6 IPM Motor Design PDF

Design of Interior Permanent Magnet and Brushless DC May 10-12, 2010, Torrance, CA
Machines Taking Theory to Practice
IPM MOTOR DESIGN
Mehdi Abolhassani, PhD

Austin, Texas
Tel: (703)964-7121
mehdita@ieee.org
2010 Advanced MotorTech LLC Largo FL USA & 2010 Mehdi Abolhassani, Austin TX USA 6-1
2010 Advanced MotorTech LLC Largo FL USA & 2010 Mehdi Abolhassani, Austin TX USA
IPM Rotor Configurations

q
d
Tangential V-type
Radial Multi-barrier
IPM Motor Characteristics

IPM rotor Configurations exhibit magnetic
paths with different permeance, from which
possibility of developing reluctance torque.
The d-axis is set to be the polar axis (PM axis),
while the q-axis is 90 in advance.
Since the permeability of Pm are similar to air,
the d-axis magnetic permeance is lower than
the q-axis yielding Ld<Lq.
Torque in PM Motors
Torque of PM Motors T q
=
3p
2
[ m I q
+ (L L )I I ]
d q d q
PM Torque Reluctance Torque
Saliency Ratio =
L q
L d
Torque of PM Motors with Saliency ratio T q

=
3p
2
[ m I ( 1) Ld I I
q d q
]
IPM Motor Torque

Reluctance IPM motor
PM Torque
+ Torque = Torque
Magnet
Air Magnet
+ =
Surface-mounted Synchronous
Interior PM
PM Motor (SPM) Reluctance
Motor (IPM)
Motor
Optimum Phase Advance

1.4
Angle in IPM
Optimum Angle
Magnet Torque
1.2
Reluctance Torque
Mag.+Rel Tq=IPM Tq
1
Torque (p.u.)
0.8
0.6
0.4
0.2
0
0 10 20 25 30 40 50 60 70 80 90
Advanced firing angle(Deg.)
Optimum Phase angle;Max Torque per

Amp
T = pmiq + ( Ld Lq )id iq = Lq=2*Ld
= pm i sin( ) + ( Ld Lq )i 2 cos( ) sin( ) 18
16
dT
= pmi cos( ) + ( Ld Lq )i 2 cos(2 ) = 0 14
d 12
pm i cos( ) + ( Ld Lq )i 2 (2 cos 2 ( ) 1) = 0 10
mi 1 8
cos 2 ( ) + cos( ) =0
2( Ld Lq )i 2 2 6
4
2
pm pm 1 2
cos( ) = +
4( L L )i 2
-10 -5 0 5
4( Ld Lq )i d q
Ideal Field weakening Characteristics
Ideal Torque Speed Curve Ideal Power Speed Curve
Field Weakening in PM Motors
Excitation flux of PMs are

fixed and can not be varied
as separately excited DC
motor.
However, a control of the
total flux in the d-axis is
achieved by introducing an
armature flux against the
fixed excitation field from the
magnets. It is achieved by
injecting a negative d-axis
current Id.
Field Weakening in IPM Motors

V ( PM + Ld I d ) + (Lq I q )
2 2 2 2
Voltage Limit b
Q-axis Q-axis
jLqiq
jLdid E jLqiq
jLdid E
Max Vs Loci is iq
Vs is
iq
D-axis Max Vs Loci
Vs D-axis
id Pm id Pm
(b)
(a)
Phasor diagram of IPM Motor Q-axis

jLqiq
a) At low speed
jLdid E
b) At rated speed
Vs
c) Beyond rated speed with Max Vs Loci is

iq
field weakening D-axis
id Pm
2010 Advanced MotorTech LLC Largo FL USA
(c)
& 2010 Mehdi Abolhassani, Austin TX USA 6-10
Field Weakening in SPM Motors

V ( PM + Ld I d ) + (Lq I q )
2 2 2 2
Voltage Limit b
Phasor diagram of PM Motor

a) At low speed
b) At rated speed
c) Beyond rated speed with
field weakening (Impossible)
d) Beyond rated speed with
field weakening
IPM Parameter Plane

Torque-Speed characteristics of IPM depends on two independent
parameters: The saliency ratio ,and Normalized Magnet Flux Linkage mn

m
Normalized Magnet flux linkage = b

mn

V b

Source: Soong W.L., Miller T.J.E., Field-weakening performance of brushless synchronous AC motor drives, IEE Proceedings of Electric Power
Application, 141(6), pp. 331 ~ 340, 1994.
Optimal IPM Parameters
Source: Soong W.L., Miller T.J.E., Field-weakening performance of brushless synchronous AC motor drives, IEE Proceedings of Electric Power
Application, 141(6), pp. 331 ~ 340, 1994.
Optimal IPM Design
Constant Power Speed Range

