doi 10.

1515/ijeeps-2013-0072

International Journal of Emerging Electric Power Systems 2013; 14(5): 459465

Research Article
Javier de la Cruz, Juan M. Ramirez*, and Luis Leyva

Voltage THD Improvement for an Outer Rotor

Permanent Magnet Synchronous Machine
Abstract: This article deals with the design of an outer rotor
Permanent Magnet Synchronous Machines (PMSM) driven by
wind turbines. The Voltage Total Harmonic Distortion (VTHD)
is especially addressed, under design parameters handling,
i.e., the geometry of the stator, the polar arc percentage, the
air gap, the skew angle in rotor poles, the pole length and the
core steel class. Seventy-six cases are simulated and the
results provide information useful for designing this kind of
machines. The study is conducted on a 5 kW PMSM.
Keywords: electrical machines,
machines, power quality

permanent

magnet

*Corresponding author: Juan M. Ramirez, Department of Electrical

Engineering, Centro de Investigacion y Estudios Avanzados, Av del
Bosque 1145 Col El Bajio, Zapopan, Jalisco 45019, Mexico, E-mail:
jramirez@gdl.cinvestav.mx, jramirez1502@gmail.com
Javier de la Cruz: E-mail: jcruz@gdl.cinvestav.mx, Luis Leyva:
E-mail: Luis.Leyva@cts-design.com, Department of Electrical
Engineering, Centro de Investigacion y Estudios Avanzados, Av del
Bosque 1145 Col El Bajio, Zapopan, Jalisco 45019, Mexico

1 Introduction
The harmonic components are produced by distortions of
the magnetic field and the induced electromotive force in the
stator winding. This phenomenon reduces the rotating
machines efficiency and generates heat in the stator core,
noise and distortions in the output voltage waveform. Thus,
VTHD must be kept at the minimum possible value [1].
THD is usually used as a quality index to quantify the
distortion of a waveform [2], which is defined by the
IEEE-519 standard [3] to quantify the signals energy contained in all other signal components different from the
fundamental frequency.
The standard defines the way THD shall be computed,
q

PH
2
V
h2 h
THD
1
V1
where h is the index numbering the different harmonic
components contained in the signal under study. This article

study uses the first 19 components, H 19. Expression (1) is

used along the document to calculate the VTHD. The standard ANSY/NEMA MG 12003 [1] specifies that the VTHD of
the line-to-line open-circuit voltage must be less than 5%.
PMSMs are frequently used as generators in small wind
and mini-hydro turbines applications. Design engineers are
faced all the time to design generators that will provide
power quality, as much as possible, in terms of the VTHD.
Several authors have developed design methodologies
for the PMSM, but they do not always take the VTHD into
account. For example, Wang [4] presented an optimal
design of a PMSM, which minimizes losses and the
machines size. In Ref. [5] a model to reduce the peak
value of the PMSMs cogging torque is proposed. Design
consists in the asymmetrical position of permanent magnets
along the rotor having a reduction of about 5.8% in the
torque ripple. In Ref. [6] designs of PMSM using ferrite
magnets and NdFeB magnets are shown; furthermore, the
influences of the stator winding type and slots in the
machine operating characteristics are analyzed. They
demonstrated that ferrite magnet, to some extent, are used
to replace the NdFeB magnets.
Some authors have proposed design methodologies
trying to meet the VTHD reduction. Ming Jiang et al. [7]
studied the VTHD improvement in an inner rotor PMSM
having a polar arc percentage of 100%. The proposed
method consists of modifying the polar arc percentage
until the best VTHD is attained. Authors found that a
polar arc percentage of 81% renders a VTHD of 1.10%.
In Ref. [8], an outer rotor PMSM is studied and authors
propose to reach a commitment between the VTHD, the
number of poles and the skew angle they are assembled
in the outer rotor. The VTHD becomes 0.95% for an outer
rotor with 14 poles assembled with a 15 skew angle.
Reaching accuracy in this type of simulations is a complicated task due to the precise physical parameters of
materials are required, besides the correct machines geometry and the ability to use FEA and CAD software. If greater
accuracy is needed, the computational effort becomes bigger. In the sequel, the strategy followed to design PMSM is
summarized, emphasizing the more important aspects; a

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J. de la Cruz et al.: Voltage THD Improvement for an Outer Rotor PMSM

Figure 2 Outer rotor PMSM prototype.

