IJAEA, Volume 1, Issue 5, pp.

57-63 (2008)

Thermal And Vibration Characterization Of High Speed Switched Reluctance

Motor With Soft Magnetic Composite Material
K. Vijayakumar1, R. Karthikeyan1 and R. Arumugam2
1

Research Scholar, Department Of Electrical Engineering, Anna University, Chennai, India

Research Scholar, Department Of Electrical Engineering, Anna University, Chennai, India
2
Retired Professor, Department Of Electrical Engineering, Anna University, Chennai, India
1

vijipreethi@rediffmail.com

Abstract
In aircraft electric motor driven fuel delivery system, the motor must be characterized by high power density, reliability,
less size, less weight and high speed. The high speed operation, fault tolerance, high power density makes switched
reluctance motor an ideal candidate for high speed aerospace applications. This paper investigates the application
potential of soft magnetic composite material (SOMALOY 500) in high-speed switched reluctance motor. Two
configurations viz (1) All sheet metal and (2) All Soft magnetic composite have been studied extensively using finite
element analysis to obtain their thermal and vibration characteristics with two different type of stators such as stator with
smooth and ribbed frame. The study reveals that the all soft magnetic composite configuration albeit suffers from poor
average torque posses better thermal capability, lesser vibration of stator that may result in low acoustic noise level a
desirable feature in high speed aerospace applications.

Keywords: Finite element analysis, Soft magnetic composite (SMC), Switched reluctance motor (SRM),
Thermal characterization, Mode shapes.
1.0 INTRODUCTION
The low cost, high speed, high power density, fault
tolerance and reliability of switched reluctance motor
make it a viable alternative in aircraft electric-motordriven fuel pump system [3]. Recently soft magnetic
composite materials find rampant application in
electrical machines [1]-[2] and these materials are
characterized
by
three
dimensional
isotropic
ferromagnetic behavior, very low eddy current loss,
flexible machine design and assembly and a prospect for
greatly reduced production cost. This paper investigates
the suitability of soft magnetic composite material in
switched reluctance motor designed for high-speed
aerospace application from a study of its thermal and
vibration behavior. Two configurations viz (i) All
laminated sheet steels (ii) All Soft Magnetic Composites
(SMC) have been extensively studied using finite
element analysis based software tool. The study
concludes that all SMC configuration albeit its poor
average torque in comparison with conventional motor,
promises to be suitable for high-speed aerospace
application with better thermal behavior and lesser
acoustic noise.
2.0 SWITCHED RELUCTANCE MOTOR
A switched reluctance motor is an electrical machine in
which the torque is developed by the tendency of the
rotor to occupy a position so as to minimize the

Fragrance

reluctance of the magnetic path of the excited stator

phase winding. The switched reluctance motor is a
doubly salient but singly excited machine wherein the
stator carries the winding while the rotor is simply made
of stacked silicon steel laminations. This lends to a
simpler geometry for switched reluctance motors as
evidenced from the two-dimensional Computer Aided
Design (CAD) model of a 6/4 switched reluctance motor
shown in Fig. 1.

Fig. 1: CAD Model of 6/4 (3phase) SRM

3.0 SOFT MAGNETIC COMPOSITE MATERIALS

IN ROTATING ELECTRICAL MACHINES
Electrical steel lamination is the most commonly used
core material in electrical machines. Electrical steels are
typically classified into grain-oriented electrical steels

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IJAEA, Volume 1, Issue 5, pp.57-63 (2008)

and non-oriented electrical steels. Typical applications

for grain-oriented steels are power transformer cores
whereas non-oriented steels are broadly used in different
kinds of rotating electrical machines. Electromechanical
steels currently used in the manufacture of electrical
machines posses high induction of magnetic saturation
(Bs~2T), low coercive force (Hc< 100A/m), and they are
characterized by low total losses [2] , [3]. Electrical sheet
steels have been the dominant choice for the soft iron
components in electrical machines subject to time
varying magnetic fields. The new soft iron powder
metallurgy materials can be considered as an alternative
for magnetic core of these electrical machines. The basis
for soft magnetic composites is bonded iron powder as
shown in Fig.2.

Fig. 2: Iron Powder Particle

The powder is coated, pressed into a solid material using

a die, and heat-treated to anneal and cure the bond. The
B-H characteristics of M19 silicon steel and SMC
material SOMALOY 500, shown in Fig. 3, reveals that
although the SMC has inferior relative permeability
when compared with lamination steel it still posses the
following desirable characteristics [4].

c.

Modular construction allows the possibility of easy

removal of an individual modular unit for quick
repair or replacement,
d. Stator is easily recyclable since the stator can again
be compressed back into powered form.