Constant Power Speed
CPSR =
cpsr
Max speed with power equal
Range to rated power
b
Surface Permanent Magnet motor (SPM):

- Commercial SPM designs generally have a mn between 0.83 and 0.96. The
constant power speed range (CPSR) is usually lower than 2.
Single-barrier synchronous reluctance motor:
- A CPSR below 2 and with saliency ratios in the range from 2 to 5.
Single-barrier IPM motor:
- CPSR between 1.5 and 3.
Multiple-barrier (axially laminated) IPM motor:
- High saliency ratios between 5 and 14 can be achieved.
Theoretically this implies that these designs offer a wide field weakening region.
- It is possible to obtain a design with the optimum field-weakening
performance (infinite speed range) by adding a suitable quantity of
permanent magnets. For example, one of the SOON (marked X)
designs
Effect of Magnetic Saturation on

Ld and Lq
Lq, Ld
Lq
Ld
Id, Iq
Magnetic saturation has a significant impact on the performance characteristics

of IPM machines. Lq is very sensitive to magnetic saturation as Iq increases. Ld
tends to be much less sensitive to magnetic saturation because this magnetic
path is dominated by the thickness of Pm that behaves as air.
Lamped Parameter Magnetic

Equivalent Circuit
It is easy to relate to physical properties.
It can be evaluated quickly, making them conveniently

compatible with the optimization software.
Torque ripple is ignored and must be evaluated during

post-processing.
Magnetic cross-coupling between the d- and q-axes is

ignored.
Demagnetization thresholds cannot be

accurately evaluated.
Optimal Control Under Voltage &

Current Constraint
Max available inverter current
2 2
I a
= i +i I
d q am
Max available output voltage of inverter which depends on dc-link voltage Vdc
2 2
V a
= v + v V
d q am
Assuming steady state and V om

= V am R a I am
V =o e
(L i + ) (L i )
d d pm +
2 2
q q V om
Current-Limit Circles and the

Voltage-Limit Ellipse
The voltage-limit ellipse
shrinks to the center
point of M as the speed
increases.
The current vector
satisfying both
constraints of voltage
and current must be
inside of both the current
limit circle and voltage
limit ellipse.
Max Torque Production I

In the consideration of voltage and current
constraints, the max torque per amp can be
achieved as:
Region I( constant torque region): Below the base
speed, the maximum torque is produced by
maximum torque per amp control.
Region II (FW, constant VA region): Beyond the base
speed, the current is controlled by the flux-
weakening control, (Max voltage) Vo=Vom.
Region III( FW, decreasing VA region) In case dmin=
pm-LdIam<0, max torque per volt control can be
applied.
Max Torque Production II
Reference: S Morimoto, et-al, Expansion of operation limits for permanent magnet motor by current vector control considering inverter
capacity
Characteristics of Max Torque Control with

Current and Voltage Constraints
Design Example
Design , 300W, 18V battery operated,
22000RPM motor for power tools application
Design 1 : IPM
Design 2 : SPM
IPM design data

4pole/6 Slot , IPM
Lamination: M19, 0.5mm
Magnet: Neomax35
SOD: 49mm
Airgap: 0.5mm
ROD: 25.5 mm
Slot opening: 2mm
Stack length: 11mm
Magnet dimension: 12.7x3.5x11
Copper weight: 32gr
Magnet weight: 14.5 gr
Wire: AWG 18 Battery: 19.5 V, 0.130
TPC: 6 Fan power coefficient: 1.5 e-12

Control: 6-step control, 273 advanced
Ra: 32m

RDS (on)=5m
SPM design data

4pole/6 Slot , SPM
Lamination: EMP-24, 0.5mm
Magnet: Neomax35
SOD: 49mm
Airgap: 1mm
ROD: 24.5 mm
Slot opening: 2mm
Stack length: 11mm
Copper weight: 32gr
Magnet weight: 11 gr
Wire: AWG 18 Battery: 19.5 V, 0.130
TPC: 6 Fan power coefficient: 1.5 e-12
Ra: 32m Control: 6-step control, 0advanced

RDS (on)=5m
SPM and IPM Motor Performance

22000 400
20000 350
18000 300
16000 250
RPM
IPM
14000 200
SPM
12000 150
10000 100
8000 50
6000 0
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
Torque (N.m)
SPM and IPM Motor Performance

