Professional Documents
Culture Documents
AbstractThis paper reviews many design issues and analysis [16][18] show coupled electromagnetic and thermal consid-
techniques for the brushless permanent-magnet machine. It re- erations in PM machines. In recent years, there have been many
views the basic requirements for the use of both ac and dc ma- papers that cover various aspects of the electromagnetic design
chines and issues concerning the selection of pole number, winding
layout, rotor topology, drive strategy, field weakening, and cooling. on rare-earth PM motors; for instance, [19][25] show recent
These are key issues in the design of a motor. Leading-edge design papers on PM-motor design in a variety of situations.
techniques are illustrated. This paper is aimed as a tutor for motor The aim of this paper is not to highlight particular design
designers who may be unfamiliar with this particular type of aspects of one form of brushless PM motor but rather to give
machine. an overview of many of the factors dictating option selection
Index TermsAnalysis, brushless permanent-magnet (PM) and design solutions. Therefore, in this paper, the key design
motors, design, internal PM (IPM), torque. points related to the design of brushless rare-earth PM ma-
chines are outlined and solutions are discussed. Techniques for
I. I NTRODUCTION analysis are outlined, and these should be useful to a machine
designer who is unfamiliar with this particular type of machine.
T HERE ARE MANY excellent books on the design of
brushless permanent-magnet (PM) motors. Examples of
well-known and established texts are given in [1][5], while
Section II will consider electromagnetic and structural is-
sues, while Section III will discuss thermal considerations.
more recently, there have been tutorials at leading international Section IV will put forward analysis techniques. Design exam-
conferences with accompanying Course Notes Texts [6]. These ples are included in the discussions.
cover dc and ac motors and mostly cover the design of ferrite-
magnet machines although rare-earth machines are also cov- II. I NITIAL E LECTROMAGNETIC D ESIGN C HOICES
ered. Materials are discussed in a variety of specialized texts;
these include magnets [7], [8], steels [9], [10], and insulation In this section, some basic design choices are discussed.
systems [11]. Noise is also covered by several texts [12], [13]. These are necessary at the outset of the design procedure.
This list is far from comprehensive, and there are many other
monographs that cover specialist aspects of electric motor A. Radial or Axial Flux?
operation that are relevant to brushless PM motors. There is
still relatively little on the thermal design of electrical machines Generally, most PM motors are of the radial-flux type. The
in terms of texts although the number of technical papers reason for this is that fabrication is straightforward and estab-
is increasing; illustrations of this are [14] and [15], while lished, using slotted stators with standard round radial lami-
nations, and the electrical loading can be maximized because
of the use of the slots. However, there are good examples of
using axial-flux machines, and the design of these machines
Manuscript received April 14, 2010; revised July 23, 2010; accepted is discussed in [26]. In these machines, the windings tend to
October 1, 2010. Date of publication October 28, 2010; date of current version be air-gap windings (although they can have teeth [27]) which
August 12, 2011.
D. G. Dorrell is with the School of Mechanical, Electrical and Mechatronic
can limit the amount of copper that can be used and, hence,
Systems, University of Technology Sydney, Sydney, N.S.W. 2007, Australia can limit the amount of loading possible. The windings tend
(e-mail: ddorrell@eng.uts.edu.au). to be specially formed and shaped, and often, Torus windings
M.-F. Hsieh is with the Department of Systems and Naval Mechatronic
Engineering, National Cheng Kung University (NCKU), Tainan 701, Taiwan
are used; Mendrela et al. [27] review different options for
(e-mail: mfhsieh@mail.ncku.edu.tw). this type of machine. Axial-flux machines are often used as
M. Popescu, L. Evans, and D. A. Staton are with Motor Design Ltd., motors although they have many advantages (usually related
SY12 9DA Shropshire, U.K. (e-mail: mircea.popescu@motor-design.com;
lyndon.evans@motor-design.com; dave.staton@motor-design.com). to their low armature reactance) in the area of generation
V. Grout is with the Centre for Applied Internet Research, Glyndwr Univer- [28], particularly in wind generation [29]. However, axial-flux
sity, LL11 2AW Wrexham, U.K. (e-mail: v.grout@glyndwr.ac.uk). applications can still be considered as niche, and the focus of
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org. this paper will be on radial-flux laminated motors since these
Digital Object Identifier 10.1109/TIE.2010.2089940 constitute the majority of brushless PM motors.
