Permanent Magnet Brushless DC Motor Research Articles

Performance Analysis of Permanent Magnet BLDC Motor for Reducing Cogging Torque Using Taguchi Method

An electric motor is an electromagnetic machine commonly utilized across various industries and automotive products. One prevalent type of electric motor employed in electric vehicles is the Permanent Magnet Brushless DC Motor (PM-BLDC), a brushless motor employing permanent magnets. However, despite its efficiency, permanent magnet motors often experience vibrations that can disrupt their performance. This research aims to optimize the existing BLDC motor design, with a specific focus on reducing the existing cogging torque. Initially, the existing design exhibited a cogging torque level of 0.21482 Nm. The optimization process involved modifications to several key design parameters, such as air gap, magnet thickness, magnet type, and slot opening width. In previous research, only comparisons were made between stator slot designs, which proved to be less effective as significant differences were not evident in the results of the comparative analysis of BLDC motor designs. So, in this research, the Taguchi method was utilized for the optimization process due to several advantages it offers. Through an analysis of means and variance, the optimization process successfully achieved a significant reduction in cogging torque by 0.099744 and an increase in efficiency by 0.6%. The results of the optimized permanent magnet BLDC design indicated a cogging torque value of 0.115072 Nm and an efficiency of 86.64% at an operational motor speed of 1500 rpm. This research provides a substantial contribution to the development of more efficient electric motors suitable for various applications.

Comparative assessment of a novel 8/18 multi-teeth with conventional 8/10 in-wheel SRM for an E-Scooter

Electric scooters are increasingly gaining popularity in India owing to rising global crude oil prices and rising levels of vehicular pollution. Most of them are currently powered by expensive in-wheel (IW) permanent magnet (PM) brushless DC motors. Owing to their simplicity, and ruggedness while being cost-effective (since they do not employ PMs), switched reluctance motors (SRMs) are a viable alternative. Despite these benefits, SRMs possess drawbacks such as low torque density and inferior efficiency. Recently, a multi-teeth (MT) SRM with an improved performance was reported. However, the design of MTSRM topologies and their electromagnetic performance have not been explored sufficiently. In this paper, a design formula governing the selection of the number of MT and rotor poles for MTSRMs has been proposed. Using this, a novel four-phase 8/18 IW-MTSRM is derived and proposed for an E-scooter. The characteristics of the proposed SRM are numerically compared with a conventional 8/10 SRM based on magnetic characteristics, efficiencies and steady-state operation for the complete torque-speed range. Results indicate that the proposed 8/18 MTSRM has a higher peak torque capacity, torque density, superior drive cycle efficiency and reduced torque ripple. Further, the FEA model is validated experimentally on a downsized 8/18 MTSRM prototype.

Performance and Analysis of PMBLDCM Drive using A Single-Stage PFC Half-Bridge Converter

Because of their excellent torque-to-weight ratio, small size, and great efficiency, Permanent Magnet Brushless DC Motors are widely used in a variety of applications. A buck half-bridge DC-DC converter acts as a single-stage PFC for a VSI-driven PMBLDCM powering an air conditioner's compressor. The PFC converter is fed from a single-phase AC main via a diode bridge rectifier. The VSI controls the PMBLDCM speed by adjusting the DC link voltage proportionally. The VSI functions solely as a commutator for the PMBLDCM, with stator current controlled by a rate limiter for speed changes. The PMBLDCM drive, incorporating a voltage-controlled PFC converter, is constructed, modeled, and simulated using the MATLAB-Simulink platform for an air conditioner compressor application. The system utilizes a 1.5 kW, 1500 rpm PMBLDC motor. Evaluation outcomes of the speed control strategy exhibit enhanced efficiency across a broad speed spectrum, showcasing the benefits of the drive system's integrated PFC functionality. Key Words: permanent magnet brushless DC motor, power factor correction converter, electrical drives.