85%
80%
75%
Efficiency %
70%
IPM
SPM
65%
60%
55%
50%
50 100 150 200 250 300 350
Out Power
IPM Design Sensitivity to Advance Angle

Variation
22000 400
20000 350
18000 300
16000 250
27
RPM
14000 200 30
24
12000 150
10000 100
8000 50
6000 0
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
Torque (N.m) 6-28
IPM Design Sensitivity to Advanced Angle

Variation II
85%
80%
75%
Efficiency %
70%
27
30
65% 24
60%
55%
50%
50 100 150 200 250 300 350
Out Power 6-29
Design Example II
Multiphase Fault Tolerant IPM

Motor Drives for HEV
Applications
Reference: M. T. Abolhassani, A Novel Multiphase Fault Tolerant Permanent Magnet Motor Drive
for Fuel cell Powered Vehicles, Proceedings of IEEE Vehicles Power Propulsion Conference,
Dallas, TX, Sept. 2007.
Fault Tolerant Motor Drive
The concept of a fault tolerant motor drive is
usually referred to a system which is operable
after occurring fault with minimal derating in
performance.
Faults in Motor Drive System

Winding open circuit;
Winding short-circuit (partial turn to turn or complete);
Inverter switch open-circuit (analogous to winding open-circuit);
Inverter switch short-circuit (analogous to winding short-circuit);
DC link capacitor failure.
Fault Tolerant Motor Drive,

Design and Requirements
Thermal and magnetic isolation between coils;
Low mutual coupling between phases;
Higher reliability and performance;
Low short circuit current ==Higher INDUCTANCE.
Multiphase Concentrated winding Machine

H-bridge converter;
Electromagnetic Torque
1
T= K w . nl . nc .Q. B g . A g .I. cos( )
4
Kw : Winding factor
nl : Number of layers
nc : Number of turns per coil
Q : Number of slots
Bg : Peak flux density in airgap
Ag : Airgap area
I : Peak current
: Current angle
Power Device Failure

Short-circuit current path
Single phase bridge when T3 is faulted.
Vdc/2 T1 D1 T3 D3 Vdc/2 T1 D1 T3
Vdc/2 T2 D2 T4 D4 Vdc/2 T2 D2 T4
f
Peak short-circuit current I sc ( pu ) =
L s ( pu )
f
N N . f
Turn-to-turn short-circuit current I sc ( pu ) = =
L s ( pu ) L s ( pu )
N2
Geometry of Proposed IPM Motor

Specification Value
E- E-
B- E+ E+
C-
B+ C+
Rated power (kW) 150 B+ C+
B- C-
D+ A+
Rated speed( RPM) 5000
D- A-
D- A-
Maximum speed (RPM) 12000
D+ A+
A- D-
Rated torque( N.m) 226
A+ D+
D+
Rated current( A) 125 A+
A- D-
DC bus voltage (volts) 420 C+ B+
C- B-
C- B-
C+ B+
E- E-
E+ E+
5 phase , 18 poles, 20Slots

Windings Design
Description Value
Harmonics Value
winding factor
Armature phases 5
Kdp1 0.9755
Kdp3 0.7939 Turn per coil 12
Kdp5 0.5000
Armature winding branches 2
Kdp7 0.2061
Kdp9 0.0245 Wire size 13x awg17
Kdp11 0.0245
Max stator slot fill 0.68%
Kdp13 0.2061
Kdp15 0.5000 Armature winding resistance 5.55E-03
Kdp17 0.7939
Kdp19 0.9755
1.5
Airgap flux density
1.0
Flux density(T)
0.5
0.0
-0.5
-1.0
-1.5
-1620 -1260 -900 -540 -180 180 540 900 1260 1620
Electrical angle (Deg.)
100%
90%
Airgap flux density spectrum %
80%
70%
60%
50%
40%
30%
20%
10%
0%
1 3 5 7 9 11 13 15 17 19 21
Harmonics order
Armature Reaction at Peak Current

1.5
1.0
Air gap flux density (T)
0.5
0.0
-0.5
-1.0
-1.5
-1620 -1260 -900 -540 -180 180 540 900 1260 1620
Rotor Position in electrical degrees
100%
Airgap flux density due to windings
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
1 3 5 7 9 11 13 15 17 19 21
Harmonics order
Cogging Torque
1.00
0.80
0.60
Cogging torque(N.m)
0.40
0.20
0.00
-0.20
-0.40
-0.60
-0.80
-1.00
0 3 6 9 12 15 18
Rotor position in electrical degree
Phase and Line Bk-emf @5000RPM
400
300
200
Back emf (V)
100
0
-100
-200
-300
-400
0 180 360 540 720
Electrical Angle (Deg.)
Phase Back EMF Line Back EMF
Torque Production @ 5000RPM