Figure 1 Induced voltage on a 400 W PMSM prototype: actual and

simulated results.

previous experience on a 400 W synchronous machine indicates that the strategy becomes promising (Figure 2) [9].
Figure 1 shows simulation and actual results on the prototype. The maximum error between actual and simulated
results is around 4%.
In this article, a methodology for designing outer rotor
electric generators suitable for small wind turbines is proposed. Particularly, the main aim is the study of the VTHD
with respect to changes in the stators geometry (slot bottom diameter, yoke length, slot depth, teeth width and
outer opening of the slot) and the rotors geometry (polar
arc percentage, pole length and skew angle). The study
uses four different silicon steel foils for the stator construction. In total, 76 simulations are carried out in this study.

l
d
y

Figure 3 Outer rotor PMSM.

M agnets

2 Machine specifications
Using conventional methods, an outer rotor generator
for a wind turbine application is designed [10]. In this
case, the VTHD becomes 6.01%, which is out of specifications [2]. The parameters of this machine are summarized
in Table 1.
Table 1

Generator characteristics.

Nominal power
Poles
Stator slots
Phases
Cogging torque

5 kW
30
72
3
0.03 Nm

Rated speed
Structural elements
Material magnet
Core
VTHD

350 rpm
Steel SCM35
Neodymium N35
Silicon steel, M19
6.01%

Figure 2 shows a prototype of an outer rotor PMSM

coupled to an induction motor.
The main physical parameters of the stator and the
polar arc percentage are shown in Figure 3. Figure 4 illustrates the skew angle for the magnets mounted on the rotor.

Figure 4 Skew angle for the magnetic poles.

3 Methodology
The analysis starts by estimating the induced voltage in the
winding terminals of the generator. With this purpose the
Finite Element Analysis program from JMAG is used. The
induced voltage signal is then passed through a MatLab
FFT routine for obtaining all the frequency components
contained in the voltage signal. By these information and
from eq. (1) the VTHD is estimated (Figure 5).
The voltage induced per phase in winding of
machine can be calculated through the expression [10],
E

nt cp Cw S
60  108

2

where, t is total flux in the air gap, cp represents the

chord factor of winding, and Cw is the constant of winding.

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J. de la Cruz et al.: Voltage THD Improvement for an Outer Rotor PMSM

Tcog

Design parameters
Modify design

Frequency components
calculation

3.1 Case studies

VTHD calculation

Yes

No
END
Figure 5 VTHD calculation flowchart.

After the VTHD calculation for all cases, the cogging

torque for the best and the worst study case is estimated.
It is a quite important parameter and must be as small as
possible.
For permanent magnet machines, the cogging torque
is defined as the torque due to the magnetic attraction
between the rotor magnet and stator teeth [11]. It may be
expressed in terms of the rate of change of reluctance
with respect to the rotor position [11],
Table 2

Case 1 corresponds to the machine with the original

designed parameters. Cases 2 and 3 correspond to the
modifications on the diameter of the button slot, t.
Cases 4 and 5 correspond to the modifications on the
Yoke length, y. Cases 6 and 7 correspond to the modifications on the polar arc percentage p. The polar arc percentage is achieved by modifying the diameter of the rotor.
This modification forces to modify the slot depth l for
maintaining the original air gap. Cases 8 and 9 correspond
to the modifications on the teeth width d. Cases 10 and 11
correspond to the modifications on the air gap a. This is
achieved by modifying the outer diameter of the stator.
Cases 12 and 13 correspond to the modifications on the
number of electrical wires by slot S. Case 14 corresponds to
the modification on the enlargement of slot depth l. Cases
15 and 16 correspond to the modifications on the skew
angle in the poles p. Finally, cases 1719 correspond to
reductions in the pole length i. Table 2 presents the values
of the modified physical parameters.

Modifications on case studies.

Millimeters

Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case
Case

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

3

where R is the reluctance of the flux path, p is the

number if pole pairs, and is the rotor position in
mechanical degrees.

Induced voltage
estimation

Changes?