Radial basis function‐based Pareto optimization of an outer rotor brushless DC motor

AbstractThis paper presents the development of an optimization and modeling method for the objective functions of output power, efficiency and weight of an outer rotor permanent magnet brushless DC (BLDC) motor based on radial basis function (RBF) approximation technique. The proposed RBF‐based Pareto optimization method requires less knowledge about electric/magnetic formulas and can replace conventional optimizations based on these equations with higher accuracy. To apply the proposed optimization method, the initial design should be developed using such equations. Therefore, RBFs are used to model and predict engine behavior. To optimize the objective functions, we used a genetic algorithm optimization technique with nonlinear electric and magnetic constraints to find the Pareto front set. The design obtained by the proposed radial basis function Pareto optimization (RBFPO) method was finally verified by Ansoft Maxwell. The results of optimal design using the RBFPO method have higher output power and efficiency. Also, in addition to the advantage of a favorable accuracy, RBF‐based models are significantly faster than models available in simulation tools.

Winding Design and Lead-angle Control for the Maximum Speed of an Interior Permanent-Magnet Brushless DC Motor

Winding Design and Lead-angle Control for the Maximum Speed of an Interior Permanent-Magnet Brushless DC Motor

Analysis of electromagnetic performance of the interior permanent magnet brushless DC motor with stator slot skewed structure based on quasi-3D moving electromagnetic-field circuit coupling calculation

Analysis of electromagnetic performance of the interior permanent magnet brushless DC motor with stator slot skewed structure based on quasi-3D moving electromagnetic-field circuit coupling calculation

Design and Co-Analysis of A Permanent Magnet Brushless DC Motor By Using Clonal Selection Principle Based Wound Healing Algorithm and Ansys-Maxwell

This paper presents the design and analysis of a 550 W Permanent Magnet (PM) Brushless DC motor (BLDC). The finite element method (FEM) was employed to assess the motor's performance characteristics. The design and dynamic performance analysis were conducted using ANSYS/Rmxprt, while electromagnetic studies were carried out using ANSYS/Maxwell-2D. Additionally, optimization of the DC motor was achieved through a Wound Healing Algorithm (WHA). A PID controller was designed for this purpose. The paper also elaborates on the detailed design equations for creating a BLDC motor. BLDC motors are known for their high dynamic responses, efficiency, extended operating life, wide speed change intervals, and noise-free operation. The motor's geometry was modeled in the ANSYS-Maxwell-Rmxprt software tool and later imported into the Maxwell-2D environment for further analysis. The designed motor was observed to operate with 93% efficiency, meeting the specified torque value. The results of the optimization process were interpreted by comparing them with the values obtained from the ANSYS software.

Investigation of Various Laminating Materials for Interior Permanent Magnet Brushless DC Motor for Cooling Fan Application

Investigation of Various Laminating Materials for Interior Permanent Magnet Brushless DC Motor for Cooling Fan Application

Continuous Fast Terminal Sliding Surface-Based Sensorless Speed Control of PMBLDCM Drive

Variable frequency drives (VFDs) have been used for position sensors for many years. Alternatively, reliable VFDs for smart autonomous systems require the simultaneous configuration of sensors and sensorless operation. This paper details the design and implementation of a continuous fast terminal (CFT) sliding mode controller (SMC) based speed controller and speed estimation through the CFT sliding mode observer (SMO) that accounts for iron loss while calculating total disturbances. The rotor speed dynamics of the PM brushless DC motor (PMBLDCM) drive system is first investigated considering lumped disruption (interference, parametric complexity, and non-linear dynamics). The built-in SMC can control the rotor speed in real time, as well as analyze and compensate for aggregated interruptions in rotor speed dynamics. Additionally, the field-oriented control (FOC) method is developed to maximize torque production while drastically minimizing torque ripples. With this approach, the zero torque pulsation constraint is gradually achieved at a wide speed range. The validation of the proposed CFT-SMC with FOC is carried out using simulation and experiments. According to the comparative study, the proposed sensorless control outperforms conventional methods due to the inclusion of iron loss.

