Permanent Magnet Assisted Synchronous Reluctance Motor Research Articles

Electromagnetic Design Optimization Integrated with Mechanical Stress Analysis of PM-Assisted Synchronous Reluctance Machine Topologies Enabled with a Blend of Magnets

Permanent Magnet-Assisted Synchronous Reluctance Machines (PMASynRM) provide a low-cost alternative to Surface PM Machines due to the use of relatively lower grades of rare-earth (RE) or RE-free magnets, as the performance degradation due to weaker magnets is compensated by the presence of reluctance torque. However, the weaker magnets suffer from a high risk of demagnetization, leading to unreliable motor operation. Using a blend of RE and RE-free magnets has the potential to overcome this issue. This paper proposes to blend different grades of various rare-earth (RE) and rare-earth-free (RE-free) magnets in six different combinations and utilizes them in two-layer and three-layer U-shaped PMASynRM topologies with both eight-pole and six-pole variations. The rotor of the various designs is then optimized using a differential evolution (DE) based optimization algorithm to obtain low-cost designs with reduced RE magnet volume and minimum demagnetization risk. The optimization of each design is also integrated with the evaluation of mechanical stresses in the rotor laminations so as to maintain the stresses below the material yield strength. Furthermore, the various performance metrics, such as toque–speed/power–speed characteristics, demagnetization, and efficiency maps, are evaluated for each of the optimized and mechanically feasible designs. A quantitative comparison of the various optimized designs is also obtained to highlight the various trade-offs. The results indicate the feasibility of meeting the baseline torque requirement across the entire speed range, even with a 100% reduction in RE magnet volume and less than 5% demagnetization risk, while achieving a cost reduction exceeding 50%. Moreover, the two-layer, eight-pole designs exhibit relatively higher performance, whereas the three-layer, eight-pole designs are found to be the most economical option.

Multi-physics and multi-objective optimization of a permanent magnet-assisted synchronous reluctance machine for traction applications

This contribution addresses the rotor design process of a Permanent Magnet-assisted Synchronous Reluctance Machine by adopting a multi-physics and multi-objective optimization algorithm. A Finite Element (FE) approach is employed to determine the electromagnetic and structural responses during the optimization. In particular, a detailed FE structural modeling is used, which often is based on simplifications and inaccuracies in the available literature. A genetic algorithm is adopted, with the objectives being the maximization of the mean torque, the minimization of the torque ripple and the minimization of the stress in the rotor. A parametric analysis of the geometric features precedes the optimization to establish the design variables which mostly affect the machine performance, and thus to reduce the computational cost of the optimization. The presented methodology consists of a useful tool for the final stages of the design process, and provides a rotor with a torque ripple reduced by 15.1% compared to an existing design used as a benchmark, while the mean torque and the maximum stress remain the same as the original configuration.

Design and Performance Analysis of an Outer-Rotor PMaSynRM

Permanent magnet synchronous motors (PMSMs) are consciously used as traction motors in electric vehicles (EVs) and hybrid electric vehicles (HEVs). The rotor position (inner-rotor, outer-rotor) and topology of PMSMs significantly impact their torque profile, efficiency, and demagnetization characteristics. This article focuses on designing an outer-rotor permanent-magnet-assisted synchronous reluctance motor (PMaSynRM) under traction motor requirements and investigating its electromagnetic performance using the finite element method (FEM). This study's primary challenge is achieving optimal machine performance, considering high maximum torque and the risk of demagnetization at low levels. The design, derived from analytical calculations, was subjected to Finite Element Method (FEM) analyses. These analyses investigated motor performance in terms of efficiency, the ability to generate torque at different drive currents, and the risk of demagnetization. As a result of the study, the proposed PMaSynRM design was obtained that provides an adequate demagnetization performance even under 300% loading, has a maximum torque exceeding 35 Nm, and achieves an efficiency of 90% at rated conditions.

Circular Economy Aspects of Permanent Magnet Synchronous Reluctance Machine Design for Electric Vehicle Applications: A Review

Innovative technological solutions have become increasingly critical in addressing the transportation sector’s environmental impact. Passenger vehicles present an opportunity to introduce novel drivetrain solutions that can quickly penetrate the electric vehicle market due to their shorter development time and lifetime compared to commercial vehicles. As environmental policy pressure increases and customers demand more sustainable products, shifting from a linear business approach to a circular economy model is in prospect. The new generation of economically competitive machines must be designed with a restorative intention, considering future reuse, refurbishment, remanufacture, and recycling possibilities. This review investigates the market penetration possibilities of permanent magnet-assisted synchronous reluctance machines for mini and small-segment electric vehicles, considering the urban environment and sustainability aspects of the circular economy model. When making changes to the materials used in an electric machine, it is crucial to evaluate their potential impact on efficiency while keeping the environmental impact of those materials in mind. The indirect ecological effect of the vehicle’s use phase may outweigh the reduction in manufacturing and recycling at its end-of-life. Therefore, thoroughly analysing the materials used in the design process is necessary to ensure maximum efficiency while minimising the environmental impact.

