Torque Ripple Minimizing of Uniform Slot Machines with Delta Rotor via Subdomain Analysis

Since the slot opening is large in the uniform slot machine, the torque ripple generated by overlapping or misaligning with the rotor cavity is remarkably large in the case of interior permanent magnet (IPM) machine. In this work, it is observed that the magnitude of torque ripple depends strongly on the phase difference between air-gap field harmonics: The ripple is minimized when the two dominant harmonic components cancel each other. Based on this fact, a condition is developed to minimize torque ripple by adjusting the q-flux channel width and d-flux barrier width. The torque ripple minimizing solution is found from a level chart made by subdomain time-stepping analysis. Finite element analysis (FEA) also gives a very similar minimizing solution. A prototype machine is manufactured, and its performances are validated through experiments.

A Novel Interior Permanent Magnet Machine with Magnet Axis Shifted Effect for Electric Vehicle Applications

This paper proposes a novel interior permanent magnet (IPM) machine with asymmetrical PM configuration. Different from the traditional IPM counterparts, the proposed machine can perform a magnet axis shifted (MAS) effect. The magnet axis is shifted towards the reluctance axis so that a higher resultant torque capability can be obtained. Firstly, the configuration and the basic principle of the proposed machine are described. The design parameters are optimized to improve the torque capability, and the effect of the PM asymmetry ratio on the torque performance is then evaluated in detail. In addition, the major electromagnetic characteristics of the optimized machine are investigated and compared with those of the Prius 2010 IPM machine by finite element method (FEM). The results demonstrate that the proposed asymmetrical PM configuration can achieve the torque improvement due to the MAS effect.

Analysis and Experimental Verification of the Demagnetization Vulnerability in Various PM Synchronous Machine Configurations for an EV Application

Safety is a critical feature for all passenger vehicles, making fail–safe operation of the traction drive system highly important. Increasing demands for traction drives that can operate in challenging environments over wide constant power speed ranges expose permanent magnet (PM) machines to conditions that can cause irreversible demagnetization of rotor magnets. In this paper, a comprehensive analysis of the demagnetization vulnerability in PM machines for an electric vehicle (EV) application is presented. The first half of the paper presents rotor demagnetization characteristics of several different PM machines to investigate the impact of different design configurations on demagnetization and to identify promising machine geometries that have higher demagnetization resistance. Experimental verification results of rotor demagnetization in an interior PM (IPM) machine are presented in the latter half of the paper. The experimental tests were carried out on a specially designed locked-rotor test setup combined with closed-loop magnet temperature control. Experimental results confirm that both local and global demagnetization damage can be accurately predicted by time-stepped finite element (FE) analysis.

Analytical Design of Sculpted Rotor Interior Permanent Magnet Machines

A computationally efficient design of interior permanent magnet (IPM) motor rotor features is investigated utilizing analytical methods. Over the broad operating range of IPM machines, interactions of MMF sources, permeances, and currents result in torque harmonics. The placement of traditional rotor features along with sculpt features are utilized to minimize torque ripple and maximize average torque. We extend the winding function theory to include the IPM rotor’s primary and secondary reluctance paths and the non-homogeneous airgap of the rotor sculpt features. A new analytical winding function model of the single-V IPM machine is introduced, which considers the sculpted rotor and how this model can be used in the design approach of machines. Results are validated with finite elements. Rotor feature trends are established and utilized to increase design intuition and reduce dependency upon the lengthy design of experiment optimization processes.

Analysis of Torque Ripple of a Spoke-Type Interior Permanent Magnet Machine

This paper investigates the theoretical reasons behind the low torque ripple of a fractional-slot concentrated-winding (FSCW) spoke-type interior permanent-magnet (IPM) machine obtained via a genetic algorithm-based optimization. To better understand the torque performance of the IPMM, this paper uses the frozen permeability method to segregate the overall torque into four components—magnet torque, reluctance torque, cogging torque, and the torque caused by cross-magnetization. Equations and detailed procedures of the torque separation method are discussed in the paper. Analysis of the separated torque components reveals that the counteraction between ripples of different torques leads to the low torque ripple. At high-load conditions, the magnetic saturation alters the torque ripples caused by cross-magnetization to offset ripples of other components resulting in minimization of the overall torque ripple. A detailed parametric analysis of the geometric parameters was carried out to understand their effect in producing minimum torque ripple in the optimized design. In the end, a prototype was built and used for the verification of the torque separation method and the analytical findings based on it.