Surface-mounted Permanent Magnet Synchronous Motor Research Articles

Unraveling Magnet Structural Defects in Permanent Magnet Synchronous Machines—Harmonic Diagnosis and Performance Signatures

Rare-earth-based permanent magnets (PMs) have a vital role in numerous sustainable energy systems, such as electrical machines (EMs). However, their production can greatly harm the environment and their supply chain monopoly presents economic threats. Alternative materials are emerging, but the use of rare-earth PMs remains dominant due to their exceptional performance. Damage to magnet structure can cause loss of performance and efficiency, and propagation of cracks in PMs can result in breaking. In this context, prolonging the service life of PMs and ensuring that they remain damage-free and suitable for re-use is important both for sustainability reasons and cost management. This paper presents a new harmonic content diagnosis and motor performance analysis caused by various magnet structure defects or faults, such as cracked or broken magnets. The proposed method is used for modeling the successive physical failure of the magnet structure in the form of crack formation, crack growth, and magnet breakage. A surface-mounted permanent magnet synchronous motor (PMSM) is studied using simulation in Ansys Maxwell software (Version 2023), and different cracks and PM faults are modeled using the two-dimensional finite element method (FEM). The frequency domain simulation results demonstrate the influence of magnet cracks and their propagation on EM performance measures, such as stator current, distribution of magnetic flux density, back EMF, flux linkage, losses, and efficiency. The results show strong potential for application in health monitoring systems, which could be used to reduce the occurrence of in-service failures, thus reducing the usage of rare-earth magnet materials as well as cost.

Optimal Design of High Specific Power Electric Machines for Fully Electric Regional Aircraft: A Case Study of 1MW S-PMSM

The aviation industry is undergoing electrification due to the increased global focus on reducing emissions in air traffic. Regarding the volatility of raw material prices, one main objective is the increase in the specific power of the motor. This matches the ambitious targets of the CoE project (Center of Excellence) in Finland on high-speed electric motors. The targeted specific power is 20 kW/kg. In this work, motors are designed and optimized for a fully electric regional aircraft. motors with different slot/pole configurations and rotational speed values are studied to determine the advantage of increasing speed in terms of weight reduction. As increasing speed requires the use of a gearbox, the overall weight of the motor and the gearbox is evaluated in post-processing, which allows for determining the impact of high speed on the overall weight. An optimization tool coupled with an electromagnetic and mechanical analysis is used to optimize 1 MW surface mounted permanent magnet synchronous motors (S-PMSMs) for given specifications of regional electric aircraft. Optimization results indicate that there is considerable gain in terms of overall weight only when increasing the speed to the range of 10,000–15,000 rpm.

Fast Terminal Synergetic Speed Control for SMPMSM Drive System

For the surface‐mounted permanent magnet synchronous motor (SMPMSM) drive system, a fast terminal synergetic speed control (FTSSC) is proposed to improve its speed dynamic performance and robustness. In the proposed control scheme, the ultra‐local model of SMPMSM drive system, which considers motor parameter uncertainties and unknown disturbances, is set up based on the algebraic parameter identification method. Then, the nonlinear terminal manifold is designed to achieve speed rapid convergence in finite time, moreover, the fast synergetic speed control law that satisfies the voltage and current constraints of SMPMSM drive system is derived. Meanwhile, the Lyapunov function is designed to prove the stability of the proposed fast terminal synergetic speed‐controlled SMPMSM drive system. Finally, the effectiveness and feasibility of proposed control is verified through the experimental research of SMPMSM drive system. © 2024 Institute of Electrical Engineers of Japan and Wiley Periodicals LLC.