Electromagnetic analysis of permanent magnet-assisted synchronous reluctance motor based on magnetic equivalent circuit

As rare-earth permanent magnet prices continue to fluctuate, interest in non-rare-earth permanent magnet-assisted synchronous reluctance motors (PMa-SynRMs) is increasing. However, non-rare-earth PMa-SynRMs have a multi-layer structure with interior permanent magnets to compensate for the low magnetic fields. Therefore, the rotor has several design parameters, and electromagnetic analysis is time-consuming. To overcome these challenges, magnetic equivalent circuit analysis was used to perform fast electromagnetic analysis of non-rare-earth PMa-SynRMs. In addition, the validity of the proposed method was confirmed through a comparison of the obtained results with those of finite element analysis.

Rare‐earth‐free Al‐Ni‐Co hybrid PMa‐SyRM for an air‐conditioner compressor

AbstractA hybrid ferrite‐Al‐Ni‐Co permanent magnet assisted synchronous reluctance motor (PMa‐SyRM) for an air‐conditioner compressor is proposed. Al‐Ni‐Co PMs have high residual flux density similar to rare‐earth PMs such as Nd‐Fe‐B and Sm‐Co. Therefore, the performance parameters of the PMa‐SyRM such as power factor, efficiency etc., with Al‐Ni‐Co PMs can be improved without significantly increasing the cost of the motor. However, Al‐Ni‐Co PMs have a steep IInd‐quadrant B‐H curve, and the challenge lies in addressing their demagnetisation issues. In the proposed hybrid PMa‐SyRM, the rotor geometry is suitably optimised for placing the Al‐Ni‐Co PMs in the centre flux barriers to address the demagnetisation issues. Further, an analytical magnetic circuit is presented to design the proposed PMa‐SyRM. Later, 2‐D finite element analysis of the proposed motor including the demagnetisation analysis of PMs and stress analysis of the rotor is carried out and presented. A prototype is fabricated, experimental validation is carried out, and the results of the performance and cost are compared with that of ferrite and hybrid ferrite‐Nd‐Fe‐B PMa‐SyRM.

Design and Control of a Permanent Magnet Assisted Synchronous Reluctance Motor

In recent years, studies aiming to use different motor types for traction purpose, such as in electric vehicles, have become increasingly widespread. Among these motor types, permanent magnet assisted synchronous reluctance motor (PMa-SynRM) has become in-creasingly preferred in commercially electric vehicles nowadays. This study addresses the design and control of a PMa-SynRM, also the comparison with the synchronous reluc-tance motor (SynRM). The motor design process is carried out using the finite element method in Ansys-Maxwell environment. A series of a simulation studies is conducted in the MATLAB/Simulink environment for controlling the obtained motor designed in An-sys-Maxwell. The field-oriented control (FOC) approach is chosen for precise speed con-trol. As a result of the simulation studies, it is observed that the designed motor tracks the reference with minimal error under various load conditions within a closed-loop system. Also, this paper investigates how the PM implementation affects the machine perfor-mance comparing to SynRMs. In addition, such a study takes into account that the de-sign of machines involves always several constraints, including geometry, materials, sup-ply limits, and performance constraints.

Multi-Objective Optimization Design of the External Rotor Permanent Magnet-Assisted Synchronous Reluctance Motor Based on the Composite Algorithm

Based on the complex structural characteristics of permanent magnet-assisted synchronous reluctance motors (PMA-SynRMs), this paper proposes a multi-objective optimization design method for the motor using a composite algorithm. Firstly, the power density, electromagnetic torque, cogging torque, and torque fluctuation coefficient were used as optimization targets based on parametric analysis data of 14 motor structure variables, where parametric sensitivity analysis helped select eight optimization variables. Secondly, the motor prediction model was fitted using the genetic algorithm–back propagation (GA-BP) neural network. Finally, non-dominated sorting genetic algorithm-III (NSGA-III), based on the reference points, was used to find the optimization of the prediction model and complete the multi-objective optimization design of the external rotor PMA-SynRM with eight inputs and four outputs. A comparative analysis of the electromagnetic performance of the motor before and after optimization verifies the feasibility of optimizing the motor using the composite algorithm. This paper provides an analytical tool for the multi-parameter and multi-objective PMA-SynRM optimization design.