4.0 LOSS CALCULATION

In order to estimate the thermal behavior of the machine
accurately meticulous attention must be paid to the
calculation of the losses. The loss components of the
machine can be summarized as:

Ploss.m=Pcu+PFe+Pmech

(1)

where Pcu, PFe, Pmec are copper losses, core (iron) losses
and mechanical loss respectively.
4.1 Copper Losses
The first step in calculating the copper losses involves
the calculation of the resistance of each phase winding of
the SRM. The mean length of a winding turn is given as,
lm= {2L+4Wt + 2Dsin{s/2}}*10-3m
(2)
The resistance of a single phase is calculated as,
Rs = 0.0177* lmTph/ac ohm
(3)
The copper losses at rated current is given by
2
Pcu = i pRs W
(4)
4.2 Core Loss
In a high-speed motor, the core loss is much greater than
copper loss. Fig. 4 shows the core loss difference
between SMC and M19 material.

Fig . 4: Core loss Vs frequency plot of laminated steel and

SMC

Fig. 3: B-H Characteristics Of Laminated Steel And SMC

a.

b.

Reduced copper volume as a result of increased fill

factor and reduced end winding length and reduced
copper loss as a result of the reduced copper
volume,
Potential for reduced air gap length as a result of the
tight tolerances maintained in manufacturing SMC
material,

Fragrance

The core loss can be calculated by

h
Pfe=
Kha
fBmaj
+Kea
(fBmaj) 2+Kaa
1.5
h
(fBmaj) +KhafBmin +Kea(fBmin)2+Kaa(fBmin)1.5
(5)
where Kha, h, Kea and Kaa are coefficients deduced
from the data provided by the manufacturer, or measured
by the standard alternating tester, Bmaj and Bmin are the
major and minor axes of the elliptical B locus during
360electrical degrees, and f is the frequency. The core
loss is computed based on nonlinear time-stepping FEA.
One electrical period is divided into 8 steps. The
meshing of stator and rotor is kept the same in each step.
Core loss in each element is calculated, and then the total
core loss of the motor is obtaining by summing up the
losses of all the elements

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IJAEA, Volume 1, Issue 5, pp.57-63 (2008)

4.3 Mechanical Losses

The equation for mechanical losses, comprising cooling
fan windage loss and motor bearings friction loss is
given by
Pmech = K (n/10)2 D4s
(6)
The designer must therefore make every effort to
minimize the windage loss and to maximize the machine
cooling.

boundary condition specifies the heat flux flow qn

through the boundary. The heat flux flow through the
boundaries to the surrounding is described with the heat
transfer coefficient h and the ambient temperature Tamb.
The governing equation [5] is given by
qn = n (kT) = h (T Tamb
(7)
The finite element thermal analysis model with the
boundary conditions applied is shown in Fig .5.

5.0 THERMAL ANALYSIS

For thermal analysis, there are two basic methods: the
thermal network method and the finite element method.
In general, the geometrical complexity of an electrical
machine requires a large thermal network. The whole
motor is modeled into many small solid elements, which
are of block shape and can be modeled by six thermal
resistances and seven nodes. However, the core loss of
each element in thermal network cannot be obtained
easily from the result of magnetic filed calculation.
Mostly, the average is used.
Because core loss
distribution is quite different in different position of the
stator core accuracy cannot be improved by increasing
the number of elements in thermal network. In this
paper, a three dimensional (3D) as well as two
dimensional finite element analysis (FEA) is used to
obtain the accurate temperature distributions for two
motor configurations by keeping the same mesh
structure.

Fig. 5: Finite Element Thermal Model With Boundary

Conditions Applied

The convective heat transfer to the surroundings is

dependent on the geometry and the cooling conditions.
Air gap convection coefficient is determined by two main
quantities: the ruggedness of the rotor and stator surfaces
and the peripheral speed of the rotor surface. By assuming
smooth surface, the convection coefficient can be
calculated by experiential formula [6]

6.0 THERMAL FIELD ANALYSIS

h =28(1+ 0.5) (W/ (m2K))

The heat transferred by radiation is ignored. The partial

differential equation of the heat conduction and
convection is expressed as

= {(0.5vr) + va (m/s)}
(9)
where vr and va are the peripheral and axial speeds of the
rotor surface, respectively.
2

(8)

1/2

7.0 RESULTS OF SIMULATION

The results obtained by the simulated thermal analysis
are presented in this section. The foot-notes in the Fig. 6
through 11 are (colour plot shown horizontally) are the
simulation descriptions of the respective plots.

where [Kg/m ] is the mass density, c [J/(KgK)] the

specific heat, T [K] the temperature, t [s] the time, {V}
the velocity vector for mass transport of heat, [D] the
Thermal conductivity matrix, Kxx Kyy Kzz and K [W/
(mK)] are the thermal conductivity alone the x, y and z
directions, respectively, and q [W/m ] is the heat
generation rate per unit volume.