Mechanism and Characteristics of Cogging Torque in Surface-Mounted PMSM: A General Airgap Field Modulation Theory Approach

Mechanism and Characteristics of Cogging Torque in Surface-Mounted PMSM: A General Airgap Field Modulation Theory Approach

Design of a six-phase surface mounted permanent magnet synchronous motor with application to electric trucks

As we have known, permanent magnet synchronous motors (PMSMs) have garnered widespread interest across various industrial applications thanks to their advantages such as high efficiency, reliable performance, simple structure, and adaptability to various shapes and sizes. Due to characteristics of the high torque and low speed, the PMSMs make particularly well-suited for traction applications such as trucks, ship propulsion, mining, and more. In this context, a combination of the analytical method and finite element method (FEM) is proposed for designing and simulating a six-phase surface-mounted PMSM. Firstly, a model of the six-phase PMSM is analytically design to make required/main dimensions. The FEM is then applied to analyse and verify electromagnetic parameters such as of the current waveform, back electromagnetic force (EMF), magnetic flux density in the air gap, flux linkage, torque, cogging torque, torque ripple and harmonic components. Via the obtained results, the research will give a contribution of valuable insights for optimizing the design, performance and reliability for this motor in diverse industrial applications.

Speed harmonic suppression of PMSM and its application in ball screw vibration suppression

Abstract The speed ripple of surface-mounted permanent magnet synchronous motor (SPMSM) causes vibration of the ball screw, which degrades the accuracy and stability of the ball screw system.The harmonic injection method can suppress the speed ripple by decreasing the speed harmonic of SPMSM. When the speed ripple is suppressed, the vibration of the ball screw is also reduced.
However, large amount of calculation, complex parameter adjustment, and long suppression time limit its performance in suppressing vibration of ball screw. Therefore, in this paper, we propose a speed harmonic suppression method based on the online measurement of the transfer function from inject voltage harmonic to speed harmonic. In the proposed method, the transfer function is measured after the motor reaches a stable operating condition. And then, the designed speed harmonic controller parameters are set according to the measurement results. Compared with the existing method, the method based on online measurement has less calculation, simple parameter adjustment, fast suppression speed, and good performance in suppressing the vibration of ball screw. Experimental verifications are carried out in the forward and backward condition of the ball screw.

Full-speed domain position sensorless control strategy for PMSM based on a novel phase-locked loop

This paper proposes a full-speed-domain position-sensor-less control strategy for precise control under forward and reverse rotation conditions to address the weak convex polarity of surface-mounted permanent magnet synchronous motor (SPMSM). The strategy comprises several key stages: pre-positioning of the rotor, constant current variable frequency (I/F) start-up, construct the Luenberger State Observer, and utilization of an improved phase-locked loop (PLL) for position estimation. In the pre-positioning stage, a constant amplitude current is applied to drag the rotor to a predetermined position. Subsequently, the I/F start-up stage accelerates the motor to a predetermined speed before transitioning to the Luenberger observer for closed-loop speed control, which is based on an extended back electromotive force (back-EMF) a two-phase rotating coordinate system. The improved PLL for position and speed estimation features three components: a phase discriminator (PD), a voltage-controlled oscillator (VCO), and loop filter (LF). Experimental results demonstrate the efficacy of the proposed strategy, showing quick start-up response, speed estimation error below 2 RPM, rotor position estimation error under 0.6 degrees post-loop closure, stable tracking during rapid speed changes, and consistent accuracy and stability even under reverse rotation conditions, thereby meeting the control strategy’s objectives.

Optimal Design of Surface-Mounted Permanent Magnet Synchronous Motors for Robotic Joint Actuation Using Multi-Objective Function Optimization

Optimal Design of Surface-Mounted Permanent Magnet Synchronous Motors for Robotic Joint Actuation Using Multi-Objective Function Optimization

Hardware-in-the-loop Simulation for Speed Control of Surface-mounted Permanent Magnet Synchronous Motor with Field-weakening Functionality

Hardware-in-the-loop Simulation for Speed Control of Surface-mounted Permanent Magnet Synchronous Motor with Field-weakening Functionality

Sensorless Capability Expansion for SPMSM Based on Inductance Parameter Identification

