Impact Analysis of PM magnetization level on motor performance: simulations and experimental results

Tiago Staudt,Leonardo Ulian Lopes,Paulo A P Wendhausen,Fernando Maccari,Thiago Akinaga

doi:10.1590/2179-10742017v16i1879

Abstract

This paper addresses the impact of magnetization level tolerances in ferrite-based permanent magnets (PM) on the performance of brushless DC motors. A case study is prepared using three motor prototypes assembled with controlled samples of ferrite arc segments, in terms of magnetization. The investigation is performed both experimentally and through simulations using the software SPEED. The results show that narrow tolerance margins for the magnetization conditions in the production line can potentially minimize the use of raw material on such motors whereas keeping the efficiency and torque behavior required by the application.

Highlights

Manufacturing tolerances are an inherent and inevitable characteristic of any production line
The paper proposes an experimental investigation on the dependence of several motor parameters that depends upon permanent magnets (PM) magnetization levels
A surface mounted PM-ferrite, brushless DC motor (BLDC) with 200 W rated power is used in this case study to assess the differences in performance due to different PM magnetization conditions

Summary

Introduction

Manufacturing tolerances are an inherent and inevitable characteristic of any production line. From the product’s side, the designer has to guarantee at least the minimum performance level required by the application and a worst-case scenario design usually applies to always fulfill the requirements. This fact may lead to non-optimal use of raw materials and extra costs for the product. [1]-[4] To address this issue, this paper investigates the tolerances of one key aspect on a ferrite PM-based motor design: the influence PM magnetization conditions on motor’s performance and raw material utilization (copper and steel). Experimental tests are reported, comparing performance characteristics among different rotors. A discussion on raw materials utilization is presented based on a simulation approach

Methods

Findings

Discussion

Conclusion