2p 
X
1 dR
 2t
2
d
1

461

5.98
5.98
5.98
7.00
5.00
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98
5.98

1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.0
2.0
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5

26.6
26.6
26.6
26.6
26.6
29.9
23.9
26.6
26.6
26.6
26.6
26.6
26.6
28.4
26.6
26.6
26.6
26.6
26.6

1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.85
2.00
1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.70
1.70

4.0
3.6
4.4
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0

12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
9.5
6.3
3.2

p (%)

Core

55
55
55
55
55
50
60
55
55
55
55
55
55
55
55
55
55
55
55

27
27
27
27
27
27
27
27
27
27
27
24
30
27
27
27
27
27
27

0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
6
0
0
0

M14, M19, M27 and M43

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462

J. de la Cruz et al.: Voltage THD Improvement for an Outer Rotor PMSM

Each case is simulated using four different silicon

steel materials for the stator core. Figure 6 depicts the
properties of materials used [12].

3
2.5
2.2

M14
M19
M27
M43

1.5
1
0.5
0
0

3
4
5
6
7
Magnetic field intensity (H)

9
x 105

Figure 6 Magnetization curves used for the stator core.

2.1
Magnetic flux density (B)

Magnetic flux density (B)

3.5

modification) the material M27 presents better performance

than material M14. This is due to the fact that material M14
shows a magnetic flux density saturation beyond 1.9
Teslas (Figure 8). For case 6, the magnetic flux density
reaches 1.97 Teslas. Saturation modifies the distortion of
the induced voltage wave.

Saturation M14
1.9
1.8
M14
M19
M2
M4

1.7
1.6
1.5

3.2 Simulation results

Magnetic field intensity (H)

Following the method detailed in Section 4 simulations

described in Table 2 for four different materials are carried out. Figure 7 shows the VTHD for 76 case studies.
Notice that the proposed modifications influence in
some way the VTHD in the induced voltage. The reduction in the pole length reduces the VTHD.
Materials also influence the VTHD, Figure 7 shows that
material M14 produces the best performance in almost all
cases. On the other hand, material M27 produces the worst
performance for almost all the case studies, due to the fact
that this material generates the smallest magnetic flux
density. However, in case 6 (polar arc percentage

0.12

For cases 15 and 16, the modification of the skew angle

creates a reduction up to 10% of the output voltage. That
is, it diminishes from 140.4 V. to 126.4 V; however, a
reduction in the VTHD is reached. Cases 17, 18 and 19
are very interesting, here the pole length is diminished
(25%, 50% and 75%). Considering that case 1 (100%) the
reference case, for case 17 the output voltage magnitude
remains the same and the VTHD is reduced in 27%. For
case 18, the output voltage magnitude remains the same

VTHD (%)

0.08
0.06
0.04
0.02
0

7
x 104

Figure 8 Saturation of M14.

M14
M19
M27
M43

0.1

10 11 12 13 14 15 16 17 18 19

Case of study
Figure 7 VTHD for all case studies.

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J. de la Cruz et al.: Voltage THD Improvement for an Outer Rotor PMSM

130

Case 1
Case 17
Case 18
Case 19

Voltage

90
50

12
Normalized amplitude (%)

and the VTHD is reduced in 78%. Similarly, for case 19,

the output voltage becomes triangular, its magnitude is
reduced and its VTHD is increased 102%. Figure 9 depicts
the output voltage waveforms for cases 1, 17, 18 and 19.

10
Case 7 - M14
8
6
4
2
0

10

30

11

13

15

17

19

17

19

Harmonic order
(a)

70

10

0.004

0.008

0.01

0.016

T ime (s)
Figure 9 Output voltage waveforms for case 1 and cases 1719 by
reducing the pole length (steel M14).

Normalized amplitude (%)

110

Figure 10 reproduces the induced voltage waveforms

when the material M14 is used in the construction of
the stator. Waveforms are arranged starting with case
study 7, which produces the biggest VTHD, up to case
18 which produces the smallest VTHD.

0.8
Case 18 - M14
0.6
0.4
0.2
0
1

11

13

15

Harmonic order
(b)

Figure 11 (a) Harmonics of voltage with steel type M14, Case 7; (b)
Harmonics of voltage with steel type M14, Case 2.

3.3 Cogging torque

Figures 12 and 13 show the calculated cogging torque for
cases 7 and 18. For case 2, the RMS value of the torque
becomes 0.0226 Nm, and for case 7 the RMS value of the
torque is 0.0247 Nm. Both values are small. It means that

0.04
Figure 10 Voltage waveforms for cases using steel M14.

Torque (Nm)

0.02

Figure 11(a) and (b) presents the harmonic components of

the generated voltage waveforms for the worst (10.34%,
case 7) and best (0.80%, case 18) cases. Nineteen harmonics are depicted. Notice that for case 7, the third harmonic exhibits the largest contribution to the VTHD, while in
case 18 the large contribution to the VTHD is due to the
fifth and ninth harmonics.
Case 18 with 0.80% fulfils the VTHD required by the
ANSY/NEMA MG1-2003 standard, which requires a maximum of 5% [1].