Pulsating high-frequency voltage injection can be used for the sensorless control of a surface-mounted permanent magnet synchronous motor (SPMSM) at zero- and low-speed ranges. However, the sensorless capability still faces challenges to the requirements of industrial application, especially at heavy load status. Aiming at this issue, this article proposes a sensorless capability expansion method for an SPMSM based on inductance parameter identification. Firstly, incremental inductances at the d-q-axis and cross-coupling inductance are identified offline by three steps combining the rotating high-frequency voltage injection and pulsating high-frequency voltage injection. Using a polynomial curve fitting algorithm, apparent inductances are calculated. Secondly, positive DC current injection at the d-axis is proposed to enhance the saliency ratio based on the analysis of parameter identification results. Compared with the conventional id = 0 or id < 0 method, the saliency ratio is enhanced obviously when a positive DC current is injected at the d-axis. Then, the convergence region of the sensorless control method at heavy load status is expanded and the accuracy of rotor position estimation is improved using the proposed method. Finally, the experimental results validate that the sensorless capability of the SPMSM is expanded.

A Reliable and Efficient I-f Startup Method of Sensorless Ultra-High-Speed SPMSM for Fuel Cell Air Compressors

Extended back electromotive force (EEMF)-based position sensorless field-oriented control (FOC) is widely utilized for ultra-high-speed surface-mounted permanent magnet synchronous motors (UHS-SPMSMs) driven fuel cell air compressors in medium-high speed applications. Unfortunately, the estimated position is imprecise due to too small EEMF under low speed operation. Hence, current-to-frequency (I-f) control is more suitable for startup. Conventional I-f methods rarely achieve the tradeoff between startup acceleration and load capacity, and the transition to sensorless FOC is mostly realized in the constant-speed stage, which is unacceptable for UHS-SPMSM considering the critical requirement of startup time. In this article, a new closed-loop I-f control approach is proposed to achieve fast and efficient startup. The frequency of reference current vector is corrected automatically based on the active power and the real-time motor torque, which contributes to damping effect for startup reliability. Moreover, an amplitude compensator of reference current vector is designed based on the reactive power, ensuring the maximum torque per ampere operation and higher efficiency. Furthermore, the speed PI controller is enhanced by variable bandwidth design for smoother sensorless transition. These theoretical advantages are validated through experiments with a 550 V, 35 kW UHS-SPMSM. The experimental results demonstrated the enhanced startup performance compared with conventional I-f control.

Position sensorless extended and unscented Kalman filters with permanent magnet flux linkage and load torque estimation for surface-mounted PMSM

In this paper, novel position sensorless state estimators with improved robustness to permanent magnet (PM) flux linkage variations in permanent magnet synchronous machines (PMSMs) are presented. Unlike state estimators using conventional infinite inertia or electromechanical models, the estimators presented here can also estimate the PM flux linkage, so they are not sensitive to its uncertainty. For each models used for state estimation, a detailed observability study is presented. Due to the nonlinear models, extended and unscented Kalman filter algorithms are used for the implementation. To compare the sensitivity of conventional and proposed state estimators to uncertainty in electrical parameters, numerical simulations are carried out. In addition, the computational burden of the estimators is compared by real-time execution.

Multiphysics performance of surrogate models on skewed pole surface-mounted permanent magnet motors