An Adaptive Delay Compensated Position Sensorless PMBLDC Motor Drive With Regenerative Braking for LEV Application

This paper deals with a new terminal voltage-based rotor position sensorless algorithm of permanent magnet brushless DC (PMBLDC) motor with adaptive phase angle compensation along with regenerative braking technique for light electric vehicle (LEV) application. Removal of Hall-Effect sensors from PMBLDC motor reduces the circuit complexity and makes the motor drive system robust and compact. Back EMF based position estimation of PMBLDC motor suffers poor accuracy at low speed. In this paper, position sensorless operation is achieved at very low speed below 100rpm. Position estimation of PMBLDC motor suffers with commutation error due to several factors like non-ideal back EMF, lowpass filter used, unbalanced DC bus voltage etc. An adaptive phase angle compensation strategy is developed to mitigate this issue, considering a generalized nonideal commutation case. This method is suitable for compensation of commutation error during variable speeds over a wide speed range, which is required for EV application. Moreover, the compensation method works with motor parameters variation as well. The proposed drive topology extends the vehicle's driving range with solar PV integration and energy regeneration algorithm. The system is simulated and experimentally validated in real case scenarios.

Parametric Observer Controlled Motor Invariant Electronic Commutation of Photovoltaic Powered BLDCM Without Position Sensor

The development of parameter independent position sensor free control of permanent magnet brushless DC (PMBLDC) motor is one of the most challenging tasks. A motor parameter independent parametric observer based electronic commutation control is developed here without using rotor position sensor. The effect of motor parameter variation along with the change of motor, on electronic commutation control without using the rotor position sensor is considered as the disruption parameter for the developed control algorithm to mitigate the external disruption. Mitigation of control loop disturbances is done using the parametric observer based feedback control. A hybrid maximum power extraction algorithm using traverse and incremental conductance is implemented here for effective solar maximum power extraction. The implemented parametric observer motor invariant (POMI) based position sensor free control algorithm is verified using experimental process. Performance of the implemented POMI control is observed better in performance in comparison with the conventional position sensor free control as parametric variation is not considered in conventional control. The solution proves to be the best fit for any type of BLDC motor based water pumping solution irrespective of the pump configuration.

Torque ripples enhancement of a PMBLDC motor propelled through quadratic DC–DC boost converter at varying load

The characteristic effects of a permanent magnet brushless dc (PMBLDC) motor which is propelled by a quadratic DC–DC boost converter was investigated in this paper. The boost converter applied inductor coupling with semi-conductor switches which operate concurrently to produce a high conversion voltage ratio. Modeling of the PMBLDC motor was presented while simulation was performed using a closed loop control system with different controllers for the enhancement of torque–speed performance at varied load. Simulation results show that an optimum voltage gain with minimum voltage stress was achieved at 0.9 duty cycle while varying the inductor turns ratio (n) from 1 to 6 and inductor coupling coefficient (K) from 0.1 to 1.0 so as to ensure that the entire flux generated in one coil is fully linked to the other. A simplified PI controller was designed and experimented through simulation for excellent drive performance at varying load. The results from the spectral display show that the usual speed oscillation and torque ripples produced by the machine were attenuated using different speed controllers. The Total Harmonic Distortion (THD) values indicate that the PID controller achieved a minimal value of 24.06% for speed and 23.16% for torque as compared to 28.73% and 29.82% obtained from the PI controller, while the P controller achieved 41.88% and 35.67% as shown in the graphical abstract.

Performance analysis of PID controller-based metaheuristic optimisation algorithms for BLDC motor