Design and analysis of PM‐assisted synchronous reluctance machine with shifted magnetic poles

AbstractThe authors present a new design of a PM‐assisted synchronous reluctance motor (PM‐SynRM) with uneven air‐gap length to improve the power factor and enhance the torque production capability. The rotor structure is modified to properly shift rotor magnetic poles and therefore (i) increases the back‐EMF and the electromagnetic torque, (ii) allows electromagnetic torque and reluctance torque components peak near the same current phase angle. The proposed solution is simple, does not require changing the arrangement of magnets and/or flux barriers and is applicable to all types of PM‐SynRMs. Sensitivity analysis is carried out to determine the extent of which the proposed magnetic pole shifting may impact the resultant torque profile. To assess the level of success, the electromagnetic characteristics of the proposed design (e.g. torque, power factor, and back‐EMF) are compared against the baseline structure under the same operating conditions. For verification purposes, Finite Element simulation results are validated via a series of analytical calculations and experimental measurements, and supported with detailed theoretical discussion.

Performance Validation of PM Assisted SynRM and PMSM with Optimized Design for EV Application

This paper presents the comparison of Permanent Magnet-Assisted Synchronous Reluctance Motor (PMASynRM) and Permanent Magnet Synchronous Motor (PMSM) for the same design parameters and the evaluation of various performance parameters based on the Finite Element (FE) Method. FE Analysis is conducted after selecting the optimized design for PMASynRM and PMSM using an FE tool, with loading conditions to determine various performance parameters. This is achieved by maintaining the same motor dimensions and stator parameters while altering the rotor geometry for both motors. The final simulation results are discussed, and other performance parameters are recorded for comparison purposes. A PMASynRM is introduced, in which the problems of Synchronous Reluctance Motor (SynRM) can be eliminated with a permanent magnet in the rotor flux barrier. Due to higher flux barriers in PMASynRM, the reluctance torque is higher than in PMSM. If the magnet is placed very near to the air gap in PMSM, higher magnet torque is achieved, but due to the high reluctance torque in PMASynRM, the electromagnetic torque of PMASynRM is higher compared to PMSM. The research proves that the proposed design of PMASynRM is the best choice for Electric Vehicle (EV) applications. For PMASynRM, the shape of the flux barrier is not possible to change due to the design limitation of the FE software tool. Further analysis can be conducted by changing the shapes of the flux barriers to propose the most effective barriers. Basic theory and FE analysis of conventional PMSM and SynRM are reported in the literature. An optimal design is proposed through comparative analysis for EV applications to find out the best candidate for an EV motor.

Adaptive Gain Tuning Rule for Nonlinear Sliding-Mode Speed Control of Encoderless Three-Phase Permanent Magnet Assisted Synchronous Motor

In this paper, an adaptive gain tuning rule is designed for the nonlinear sliding mode speed control (NSMSC) in order to enhance the dynamic performance and the robustness of the permanent magnet assisted synchronous reluctance motor (PMa-SynRM) with considering the parameter uncertainties. A nonlinear sliding surface whose parameters are altering with time is designed at first. The proposed NSMSC can minimize the settling time without any overshoot via utilizing a low damping ratio at starting along with a high damping ratio as the output approaches the target set-point. In addition, it eliminates the problem of the singularity with the upper bound of an uncertain term that is hard to be measured practically as well as ensures a rapid convergence in finite time, through employing a simple adaptation law. Moreover, for enhancing the system efficiency throughout the constant torque region, the control system utilizes the maximum torque per ampere technique. The nonlinear sliding surface stability is assured via employing Lyapunov stability theory. Furthermore, a simple sliding mode estimator is employed for estimating the system uncertainties. The stability analysis and the experimental results indicate the effectiveness along with feasibility of the proposed speed estimation and the NSMSC approach for a 1.1-kW PMa-SynRM under different speed references, electrical and mechanical parameters disparities, and load disturbance conditions.