0.02

0.04
0

40

80

120

160

200

240

Electrical degrees ()
Figure 12 Torque: Case 18 with steel M14.

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280

320

360

464

J. de la Cruz et al.: Voltage THD Improvement for an Outer Rotor PMSM

0.04

Torque (Nm)

0.02
0
0.02
0.04
0.06
0.08
0

50

100

150

200

250

300

350

Electrical degrees ()
Figure 13 Torque: Case 7 with steel M14.

the operation of the generator at low wind speeds is not

jeopardized.
Figure 14 shows 64 harmonics components in the
torque shown in Figure 10. Case 7 exhibits the largest
content. Likewise, the THD for the torque in both cases is
611.16% for case 7 and 15.23% for case 18. These values
indicate that case 7 is a machine with larger vibrations
with respect to the machine in case 18.

4 Discussion and conclusions

The aim of this research was to find some practical rules
for designing outer rotor Permanent Magnet Synchronous
Machines, with a VTHD within standard values.

It is assumed to have a first basic machine that fulfils

the functional requirements in terms of output voltage
magnitude, frequency and phase. Then calculate the
VTHD and having it as a reference. If the VTHD is less
than 5%, it is convenient to assemble a prototype.
However, if this is not the case, then it is recommended to run a set of simulations where geometries
are varied. It is necessary to modify the geometries
around the original ones, for instance 10%, then run
the simulations and analyze the results. From results
select the new candidates, geometries, to be modified
and perform new simulations. This process should take
you to optimize the dimensions of the machine in terms
of the VTHD.
For the analyzed cases, four geometry modifications
conduct to a VTHD within the standard, i.e., less the 5%:
Pole length
Slot bottom diameter
Polar arc percentage
Pole skew angle
Notice that the pole length is an important parameter
to work with. The right commitment between the length,
magnitude and the output voltage waveform gave us the
best value for the VTHD.
It was found that the optimal relationship between
the slot bottom diameter and the teeth of the stator is
50%. That is, the total area occupied for slot and the
teeth must be shared equally. However, in some cases,
this modification requires the redesign of the stator and
in consequence the modification of the rotor too. The
designer must be careful in doing this type of

0.015
Case 18
Case 7

Torque (Nm)

0.012

0.009

0.006

0.003

0
0

200

400

600

800

1,000

1,200

1,400

Frequency (Hz)
Figure 14 Harmonic components of torque with steel M14.

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J. de la Cruz et al.: Voltage THD Improvement for an Outer Rotor PMSM

modification in order to preserve the space in the slot for

accommodating the winding.
For the case studies and the selected magnets, a
polar arc percentage of 50% gave the best results in
terms of the VTHD. For steel M19 and M27, good polar
arc percentage becomes 50%.
The modification of the pole skew gave good results
for the VTHD. However, this modification reduces the
output power. It is not recommended performing this
modification.
For the silicon steel M14, the magnetic flux density in
the stator core must be lower than 1.9 Teslas to have a
good value of VTHD.
For each case study, the cost of implementation exhibits a standard deviation about 5%, taking the base case
as reference.
Acknowledgements: The authors are grateful to JMAG
Software providers, for the period of academic license
provided. Juan M. Ramirez acknowledges support from
CONACyT projects no. 167933 and 188167.

Nomenclature
The following nomenclature will be used throughout this
article:

Polar arc percentage

Pole length

Air gap

Outer opening of the slot

Slot bottom diameter

Yoke length

Slot depth

Teeth width

Conductors per phase (coil turns)

Vn

Magnitude of voltage for nth harmonic

FEA

Finite Element Analysis

Magnetic flux density

Material permeability

Signal samples

Current in the coil

Cross sectional area of the core

Magnetic flux

Harmonic component

Skew angle in poles

FFT

Fast Fourier Transform

Total flux in the air gap

cp

Chord factor of winding

Cw

Winding constant

Reluctance of flux path

Rotor position in mechanical degrees

CAD

Computer-aided design

465

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