ABSTRACT Today, the use of permanent magnet brushless DC (PMBLDC) motors in vehicles is increasing due to the characteristics of sensorless operation. PMBLDC motor controllers can control the speed and position in the closed-loop feedback system without the need for a position sensor mounted on the shaft. Proportional – Integral – Derivative (PID) controller is one of the most common feedback control algorithms used in PMBLDC motor controllers. Optimizing problems using deterministic methods such as Lagrange and simplex methods requires basic information and complex calculations. Meta-heuristic algorithms are a type of stochastic algorithm that is used to find the optimal solution. Meta-heuristic algorithms are divided into three general categories: evolutionary algorithms, swarm intelligence algorithms, and stochastic algorithms. In this paper, using 14 metaheuristic optimisation algorithms, PID control parameters including settling time, time rise, overshoot, and stability of step response of the mentioned system are optimised. In this paper, 14 meta-heuristic algorithms are simulated and evaluated to optimise the PID coefficients of the controller, including settling time, rising time, excessive increase, and step response stability. The simulation result shows that the genetic algorithm (GA) has the best performance in terms of cost function and biogeography-based optimisation (BBO) in terms of settling time and rising time parameters. Finally, the simulation results are confirmed using experimental results.

Design and Analysis of a Permanent Magnet Brushless DC Motor in an Automotive Cooling System

Conducting excellent thermal management of a new electric vehicle motor drive system may enhance the operational efficiency of the motor drive and minimize its pollutant emissions and energy losses. As an important part of the motor thermal management system, it is necessary to improve the design of the drive motor for the fan. This paper presents the design of a 12s-10p permanent magnet brushless DC motor with a rated speed of 2200 rpm and a rated voltage of 12 V based on finite element analysis. At this rated speed, the maximum torque the motor can output is 1.80 N·m. Then, we calculated the loading capacity of the motor by parameterizing the resistance in the circuit. We have built a prototype based on the design results and built a test bench to test the loading capacity of the prototype. A comparison revealed that the error between the experimental and calculated results was small. Accordingly, it is believed that this work is capable of serving as a theoretical guide for the design and manufacture of automotive cooling fans in the future.

A Comprehensive Investigation of Winding Eddy and Circulating Current Losses of Stator Iron Coreless PMBLDC Motors

A method is proposed to comprehensively study the eddy and circulating current losses of stator winding wound by multiple parallel strands, to further improve the power density of stator iron coreless permanent magnet brushless DC (PMBLDC) motors. Analytical models of the eddy and circulating current losses in stator winding are deduced firstly to explicitly express the influencing factors of these two losses. As is shown, these factors are mutually contradicting. While the eddy current loss can be greatly reduced by using multiple parallel conductor strands, the circulating current loss will be extensively increased. The factors influencing these two winding losses, such as the strand diameter, magnetization types, and rotating speed, are investigated. A prototype of stator iron coreless PMBLDC motor without an inner rotor core is manufactured and tested to validate the theory. The experimental results of winding eddy and circulating current losses with different combinations of strand diameters and parallel numbers agree well with the theoretical results.

Hybrid Optimization Approach for Improved Efficiency in Permanent Magnet Brushless DC Motor Design: Combining Cauchy Particle Swarm & Moth Flame Methods

This article proposes a novel design strategy for a PMBLDC motor through hybrid optimization, combining Cauchy Particle Swarm Optimization and Moth Flame Optimization approaches to find the optimal set of design parameters that yield the highest efficiency. The motivation is to improve the efficiency of PMBLDC motors, which are widely used in electric cars and renewable energy systems that place a premium on minimal power usage. The proposed work implements the hybrid optimization technique performs conventional single optimization strategies in terms of efficiency improvement. This study contributes in identifying the optimal values for the various design parameters of PMBLDC motors using the hybrid CPSO-MFO approach, which converged to the optimal design parameters. The performance of the PMBLDC motor was evaluated using the optimal design parameters, with an overall power loss of 49.1 W, and an efficiency of 97.88%. The study’s results provide valuable insights for design engineers into the optimal geometrical parameters of PMBLDC motors to achieve higher efficiency and lower power loss. The proposed novel hybrid optimization approach, which is faster and more efficient than conventional single optimization approaches, making it a useful tool for designing high-performance PMBLDC motors.