235
Healthy
230
Electromagnetic Torque (N.m)
225
0 90 180 270 360 450 540 630 720
300
1 switch fault
200
100
0 90 180 270 360 450 540 630 720
300
1 phase fault
200
100
0 90 180 270 360 450 540 630 720
Rotor position in electrical degree
Condition Torque (N.m) Torque ripple %
Healthy 224 0.5
Failure in 1 switch 201 24
Failure in one phase 177 50
Torque Speed Performance

250
200
Torque (N.m )
150
100
50
0
0 2000 4000 6000 8000 10000 12000
Speed (RPM)
Healthy 1 Switch fault 1 Phase fault
Power Performance Curves

160000
140000
120000
Out Power (W )
100000
80000
60000
40000
20000
0
0 2000 4000 6000 8000 10000 12000
Speed (RPM)
Efficiency Curves
100%
95%
Efficiency %
90%
85%
0 2000 4000 6000 8000 10000 12000 14000
Speed (RPM)
Phase Self Inductance

5.00E-04
U n s a tu ra te d p h a s e s e lf-in d u c ta n c e in H
4.50E-04
4.00E-04
3.50E-04
3.00E-04
2.50E-04
0 180 360 540 720
Rotor Position in electrial degree
Short Circuit Current

250
200
150
S hort C irc uit C urrent (A )
100
50
0
-50
-100
-150
-200
-250
0 90 180 270 360
Rotor Position in Electrical Degree
Conclusions
A Fault tolerant 5-phase IPM motor drive (Concentrated
windings with18 poles, 20 slots;
Max Cogging torque 0.8N.m
0.5% Torque ripple
Short Circuit Current :0.88 pu
2% mutual inductance

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Design of Interior Permanent Magnet and Brushless DC May 10-12, 2010, Torrance, CA

Machines Taking Theory to Practice

IPM MOTOR DESIGN

Mehdi Abolhassani, PhD

IPM Rotor Configurations

IPM Motor Characteristics

PM Torque Reluctance Torque

Torque of PM Motors with Saliency ratio T q

IPM Motor Torque

Optimum Phase Advance

Optimum Phase angle;Max Torque per

Ideal Field weakening Characteristics

Ideal Torque Speed Curve Ideal Power Speed Curve

Field Weakening in PM Motors

Excitation flux of PMs are

Field Weakening in IPM Motors

Phasor diagram of IPM Motor Q-axis

Field Weakening in SPM Motors

Phasor diagram of PM Motor

IPM Parameter Plane

Optimal IPM Parameters

Optimal IPM Design

Constant Power Speed Range

Surface Permanent Magnet motor (SPM):

Effect of Magnetic Saturation on

Magnetic saturation has a significant impact on the performance characteristics

Lamped Parameter Magnetic

It can be evaluated quickly, making them conveniently

Torque ripple is ignored and must be evaluated during

Magnetic cross-coupling between the d- and q-axes is

Demagnetization thresholds cannot be

Optimal Control Under Voltage &

Assuming steady state and V om

Current-Limit Circles and the

Max Torque Production I

Max Torque Production II

Characteristics of Max Torque Control with

IPM design data

TPC: 6 Fan power coefficient: 1.5 e-12

SPM design data

Wire: AWG 18 Battery: 19.5 V, 0.130

TPC: 6 Fan power coefficient: 1.5 e-12

Ra: 32m Control: 6-step control, 0advanced

SPM and IPM Motor Performance

SPM and IPM Motor Performance

IPM Design Sensitivity to Advance Angle

IPM Design Sensitivity to Advanced Angle

Multiphase Fault Tolerant IPM

Fault Tolerant Motor Drive

The concept of a fault tolerant motor drive is

usually referred to a system which is operable

after occurring fault with minimal derating in

Faults in Motor Drive System

Winding short-circuit (partial turn to turn or complete);

Inverter switch open-circuit (analogous to winding open-circuit);

Inverter switch short-circuit (analogous to winding short-circuit);

DC link capacitor failure.

Fault Tolerant Motor Drive,

Low mutual coupling between phases;

Higher reliability and performance;

Low short circuit current ==Higher INDUCTANCE.

Multiphase Concentrated winding Machine

Power Device Failure