PurposeEvaluating the multiphysics performance of an electric motor can be a computationally intensive process, especially where several complex subsystems of the motor are coupled together. For example, evaluating acoustic noise requires the coupling of the electromagnetic, structural and acoustic models of the electric motor. Where skewed poles are considered in the design, the problem becomes a purely three-dimensional (3D) multiphysics problem, which could increase the computational burden astronomically. This study, therefore, aims to introduce surrogate models in the design process to reduce the computational cost associated with solving such 3D-coupled multiphysics problems.Design/methodology/approachThe procedure involves using the finite element (FE) method to generate a database of several skewed rotor pole surface-mounted permanent magnet synchronous motors and their corresponding electromagnetic, structural and acoustic performances. Then, a surrogate model is fitted to the data to generate mapping functions that could be used in place of the time-consuming FE simulations.FindingsIt was established that the surrogate models showed promising results in predicting the multiphysics performance of skewed pole surface-mounted permanent magnet motors. As such, such models could be used to handle the skewing aspects, which has always been a major design challenge due to the scarcity of simulation tools with stepwise skewing capability.Originality/valueThe main contribution involves the use of surrogate models to replace FE simulations during the design cycle of skewed pole surface-mounted permanent magnet motors without compromising the integrity of the electromagnetic, structural, and acoustic results of the motor.

Current Harmonics in Surface-Mounted PMSM Electrical Drive for Monitoring Torsional Vibrations

Current Harmonics in Surface-Mounted PMSM Electrical Drive for Monitoring Torsional Vibrations

Design of Fractional-Order Non-Singular Terminal Sliding Mode Observer Sensorless System for Surface-Mounted Permanent Magnet Synchronous Motor

A new sensorless speed control system for a fractional-order terminal non-singular sliding mode surface-mounted permanent magnet synchronous motor is proposed. The fractional terminal non-singular sliding mode surface, which can converge in finite time, is designed by combining the fractional-order control theory with the terminal attractor concept. Then, a new control rate is proposed to reduce system buffeting. Secondly, an adaptive back electromotive force filter is designed to reduce the harmonics in the sliding mode function estimation and improve the observation accuracy. In addition, the theoretical analysis of the designed system proves that the system can converge in a finite time. Then, a fraction-order phase-locked loop with variable factors is designed to make the system more capable of tracking the rotor. Finally, a simulation and experiment platform is built, and a comparison experiment is carried out, which proves that the designed algorithm has a stronger rotor position tracking ability and a better dynamic performance of the system.

FCS-MPC for Three-Level NPC Inverter-Fed SPMSM Drives Without Information of Motor Parameters and DC Capacitor

The conventional finite control set-model predictive control (FCS-MPC) suffers from poor robustness against model mismatches. This paper presents an improved FCS-MPC with a reconstructed mathematical model to predict current variations without using a lookup table (LUT) or motor parameters. The model coefficients and current variations related to different voltage vectors can be updated during each control period. As a result, the prediction error is significantly reduced at low switching frequency when compared with the prior LUT-based model-free predictive current control (MFPCC). Additionally, the tracking accuracy of the proposed method at high speeds is improved due to the elimination of approximation error. Furthermore, a simple scheme is developed to suppress neutral-point-potential drift without knowledge of the dc-bus capacitor. Simulation and experimental tests, along with comparisons with prior arts carried out on a three-level inverter-fed surface-mounted permanent magnet synchronous motor drive, confirm the superiority of the proposed method.

Improved Model Predictive Speed Control of a PMSM via Laguerre Functions

This paper proposes a model predictive speed control strategy for a surface-mounted permanent magnet synchronous motor by applying Laguerre functions. The model predictive controller (MPC) incorporates an integrator. A quadratic programming procedure is applied to solve the constrained optimization problem online. The paper also provides a solution for stability. The performance efficiency of the proposed scheme is validated by comparing the results with the performance of an optimal linear quadratic regulator, conventional state-space model predictive control, and a simple MPC algorithm with integral action. Extensive simulation results confirm the efficacy of the proposed scheme, showing that it achieves good steady-state performance while maintaining a fast dynamic response.