Intelligent Backstepping Control of Permanent Magnet-Assisted Synchronous Reluctance Motor Position Servo Drive with Recurrent Wavelet Fuzzy Neural Network

An intelligent servo drive system for a permanent magnet-assisted synchronous reluctance motor (PMASynRM) that can adapt to the control requirements considering the motor’s nonlinear and time-varying natures is developed in this study. A recurrent wavelet fuzzy neural network (RWFNN) with intelligent backstepping control is proposed to achieve this. In this study, first, a maximum torque per ampere (MTPA) controlled PMASynRM servo drive is introduced. A lookup table (LUT) is created, which is based on finite element analysis (FEA) results by using ANSYS Maxwell-2D dynamic model to determine the current angle command of the MTPA. Next, a backstepping control (BSC) system is created to accurately follow the desired position in the PMASynRM servo drive system while maintaining robust control characteristics. However, designing an efficient BSC for practical applications becomes challenging due to the lack of prior uncertainty information. To overcome this challenge, this study introduces an RWFNN as an approximation for the BSC, aiming to alleviate the limitations of the traditional BSC approach. An enhanced adaptive compensator is also incorporated into the RWFNN to handle potential approximation errors effectively. In addition, to ensure the stability of the RWFNN, the Lyapunov stability method is employed to develop online learning algorithms for the RWFNN and to guarantee its asymptotic stability. The proposed intelligent backstepping control with recurrent wavelet fuzzy neural network (IBSCRWFNN) demonstrates remarkable effectiveness and robustness in controlling the PMASynRM servo drive, as evidenced by the experimental results.

Permanent Magnet Assisted Synchronous Reluctance Motor with Asymmetric Rotor for High Torque Performance

Permanent magnet assisted synchronous reluctance motor (PMA-SynRM) is a kind of high torque density energy conversion device widely used in modern industry. In this paper, based on the basic topology of PMA-SynRM, a novel PMA-SynRM of asymmetric rotor with position-biased magnet is proposed. The asymmetric rotor design with position-biased magnet realizes the concentration of magnetic field lines in the motor air gap to obtain higher electromagnetic torque, and makes both of magnetic and reluctance torque obtain the peak value at the same current phase angle. The asymmetric rotor configuration is theoretically illustrated by space vector diagram, and the feasibility of high torque performance of the motor is verified. Through the finite element simulation, the effect of the side barrier on output torque and the Mises stress under the rotor asymmetrical design are analyzed. Then the motor characteristics including airgap flux density, back EMF, magnetic torque, reluctance torque, torque ripple, losses, and efficiency are calculated for both the basic and proposed PMA-SynRMs. The results show that the proposed PMA-SynRM has higher torque and efficiency than the basic topology. Moreover, the torque ripple of the proposed PMA-SynRM is reduced by the method with harmonic current injection, and the torque characteristics in the whole current cycle are analyzed. Finally, the endurance to avoid PM demagnetization is confirmed based on the PM remanence calculation.

Vibration and Noise Optimization of New Asymmetric Modular PMaSynRM

This study proposes an optimized structure to weaken the vibration and noise of a new asymmetric permanent magnet-assisted synchronous reluctance motor (PMaSynRM). The new asymmetric PMaSynRM has the advantages of a low torque ripple and high fault tolerance. However, the asymmetric structure generates an unbalanced magnetic force (UMF), which results in vibration and noise problems. In this study, the vibration and noise of the motor are analyzed and optimized. First, the radial pressure is analyzed, and an optimized structure is proposed. The electromagnetic performance of the motor before and after optimization is analyzed using the finite element method. Second, a three-dimensional model is established, and modal analysis is conducted considering the orthotropy of the stator and effective windings. Finally, the vibration and noise are simulated and analyzed, and the validity of the analysis results is verified experimentally. The analysis results indicate that the optimized motor realizes a reduction in the motor vibration and noise.

Measurement of the Self-Sensing Capability of Synchronous Machines for High Frequency Signal Injection Sensorless Drives

Signal injection sensor-less control for synchronous machines is known to be afflicted by an estimation error dependent on the load current. The estimation error is related to the cross-saturarion and the saliency of the adopted synchronous machine. A motor can be more or less suitable for signal injection sensorless control compared to other motors with different designs or sizes. A sensorless drive can even be afflicted by the control divergence when the machine is highly saturated, resulting in a useless drive. Moreover, even when the control converges, the actual current control trajectory is different from the given reference. In this paper, a measurement procedure of the convergence region, i.e. the operating points where the motor can be successfully controlled without a position sensor is presented and validated. In particular, two different synchronous motors are considered, a permanent magnet assisted synchronous reluctance motor (PMA-SynRM) and a synchronous reluctance motor (SynRM).

A comparative study of electric motor for low-power density electric vehicles.

