Japan

(e) IPM rotor with 2 magnets/pole in a

V-shaped flux concentrating arrangement

Rotor Flux Distribution of IPMs

Toyota Prius Hybrid Electric Vehicle (HEV)

3

1.
2.
3.
4.

Four cylinder combustion engine;

Generator/starter;
Electric Motor;
Power split device (PSD)

J. F. Gieras, Permanent Magnet Motor Technology Design and Applications, 3rd Edition, p. 282, CRC
Press, 2010.

2
J. R. Hendershot and T. J. E. Miller,
Design of Brushless Permanent Magnet
Machines 2nd Edition, p. 34, Motor
Design Books LLC, 2010.

Segmented Magnets in Large PM Rotor

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

2nd Edition, p. 94 & 602, Motor Design Books LLC, 2010.

Rotor Skew

stepped magnet

Magnetization Profile (1)

parallel magnetization

radial magnetization

most popular

radial sine magnetization

sine angle or sine direction

magnetization

Magnetization Profile (2)

Flux of a 8 pole machine at no load

radial magnetization

45

90 135

180

air gap flux density profile versus angle

Magnetization Profile (3)

Flux in 2 Pole Machine at no load

d
radial magnetization

parallel magnetization

Magnetization Profile (4)

PM embrace: emb

radial magnetization
Bg , rotor

PM

Bm

Bm

PM

PM

PM

electrical angle

PM
2
2

PM
2

de

PM

parallel magnetization
Bg , rotor

PM

Bm

PM

PM

PM
2
2

PM
2

de

Halbach Array (1)

R. Krishnan, Permanent Magnet Synchronous and Brushless DC Motor Drives, p. 25-30,

CRC press, 2010.

Halbach Array (2)

FEA

Halbach Array (3)

Airgap Flux Density

Rotor is outside

Permanent Magnet
Synchronous Motor (PMSM)
Design

Part 1 General Considerations

Stator Volume and Size

2

Dl
V0
T

Pout

Typically

V0 8 ~ 9 in / (ft lb) for 10hp or less (air cooled)

3

V0 4 ~ 5 in / (ft lb) for 10hp or more (water cooled)

3

The unit for D and L is inch.

If we design D=L, we have the stator bore (inner)
diameter estimated

Destimated (TV0 )

1
3

We can pick up D close to Destimated.

Stator Core Design

core gap , per half
l

/P

pole pitch

Bg ( a ) ris d a

D 2 /2
l Bg , pk cos( ae )d ae
2 P 0
D
lBg , pk
P

Bcore

core DBg , pk
=
d cl
Pd c

(1)

tooth l Bg ( ae ) rd
i ae Bg , pk s l
0

Btooth

Take

tooth s Bg , pk

ts l
ts

(2)

ts 0.5 s , Bcore 0.8Btooth

dc

D
1.6 P

Effect of Pole Number on Yoke Flux Density

Finite Element Analysis

with the same dc

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines
2nd Edition, p. 106, Motor Design Books LLC, 2010.

Number of Turns per Coil

V ,rated 2f e N a g , pk 4.44 f e N a g , pk
where

pk

2 Bg , pk Dl

P
N a kw N a / 1.1
k w k p kd k s

N a PqN c / C

Na is the number of series turns per phase of armature winding

C is the number of parallel circuits of armature winding

Nc

1.1V ,ratedC
2 2f e qk w Bg , pk Dl

Consider leakage flux

Stator Slot Design

General Consideration

s
ts

bs 0

d s 0d s1

ds

D
S

0.4 s ts 0.6 s
3ts d s 7ts
Define bs s ts

bs 0 (0.1 ~ 0.5)bs
d s 0 (0.1 ~ 0.5)bs
d s1 (0.1 ~ 0.5)bs

Stator Conductor Size

Stator current density

J s ,copper

I a ,rated / C
Sa

where Sa is stator (armature) conductor cross section

area and can be determined from the above formula
together with:
Air - cooled : 400A/cm2 J s ,copper 800 A/cm2

Sa

I a ,rated / C
J s ,copper

Permanent Magnets

Samarian Cobalt (SmCo)

Operating temperature of up to 350C

2nd strongest rare earth magnet

Neodymium Iron Boron (NdFeB)

Operating temperature of up to 150C

Strongest rare earth magnet

Permanent Magnet Properties

From Yeadon Handbook of Small Electric Motors

Rotor Peripheral Speed

The maximum allowable peripheral speed of the rotor is a central consideration in
machine design. With present-day steel alloys, rotor peripheral speeds of 50,000
ft/min (or about 250 m/s) represent the design limit.
1 ft/min = 0.0051 m/s

Motor Losses (1)

Copper loss

Typical

PCu I 2 R

Stray losses

Electrical phenomenon such as skin and proximity

effect

Motor Losses (2)

Core (Iron) Loss

Hysteresis loss
Eddy Current loss

PIron h B f
n

Mechanical loss

Windage loss
Friction loss

c ( Bf ) e ( Bf )
2

3/ 2

Finite Element Analysis

Fundamental harmonic

J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent Magnet Machines

2nd Edition, p. 174-175, Motor Design Books LLC, 2010.