Sensorless Control of Surfaced-Mounted Permanent Magnet Synchronous Motor in a Wide-Speed Range

This paper delves into a comprehensive study of a wide-speed-range sensorless control approach for surface-mounted permanent magnet synchronous motors (SPMSMs). In the low-speed range, a novel high-frequency pulse voltage injection (HFPVI) method is introduced for rotor position estimation, which does not depend on motor saliency and is well-suited for SPMSMs. This method incorporates a second-order generalized integrator (SOGI) and a new modulation signal to enhance the accuracy of rotor position estimation. For medium-to-high speeds, an improved super-twisting sliding mode observer (STSMO) utilizing a continuous hyperbolic tangent function is proposed to mitigate chattering. Additionally, a new phase-locked loop (NPLL) is introduced to accurately obtain the rotor position. Furthermore, this paper designs an exponential weighted switching function to facilitate a smooth transition of the motor from the low-speed domain to the medium- and high-speed domains. The effectiveness and superiority of the proposed methods are validated through simulations and experiments conducted on an RTU-BOX platform. The rotor position estimation errors of the proposed new HFPVI method and the improved STSMO method under various operating conditions are both approximately 0.05 rad (2.8 elc·deg), and the SPMSM can switch smoothly from the low-speed range to the medium- and high-speed ranges.

Design and Optimisation of a 5 MW Permanent Magnet Vernier Motor for Podded Ship Propulsion

The evolution of electric propulsion systems in the maritime sector has been influenced significantly by technological advancements in power electronics and machine design. Traditionally, these systems have employed surface-mounted permanent magnet synchronous motors (PMSMs) in podded configurations. However, the advent of permanent magnet Vernier motors (PMVMs), which leverage magnetic gearing effects, presents a novel approach with promising potential. This study conducts a comparative analysis between PMVMs and conventional PMSMs at a power level of 5 MW for podded ship propulsion, with a particular focus on the impact of gear ratios (Gr). An objective function was developed that integrates motor dimension constraints and the power factor (PF), a critical yet frequently neglected parameter in existing research. The findings indicate that PMVMs with lower Gr have lower mass and cost compared to those with higher Gr and traditional PMSMs, at a PF level of 0.7, which is high for Vernier machines. Moreover, PMVMs with lower Gr achieve efficiencies exceeding 99%, outperforming both their higher Gr counterparts and conventional PMSMs. The superior performance of PMVMs is attributed to lower current density and reduced copper loss, which contribute to their enhanced thermal performance. These details are elaborated on further in the paper. Consequently, these findings suggest that PMVMs with lower Gr are particularly well suited for high-power maritime propulsion applications, offering advantages in terms of compactness, efficiency (EF), cost-effectiveness, and thermal performance.

Prediction of Electromagnetic Performance for IPMSM Based on Improved Analytical Model Considering Saturation Effects

Unlike surface-mounted permanent magnet synchronous motors (SPMSM), the rotor structure of interior permanent magnet synchronous motors (IPMSM) is irregular and relatively complex. This makes the analytical calculation for IPMSM quite complicated. Except for the use of some equivalent methods to make irregular permanent magnets (PMs) regular, existing subdomain models often cannot effectively and directly account for the complex rotor structure and cannot be easily applied to IPMSM. For this reason, an improved analytical model applicable to IPMSM is presented, studied, and developed in this article. First, a novel subdomain model division method is innovatively introduced. Complex rotor structure can be well accounted for. This not only facilitates the expression of vector potential and satisfies the establishment of subdomain model, but also recovers the original rotor topology to the maximum extent and effectively avoids many uncertainties and unreliability caused by over-equivalence. Afterwards, the magnetic equivalent circuit and equivalent surface current method are combined to fully consider the saturation effects of magnetic isolation bridges, rotor ribs, and cores. Model analysis accuracy is well guaranteed. Further, the precise subdomain method is investigated to achieve fast prediction of key electromagnetic performance. Both finite element analysis (FEA) and prototype experiment strongly highlight the validity of the improved analytical model. In addition, compared to FEA, the improved analytical model does not require tens of thousands of computation cells, which saves a lot of time and storage while ensuring the same prediction accuracy. This opens up unlimited possibilities for the design and optimization of IPMSM.