(112223881) 25 Permanent Magnet Motor Design

8/13/2019 (112223881) 25 Permanent Magnet Motor Design

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PermanentMagnetSynchronous Motor (PMSM) Design


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Part 1 General Considerations


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Permanent Magnet (PM) Motor

?

Characterized by permanentmagnets on rotor

?? Known for its simplicity and low maintenance

? No copper loss on rotor


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Permanent Magnet (PM) Motor

? High efficiency


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Exploded Vie o! 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.


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"nner #otor Possi$ilities ()

s!r"a#e radial$agnet s!r"a#e parallel


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"nner #otor Possi$ilities (%)

$agnet

&readloa" $agnet

ring $agnet


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'e( )*M in To+ota *ri!s


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%oyota Prius &y$rid Electric Vehicle (&EV)


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1. -o!r #+linder #o$&!stion engine

2. /eneratorstarter

. Ele#tri# Motor

4. *oer split dei#e '*3D(

J. -. /ieras, Permanent Magnet Motor Technology - Design and Applications,

3rdEdition, p. 22, CRC *ress, 2010.

2

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

Permanent Magnet Machines 2nd

Edition, p. 4, Motor

Design Books LLC, 2010.


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Segmented Magnets in 'arge PM #otor


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2ndEdition, p. 54 6 02, Motor Design Books LLC, 2010.


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#otor Se


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#otor Se

stepped $agnet


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Magnetiation Pro!ile

parallel $agneti7ation radial $agneti7ation

most popular

radial sine $agneti7ationsine angle or sine dire#tion $agneti7ation


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Magnetiation Pro!ile


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&al$ach *rray (1%)

R. 8rishnan, Permanent Magnet Synchronous and Brushless D Motor Dri!es,p. 29:0, CRC press, 2010.


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&al$ach *rray (1)


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&al$ach *rray (15)

-E;


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&al$ach *rray (20)

Airgap Flux Density

Rotor is outside


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Stator Volume and Sie

T+pi#all+

D

2l

T

?"0

T ?Pout?

m

"0

? < 5 in '"t ?l&( "or 10hp or less 'air #ooled(

"0?

4 < 9 in '"t ?l&( "or 10hp or $ore 'ater #ooled(

The !nit "orD and# is in#h.)" e designD$#, e hae the stator &ore 'inner(

dia$eter esti$atedD

estimated

?1

'T"0

(

=e #an pi#k !pD #lose toDestimated%


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Stator Core Design

?core

??gap,per half polepitch

?P?leff

?0

Bg

'?

a

(ris

d?

a

D? leff

2 ? 2

?Bg,p& #os'?ae (d?ae

2 P0

D? leffBg,p&P

?coreDBg ,p& leff '1(

Bcore ,p& ? ?d

c

&il

i

Pd

c

&i

li

?tooth ?leff

?

?Bg '?ae ( ri d ?

ae

?B g ,p& ?s leff

0

?tooth ?sB g ,p& leff


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Stator Core Design

'2(

Btooth ?

ts&

?i

li

ts& i

li

Take

ts

?0.9?s

, Bcore ,p&

?0.Btooth

?d c?

D1.P


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E!!ect o! Pole +um$er on ,oe -lux Density

-inite Ele$ent ;nal+sis


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ith the sa$e dc


2nd

Edition, p. 10, Motor Design Books LLC, 2010.


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+um$er o! %urns per Coil"

?,rated

? 2?fe

'>a

?

g ,p&

?4.44 fe

'>a

?g ,p&

here ?p& ?

2Bg,p&

Dl

P'>a

?&(

'a

1.1

&(

? &p

&d&

s

'a

? P)'c

'a

is the n!$&er o" series t!rns per phase o" ar$at!re inding

is the n!$&er o" parallel #ir#!its o" ar$at!re inding

' c ?

1.1"?,rated

Consider leakage "l!?


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2 2?fe

)&(

Bg ,p&

Dl


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Stator Slot Design

/eneral Consideration

ts *s0

ds

ds1 d

s0

?D?s

?S

0.4?s

?s

?ts

?0.?s

ts

?ds

?%ts

De"ine *s

??s

?ts

*

s0

ds0

ds1

?'0.1 < 0.9(*

s?'0.1 < 0.9(*

s

?'0.1 < 0.9(*s


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Stator Conductor Sie

3tator #!rrent densit+

+s,copper

?

,a,rated

Sa

here Sa

is stator 'ar$at!re( #ond!#tor #ross se#tion area and #an &e deter$ined "ro$ the a&oe

"or$!la together ith@

;ir : #ooled @400;#$

2 ?+s,copper

?00;#$

2

S ?

,a ,rated

a

+

s ,copper


30/55

Permanent Magnets

? amarian Cobalt !mCo"? #perating temperature of up to $%&'C

? (nd

strongest rare earth magnet

? Neodymium )ron *oron !NdFe*"

? #perating temperature of up to +%&'C

? trongest rare earth magnet


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Permanent Magnet Properties

-ro$ Aeadon Hand&ook o" 3$all Ele#tri# Motors


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#otor Peripheral Speed

The $a?i$!$ alloa&le peripheral speed o" the rotor is a #entral #onsideration in $a#hine design. =ith present:da+ steel allo+s, rotor

peripheral speeds o" 90,000 "t$in 'or a&o!t 290 $s( represent the design li$it.

1 "t$in 0.0091 $s


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Motor 'osses ()

? Copper loss? ,ypical

P

u

?2

? tray losses? -lectrical phenomenon such as s.in and proximity effect


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? Core !)ron" /oss? Hysteresis loss

? -ddy Current loss

n

? Pron

??hB f

??c

'Bf (2

??e

'Bf

( 2

? 0echanical loss? 1indage loss

? Friction loss


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-inite Element *nalysis

-!nda$ental har$oni#



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2nd

Edition, p. 1%4:1%9, Motor Design Books LLC, 2010.