Part 2 Surface Mount Round

Rotor Multi-Pole PM Motor
Design

Magnetic Circuit Analysis

For a multi-pole surface mount rotor

dm

Da

Poles

2 H g g 2 H m d m 0 gBg 0 H m d m 0

m Bm Am
g Bg Ag

dm
Bm kl Am

g
0 H m Ag

g kl m

kl : Leakage Coefficient

Working Point for Permanent Magnetics (1)

Maximum Energy Point

Br
BmR

0 H c

0 H mR

Br
B
(H Hc )
Hc

To get (BH) max

0 H

Br
BH
(H H c )H
Hc

( BH )
Br
Hc

0 Bm
, Hm
H
2
2

Working Point for Permanent Magnetics (2)

rm

Br
0 H c

1 rm 1.2

Load Line:

Bm

d m Ag
0 H m
g kl Am

Pc 0 H m

Define: Bm m Br

Pc is called permeance coefficient

Ag / g
Bm
d m Ag
Rm Pg
Pc

0 H m
g kl Am kl Am / d m Rg Pm

H m (1 m ) H c

Typically pick up: m 0.6

0.9

Pc

Bm
m

0 H m 1 m rm

Airgap Magnetic Field from PM Rotor

PM embrace: emb

Bg , rotor

PM

Bm

Bm

PM

PM

Bg , rotor
BRh

h 1,3,5...

PM PM

2
2

2 PM
2

BRh

PM

electrical angle

de

de

P
d
2

P
Brh cos( h de ) Brh cos( h d )
2

PM /2
2 PM /2
B
cos(
h

)
d

( Bm ) cos( h ae )d ae
m
ae
ae

PM /2
2 PM /2

pitch factor for
sin h PM
4
th harmonic
2 B
h

h

k ph sin h PM
2

Brh

the

Phasor Diagram

B net
jX S I A

BS

BR

EA

Typically, design cos 1 at full-load for PMSM.

Need to specify torque angle, if sin 1/3 ( =19.47 ),
Tfull-load (1 / 3)Tpull out .
Bg , pk cos Br , pk 0.94 Br , pk
Ba , pk sin Br , pk 0.33Br , pk

Br , pk

4 PM
sin
2

Bm

Air Gap Size and PM Thickness

From:
Ba , pk

4 0 N a

1.5 2 I A,rated
g total P

Initial total effective air gap size:

g total

From:

g total k c g 'total

4 0 N a

1.5 2 I A,rated
Ba , pk P

g 'total g d m / rm

dm
k A
Pc l m
g
Ag
Pc

Carters coefficient
can obtain g and d m

rmg

m
rm
1 m

Effective Air Gap

g total kc g 'total
where the Carters coefficient
kc

s
2
bs 0
2bs 0
bs 0
g 'total

ln 1

atan


2 g 'total
bs 0
2
g
'

total

approximately
kc

s
bs20
s
5 g 'total bs 0

ts

g total

bs 0

d s 0d s1

ds

Rotor Sizing
Total rotor diameter, including magnet

Rotor inner diameter

Di Dr 2d m

Dr D 2 g

Part 3 Two Pole Super High

Speed PM Motor with Magnet
Inserted in Rotor Shaft

Prototype

Rotor is assembled by
heating and cooling.
Rotor is welded and
well balanced after
assembly.

Air Gap Size

For a 2-pole PM rotor

2 g eff H g H m Dr 0
( Ag Am )

2 g eff Bm 0 H m Dr 0

Dr

Dr / 2
Bm

Pc
g eff
0 H m

Carters coefficient

g eff
g eff

S
(

Dr D

2
2

1
1 Dr
D
1 Dr

)
kc
k c (1
)
Pc
rm 2
2
rm 2

Dr

Define: Bm m Br

Dr
Dr
kc ( g
)
2 rm
2 rm

kc

1
1 kc
kc

Pc
rm

H m (1 m ) H c

Typically pick up: m 0.6

0.9

Pc

D Dr
2

Bm
m

0 H m 1 m rm

Effective Air Gap

g total kc g 'total

g total g eff

Dr
,
2 rm

g 'total g

where the Carters coefficient

kc

s
2

2bs 0
bs 0
g 'total
bs 0

ln 1
atan


2 g 'total
bs 0

2 g 'total

approximately
kc

s
bs20
s
5 g 'total bs 0

ts

bs 0

s
g total

d s 0d s1

ds

Dr
2 rm

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