Optimal design of brushless DC motor for electromobility propulsion applications using Taguchi method

Abstract This paper presents the optimal design of the permanent magnet brushless DC (BLDC) motor for electromobility propulsion applications. Two BLDC machines were analyzed: (a) – exterior rotor machine, and (b) – interior rotor machines The optimization of both motors structures was executed by the Taguchi method. The device structure was described by three design variables. The functional parameter (efficiency) and the economic parameter (total mass of the permanent magnets) were included in the objective function. The BLDC motors have been modelled using a finite element method (FEM). Finally, the functional parameters for both motor constructions were compared. The selected results of the calculations were presented and discussed.

Simulation Approach for Torque Ripple Minimization of BLDC Motor

This project presents the design and implementation of neural network controller for reducing torque ripples in permanent magnet brushless DC (PMBLDCM) motor drive with trapezoidal back-emf. The performances of the proposed neural network controller are compared with the corresponding fuzzy PI controller and conventional PI controller. Simulation results are used to show the abilities and shortcomings of the proposed speed regulation scheme for brushless dc motor which is considered as a highly nonlinear dynamic complex system. Matlab/Simulink software was used to simulate the proposed model. Buck-boost converter connected in between the input DC source and three phase bridge inverter, used for minimizing the commutation torque ripples in Permanent Magnet Brushless DC Motor is presented in this paper. Torque during the commutation period depends on phase current which is not undergoing commutation, so by controlling it, torque ripple can be minimized. Moreover, a greater DC link voltage is needed during the commutation time period in comparison to the normal conduction period. The Buck-boost converter operates in boost mode in commutation period for stepping up the DC voltage to the inverter. A simple mode switching circuit is employed to amend the output modes of the Buck-boost converter in normal and commutation time intervals. Simulation studies of this topology are carried out in MATLAB/Simulink environment. Index Terms – Permanent Magnet Brushless DC Motor (PMBLDCM), Buck-boost Converter, Commutation Time period,PI Controller.

Hybridized GWO-RUN optimized fractional order control for permanent magnet brush-less dc motor

The permanent magnet brush-less dc motor is a nonlinear, multivariable structure and magnetic coupled system wherein the load disturbances and the parameter uncertainties adversely affect the dynamic performance. From this, it required that the designed controller for the system must deal with the complexities. The objective of this paper is to introduce a novel fractional order proportional-integral controller for permanent magnet brush-less dc motor dealing with set parameter tracking problem. In this paper, in order to find the needed optimal gain parameters combination of metaheuristic and numerical optimization algorithm called Grey Wolf-Runge–Kutta algorithm is proposed. The efficacy of the proposed technique is demonstrated by comparing it with existing optimization technique viz. particle swarm, grey wolf, and Runge–Kutta algorithm. Furthermore, the stability and robustness analysis for the proposed controller is also studied for different operating conditions such as set speed variations, load disturbances and parameter variations. The simulation is performed using MATLAB toolbox. From the simulation results it is evident that FOPI controller optimized with novel hybrid algorithm guarantee the best set speed tracking and also capable to ameliorate the system robustness for parameter variations as well as external load disturbances.

Design and Simulation Analysis of Stator Slots for Small Power Permanent Magnet Brushless DC Motors

With the development of power electronics technology, permanent magnet brushless DC motors have developed rapidly and are now widely used in electric vehicles, flywheel energy storage, rail transit, and other applications. The stator slot structure is one of the main factors affecting the performance of the motor. A low-power permanent magnet brushless DC motor was selected as the research object, and the finite element analysis method was used to study the effects of different slot and pole combinations and stator slot types on the cogging torque, reluctance torque, and back electromotive force of the permanent magnet brushless DC motor. The influence of the stator slot structure of the motor on the performance of the motor was analyzed, and the optimal slot-pole combination and stator slot type were determined. The results showed that the cogging torque of the 2-stage 24-slot motor was 14 mN·m, and the reluctance torque was 75 mN·m. The cogging torque and reluctance torque were the smallest, and the back electromotive force waveform was similar to a trapezoidal wave. The motor cogging torque of the pear-shaped round slot was the smallest, with a value of 460 mN·m, and the motor reluctance torque of the pear-shaped trapezoidal slot was the smallest, with a value of 1.2 N·m. The back electromotive force waveforms of the motors with four different stator slot types were similar.