a)

6.1 Boundary Conditions

The boundary conditions can be of Dirichlet type, where
the temperature T* on the boundary is specified. This
boundary condition can be applied to the surface
between the frame and outer air. A Neumann type of

Fragrance

b)

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IJAEA, Volume 1, Issue 5, pp.57-63 (2008)

c)
c)

d)

d)

Fig. 6: Nodal Temperature Distributions In Different Parts

Of SRM With Soft Magnetic Composite Material. (A)
Temperature Distribution With Smooth Frame. B)
Temperature Distribution With Ribbed Frame (Number Of
Ribs 40). C) Temperature Distribution With Ribbed Frame
(Number Of Ribs 36). D) Temperature Distribution With
Ribbed Frame (Number Of Ribs 32)

Fig. 7: Nodal Temperature Distributions In Different Parts

Of SRM With Laminated Sheet Steel. (A) Temperature
Distribution With Smooth Frame. B) Temperature
Distribution With Ribbed Frame (Number Of Ribs 40). C)
Temperature Distribution With Ribbed Frame (Number Of
Ribs 36). D) Temperature Distribution With Ribbed Frame
(Number Of Ribs 32)

a)

Fig. 8: 3D Nodal Temperature Distributions In Different

Parts Of SRM With SMC

b)
Fig. 9: 3D Nodal Temperature Distributions In Different
Parts Of SRM With M19

Fragrance

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IJAEA, Volume 1, Issue 5, pp.57-63 (2008)

The superior heat evacuation capability of soft magnetic

composite material (SMC) compared with M19 has been
evidenced from Table I, II and III.
8.0 VIBRATION AND ACOUSTIC NOISE
SOURCES OF SWITCHED RELUCTANCE
MOTOR
Two disadvantages of the machine are its torque ripple
and acoustic noise [11].The acoustic noise sources are
listed as follows:

Fig. 10: Transient Temperature-Time Curve Of Stator

Body For The Continues Duty Cycle For SMC

Fig. 11: Transient Temperature-Time Curve Of Stator

Body For The Continues Duty Cycle For M19
TABLE I: NODAL TEMPERATURE DIFFERENCES BETWEEN
TWO CONFIGURATIONS WITH SMOOTH STATOR FRAME
Material

Minimum
temperature

Maximum
temperature

SMC

316.34

319.04

M19

319.126

321.499

% difference in
Temperature

27.86

24.59

TABLE II: NODAL TEMPERATURE DIFFERENCES BETWEEN

TWO CONFIGURATIONS WITH RIBBED STATOR FRAME
SMC

M19

Min
temp
310.105
310.563
310.744

Max
temp
312.846
313.383
313.495

Min
temp
311.334
312.445
313.205

No.
Of
Ribs

Max
temp
313.925
314.275
315.381

40
36
32

%
difference
in max
Temperature
10.79
8.92
18.86

TABLE III: COMPARISON BETWEEN 3D AND 2D THERMAL

ANALYSIS
2D Thermal analysis
M19
Min
319.3
4

3D Thermal analysis

SMC

M19

SMC

Max

Min

Max

Min

Max

Min

Max

321.499

316.34

319.04

311.09

312.191

309.602

311

% difference
in temp is
24.59

* Temperatures are in Kelvin

Fragrance

% difference in
temp is 11.91

1) SRM has a doubly salient structure. The rotor poles

behave like blades, which cause acoustic noise due to
windage;
2) Non-uniform characteristics of materials produce
mechanically dynamic unbalance of the rotor and a nonuniform distribution of magnetic flux, which cause both
magnetic and mechanical forces on the rotor and results
in acoustic noise;
3) Manufacturing asymmetries of the rotor and stator,
especially a non-uniform air gap, excites asymmetric
forces on the rotor;
9.0 VIBRATION ANALYSIS OF SWITCHED
RELUCTANCE MOTOR
Usually, the main stages of the analysis and calculations
are:
9.1 Calculation And Verification Of The System Natural
Frequency: The subassemblies (wounding stator, rotor
stack with shaft etc.) model can be built and the natural
frequencies and mode shapes can be calculated.
9.2 Electromagnetic Model And Force Calculation: All
the related dimensions, phase winding turns and the
properties of all materials are modeled in a software
package, for instance, in ANSYS, to calculate the flux
linkage curves as a function of rotor position and phase
current. Based on the current and rotor position, both
radial and tangential forces are calculated.
10.0 VIBRATION MODES OF ALL
LAMINATIONS (M19) AND ALL SMC
CONFIGURATIONS
The vibration modes and resonant frequencies has been
calculated with the aid of ANSYS commercial finite
element package. The following assumptions are made in
predicting the frequencies: (1) the stator yoke is a round
rigid body; (2) the teeth and windings have no rigidity,
so that their mass is attached to the yoke; (3) the periodic
force waves with rth order are symmetrically exerted on
the stator yoke ring; (4) the only effects of all defects and
notches is a reduction in the mass.
The following formulas are used to predict the natural
vibration frequencies for the force wave with rth order,
where m is the equivalent mass per square meter (kg/m2)
on the cylindrical surface at the average yoke radius,
which can be expressed by the following formula:

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IJAEA, Volume 1, Issue 5, pp.57-63 (2008)

(10)

(11)
and the equivalent spring stiffness coefficient per square
meter kr (N/m3) on the cylindrical surface at average
yoke radius.

a)Mode at 901.147HZ
4454HZ

b)Mode at 2298 HZ

c)Mode at

Fig .12:Vibration Modes Of The Stator Laminations With

Smooth Frame

(12)
My is the yoke mass including stator windings and poles
(kg); hy is the yoke height in the radial direction (m);
Ry(av) is the average radius of yoke (m); Ly(eff) is the
effective length of yoke ; kD is the spring stiffness
coefficient of the shock absorber under the motor. The
resonant frequencies calculated for the two
configurations viz (i) All laminated sheet steels (ii) All
Soft Magnetic Composites (SMC) using structural finite
element analysis are listed in Table IV.

a)Mode at 484HZ b)Mode at 1527HZ c)Mode at 1972HZ

Fig.13:Vibration Modes Of The Stator Laminations With
Ribbed Frame.

TABLE IV: COMPARISON OF SMOOTH FRAME AND RIBBED

FRAME WITH TWO MOTOR CONFIGURATIONS

S.
No.

Motor
configuration

All SMC

Mode
shape
frequencie
s of Stator
lamination
s with
smooth
frame (Hz)
a)700

Mode shape
frequencies
of Stator
laminations
with ribbed
frame (Hz)

Differences
in
frequencies
(Hz)

b)1786
c)3470

a)371
b)1170
c)1512

329
616
1958

a) 901
b) 2298

a) 484
b) 1527

417
771

c) 1972

2482

a)Mode at700

b)Mode at 1786

c) Mode at3470

Fig.14:Vibration Modes Of The SMC Stator With Smooth

Frame

All M19
2

c) 4454

This paper also considers the effects of the frame on the

mode shapes and frequencies. A tight friction coupling
between the laminations and frame is assumed. Fig. 12
and 13 shows the effects of smooth frame and ribbed
frame to the all laminations (M19) stator. Given the
influence of the smooth frame and frame with ribs on the
natural frequency, it is therefore of interest to examine
the effects of the smooth frame and frame with ribs on
the natural frequencies. Fig. 14 and 15, summarizes the
results for the case of a z-constrained vibration of a
smooth frame and frame with ribs for all SMC
configuration, the result showing that a gradual decrease
(almost 45%) in the mode shape frequencies of frame
with ribs. The overall vibration mode shape frequencies
shows that the structural capability of configuration (ii)
is better when compared with configuration (i) in the
high-speed aerospace applications regime.

Fragrance

a)Mode at 371 b)Mode at 1170

c) Mode at 1512

Fig.15:Vibration Modes Of The SMC Stator With Ribbed

Frame

11.0 CONCLUSION
The application potential of soft magnetic composite
material in high-speed switched reluctance motor has
been analyzed. The results were presented by
considering the excitation of one phase. The key points
in determining the steady-state and transient thermal
characteristics of SRM are no-load temperature
distributions at the different parts of the machine,
temperature-time curves of stator body with SMC and
M19 configurations, smooth stator frame, ribbed stator
frame, and finally differences between 3D and 2D finite
element analysis. It has been observed that the steady-

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IJAEA, Volume 1, Issue 5, pp.57-63 (2008)

state temperature is 319 K for configuration-2 and 321.5

K for configuration-1 considering copper and core loss.
The final study has led to the SMC based switched
reluctance motor configuration with ribs provision has
enhanced the heat dissipation. Also an in-depth analysis
of vibration modes of the stator of switched reluctance
machine with two configurations has been discussed.
The study started with the lamination and SMC with a
smooth frame, and then extended as well as to a ribbed
frame. The obtained result shows that a gradual decrease
(almost 45%) in the mode shape frequencies of frame
with ribs. The considerable torque reduction in
configuration-2 is due to the poor permeability of soft
magnetic composite material. At the same time the
structural capability of configuration-2 is better when
compared with configuration-1 in the high-speed
aerospace applications regime. The finite element
analysis aided in the estimation of
mode shape
frequencies for the two motor configurations and in their
visualization.
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Composites in Electrical Machines, International
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[3] A. V. Radun, High-power density switched
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Jan/Feb. 1992.

Fragrance

[4]The Latest Development in Soft magnetic

Composite Technology from Hoganas Metal Powders,
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