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Part . Sur!ace Mount #ound#otor Multi/Pole PM MotorDesign


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Magnetic Circuit *nalysis

-or a $!lti:pole s!r"a#e $o!nt rotor

dm

Da

gD

2.gg

?2.m

dm

?0 ?gBg ??0.mdm ?0

*oles

Bm

Am

?Bg

Ag

?

dm

g??

Bm

Am

?

0

.m

Ag


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0oring Point !or Permanent Magnetics (5)

Ma?i$!$ Energ+ *ointBB

r

Bm-

??

0

.c

B r

?

0

.m-

B

?

0

.

B ? '. .c ?.

c( ?B.

?r

'. .c

?.c

(.

To get 'B H($a?

?

?'B. (?.

?0 ?Bm

? Br

,.2 m ??

.c

2


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?rm

?Br

?

0

.c

1 ??rm

?1.2

B ??dm Ag ?.Load Line@ ? 0 ?

Pc is #alled per$ean#e #oe""i#ientm


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m

g Am

??Pc ??0. m ? P ?

d

m

A

g ?

Ag

g

?

R

m ?

*

gc

g A A d R *m m m g m

De"ine@ Bm

??mBr .m ??'1??m (.c ?P ??

Bm ?

?m

?c r m

T+pi#all+ pi#k !p@?

m? 0.9D 0.5

?0

.m

1 ??m


42/55

*irgap Magnetic -ield !rom PM #otor

Bg , rotorB

m

???PM

???

PM

2

*M e$&ra#e@

??

?PM

2

?

PM

?

ele#tri#al angle

?Bm

?

?PM

2

?PM

2

?

2??

?PM

2?

2?

de

? ?

P

?Bg , rotor

?

?h?1,,9...

B-h

P

de

2d

B-h

?Brh

#os'h?de

( ? Brh

#os'h

?d (2

?B ? 2 ? ?PM 2B

PM

#os'h?(d?

???PM 2PM? '?B

(#os'h? (d? ?

rh2?

??? 2 m ae ae

???? 2 m ae ae

sin ?h ?PM ? pit#h "a#tor "or the? ?B

?

4 ? 2 ?

? hm

hth

har$oni#

& ?sin ?h ?PM ?


43/55

ph? 2 ?? ?


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Phasor Diagram

V

?

? ?/0S

IA

E

A

Bnet

B

S

B-

T+pi

#all+

,

desi

gn

#os?

D

?1

at

"!ll:

loa

d"or


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*M3M.sin?

?1'?

15.4% ( so that

T"!ll:load

?'1

(Tp!ll o!t?

Bg ,

p&

?#os

?

Br,

p&

?0.54Br,p&

Ba

,

p

&

?sin

?

Br,p&

?0.Br,p&

4 ??PM

?

Br,p& ??sin ?

2 ?Bm

? ?


46/55

*ir Gap Sie and PM %hicness

-ro$@ B ?

4 ?

0

'>

a 1.9 2,a,p&

?g

>

total

P A,rated

)nitial total e""e#tie air gap si7e@

g> ?

4 ?

0

'>

a 1.9 2,total A,rated

g> ?& g E

?Ba,p&

P

g ?g ?d ?d m ?P 'A ?A (-ro$@

totalc

total total m rmg

c g m

m

P ?

?m

?CarterFs #oe""i#ient

?g ?'1??

m

(g total

c

1 ??r m

dm

??mg E

total

?rm


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E!!ectie *ir Gapg>

total

here the CarterFs #oe""i#ient

?&

c

g

total

&c

?

?

?s

2

? ? ? ??

?s ?

2*s 0

?

atan

*s 0

?

g Eto ta l ln ?1 ? *s 0 ?

?? ? ?

? ?

?

?

2g Eto ta l

*s 0

?

2g Eto ta l

?

appro?i$atel+

*

? &c

?s

2

s 0

? ?stsd

*s0

sd

s1 ds0

9g total

? *s 0

?sg

total


48/55

#otor Siing

,otal rotor diameter2 including magnetD

r

?

D ?2g

Rotor inner diameter Di

?Dr

?2dm


49/55

Part 2 %o Pole Super &ighSpeed PM Motor ith Magnet"nserted in #otor Sha!t


50/55

Prototype


51/55

? Rotor is assembled by heating and cooling3

? Rotor is welded and well balanced after

assembly3


52/55

*ir Gap Sie

-or a 2:pole *M rotor 2g . ?

. D?0eff g m r

? 2geff

Bm

??0

.m

Dr

?0 'Ag

?Am

(

Dr3 G ?

Dr

2

? ?

Bm

?Pcg

eff

gef f

?0

.m

CarterFs #oe""i#ientg ?

Dr ?& 'g ?

Dr ( g ?

Dr

?D

eff

2 ?

c

2 ? 2 2rm rm

? '

1

?

1

(

Dr

? &

D

?&'1 ?

1

(

Dr

P ? 2

c

2

c

? 2c rm rm

?Dr

?

c

&

&c

D

?

1

?

1 ?&c

g ?D ?Dr

2

Pc

?r m

B ?

De"ine@ Bm ??mBr .m ??'1??m (.c ?P ??m

?m

?c r mT+pi#all+

pi#k

!p@?

m?


53/55

*ir Gap Sie

0.9D 0.

?0

.m

1 ??m


54/55


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Example /Speci!ications

Design a 2k=, 100krp$, Gd-eB: *M3M, 2 pole

ter$inal oltage, A #onne#ted, 50I e""i#ien#+.

(112223881) 25 Permanent Magnet Motor Design

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