Due to the price uncertainty of rare-earth PM materials and limited availability around the globe, it is required to think about new electric motor candidate for automotive industries. According to the literature survey, it is observed that PMBLDC is the widely used in automotive industry for low power applications. There are some noticeable limitations reported with this motor such as high cost of PM, demagnetization, and complex control. Based on the comparative analysis of three motors, i.e., Synchronous Reluctance Motor (SynRM), Permanent Magnet Synchronous Motor (PMSM), and PM-assisted Synchronous Reluctance Motor (PMASynRM) through Finite Element Method (FEM) for the same design parameters, it is concluded the proposed alternative is a PMASynRM. As per the research gap findings, authors have designed the PMASynRM for low-power EV applications with novel rotor geometry. The simulation results of FE analysis validate the proposed motor design for the various performance parameters.

Modifications to PM-Assisted Synchronous Reluctance Machine to Achieve Rare-Earth Free Heavy-Duty Traction

Automotive applications require electrical machines designed for high torque density, wide speed range, and low cost. NdFeB magnets can achieve a high torque density and wide speed range, and however, they have a high cost. Therefore, this article explores the capability of rare-earth-free (REF) design through a PM-assisted synchronous reluctance (PM-SynRel) motor. A PM-SynRel design with NdFeB has been used in this study where the NdFeB magnets have been replaced with ferrite magnets. Then, several modifications on the rotor have been made to ensure mechanical safety. Thermal analysis has been conducted last to evaluate the temperatures in the different machine parts to avoid exceeding the required limits. Finally, a prototype has been made and tested to validate the simulation results.

Design of Permanent Magnet-Assisted Synchronous Reluctance Motor with Low Torque Ripple

Permanent magnet-assisted synchronous reluctance motors (PMSRMs) have been widely used in household appliances, national defense and the military, due to their advantages of low cost and high efficiency. However, their excessive torque ripple cause a series of problems, such as high vibration and noise. To solve this problem, this paper first considers the important factor that causes the torque ripple—the cogging torque. Firstly, the generating principle of the cogging torque is analyzed, and a method combining magnetic pole migration and the stator auxiliary groove is proposed. On this basis, considering the position, width, depth, quantity and shape of the auxiliary groove, the Taguchi method is used to optimize the proposed improved structure. Finally, a new motor structure that can minimize torque ripple is obtained. Compared with the original structure, the cogging torque is reduced by 57.6%, the torque ripple is reduced by 38%, and the electromagnetic torque is only reduced by 1.6%.

Design and Experimental Performance Assessment of an Outer Rotor PM-Assisted SynRM for the Electric Bike Propulsion

Brushless dc motor (BLDCM) is a conventional machine type used in the electric bike (e-bike) industry due to its simple controllability and drive system. However, the fluctuating price and scarcity of NdFeB magnets used in BLDCMs, lower power density compared to ac machines, and high torque ripple have pushed researchers in industry and academia to investigate technology alternatives to BLDCMs in e-bike applications. Permanent magnet-assisted synchronous reluctance motor (PMaSynRM) is an attractive option to this end because of its adjustable reluctance torque component and the recent advancements in finite-element (FE)-based design algorithms and implementation. Not yet covered in the existing literature and industry reports for e-bike applications, an in-hub outer rotor PMaSynRM is designed in this article to improve the power density and reduce the torque ripple characteristics for replacing a 500-W commercial BLDCM. The designed PMaSynRM is fabricated and tested to validate the power density and torque ripple improvements compared to an existing Golden Motor MP2 BLDCM counterpart.

Intelligent Computed Torque Control With Recurrent Legendre Fuzzy Neural Network for Permanent-Magnet Assisted Synchronous Reluctance Motor

The goal of this research is to develop an intelligent controlled permanent-magnet assisted synchronous reluctance motor (PMASynRM) drive system by utilizing an intelligent computed torque control with recurrent Legendre fuzzy neural network (ICTCRLFNN), in order to adjust the nonlinear and time-varying control specifications of the motor. The team first proposes an ANSYS Maxwell-2D dynamic model that contains a maximum torque per ampere (MTPA) control PMASynRM drive. A lookup table (LUT) is composed of the finite element analysis (FEA) results, which bring about the current angle of command within the MTPA. Subsequently, the team designs a computed torque control (CTC) system to control the speed reference command. Creating a working CTC for practical applications is quite complex because the detailed system dynamics, which includes the unpredictability of the PMASynRM drive system, is not available beforehand. Thus, this study suggests that a recurrent Legendre fuzzy neural network (RLFNN) can act as a close substitute for the CTC to resolve its existing complications. Furthermore, the team modifies an adaptive compensator to proactively adjust for the potential calculated deviance of the RLFNN. Asymptotical stability is assured by using the Lyapunov stability method, which generates the RLFNN’s online learning algorithms. This study concludes that certain experimental results verify the effective and robust qualities of the suggested ICTCRLFNN controlled PMASynRM drive.