0278-0046/$26.00 2010 IEEE
3742 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 58, NO. 9, SEPTEMBER 2011
Phase advance has the effect of weakening the main field by will be extra torque available to bring the motor back to the
rotating the current phasor so that there is a component on correct firing angle, preventing pole slipping. The saliency also
the d-axis. AC-controlled machines with internal-PM (IPM) offers additional reluctance torque, and this is illustrated by the
rotors can have much higher field-weakening capability, and the example in Section IV-B.
machine used in [30] has 60 phase advancethis is studied The phasor diagram for the two types of rotor is shown
later. IPM motors can have considerable reluctance torque as in Fig. 3(a) (assuming ac control). This is a general case in
well as excitation torque. The machine in [30] is required to steady state; the difference in operation is that if there is no
have a wide field-weakening capability because the base speed saliency, then Xd = Xq and the steady-state circuit in Fig. 3(b)
is 1500 r/min, whereas the maximum speed is 6000 r/min. can be utilized. If there is q-axis saliency, then the steady-state
circuits have to be resolved into two (onto the d- and q-axes), as
shown in Fig. 3(c); this represents an IPM machine. Under low-
D. Choice of Rotors
saturation conditions, then Xd and Xq are independent and are
There are many possible topologies for the rotortoo many functions of the d- and q-axis reluctances. However, when there
to comprehensively list here. They lie in two basic topologies. is high saturation, there is cross-coupling between the d- and
One has surface magnets with little saliency, which are common q-axis components so that Xd = f (Id , Iq ) and Xq = f (Id , Iq ).
in dc motors as already mentioned (although they are also often If an extended field-weakening range (from the base speed
used in ac motors), while the second has embedded magnets upward) is required, then the IPM rotor should be used. A
and considerable saliency. Fig. 2 shows some examples of surface-magnet motor simply cannot cope with this range be-
these. Many of these topologies can be simulated in the SPEED cause the field-weakening capability is limited. This occurs
simulation package from the University of Glasgow, U.K., and when the current phasor is advanced away from the q-axis so
Miller [31] lists many brushless PM-motor rotor arrangements. that there is a component on the d-axis, as shown in Fig. 3(a).
For a surface-magnet nonsalient rotor, Xd = Xq , as shown This has three effects: It can be seen that there is a negative
in Fig. 2(a). Embedded magnets are possible in the rotor, as Xd Id phasor on the q-axis. This weakens the motor flux which
shown in Fig. 2(b). These are used in ac machines, although reduces the iron loss at high speed. Additionally, it reduces the
they can be used in dc machines. They have q-axis saliency voltage requirement from the inverter supply. The third effect
(i.e., Xq > Xd ). The advantage of this is that the peak torque is is the introduction of reluctance torque in the machine. This is
moved from the q-axis to an angle of about 100120 electrical shown in Fig. 3(c), which breaks down the voltages onto the
degrees away from the d-axis. This means that if there is a d- and q-axes. The power due to the excitation torque is 3EIq
transient overload when the current is on the q-axis, there (where E is the back EMF induced into the rotor by the IPM
3744 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 58, NO. 9, SEPTEMBER 2011
give the sheer stress. The air-gap flux density due to the PM
rotors is
br (y, t) = Brm cos (mp(r t ky + m )) (3)
m
G. Winding Arrangement
two coil sides per slot (concentric, lap, or concentrated round
There are a variety of methods for winding a brushless PM one tooth), as discussed in [31]. Here, a simple example of an
motor depending on whether it is an ac or dc motor. The aim of 18-slot 8-pole IPM machine is shown in Fig. 5. This is a
an ac winding is to obtain a sinusoidal open-circuit back-EMF fractional-slot machine. The winding is illustrated for one phase
waveform. For a dc winding, it is to obtain a trapezoidal wave- in Fig. 5(a), showing the distributed nature of the winding.
form. Therefore, is it appropriate to consider them separately. The rotor arrangement is shown in Fig. 5(b). The machine
Slot fill is considered in Section II-J. was modeled using the SPEED software package PC-BDC [47]
1) AC Windings: Distributed windings are often utilized from the University of Glasgow, U.K., and the machine data are
in ac machines with coil pitches of one slot. An excellent given in Table II; this gives the operating point data together
examination of this arrangement was put forward in [46]. The with various geometrical and winding data. There is one stator-
correct winding for a machine is very much a function of the slot skew in this machine which helps form the back EMF into
pole number and slot number and whether there are one or a very sinusoidal wave, as shown in Fig. 5(d), so that the torque
3746 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 58, NO. 9, SEPTEMBER 2011
there are three slots per pole which is not accounted for in the
waveforms.
It is also necessary to consider the torque-producing region of
the waveforms. This is shown in Fig. 7. If the back-EMF wave
is too narrow, then there is torque ripple when the back EMF
is multiplied by the current. In addition, the dc machine used
Hall probes, and if they are only slightly out of position, then
there will be considerable torque ripple. This was investigated
in [39].
3) Delta Connection: Delta connection is not recommended
in a brushless PM machine. If there is any third time harmonic
in the phase back EMF, then this will induce a circulating zero-
order current in the mesh, as shown in Fig. 8. This will cause
excessive current and copper losses and potential burnout of the
winding.
Fig. 6. Comparison of idealized short-pitched and fully pitched windings
in a 12-slot 4-pole dc machine. The windings are one phase of a balanced
three-phase set in each case. (a) Short-pitched coils (two-third pitching). H. Magnet Selection and PC
(b) Fully pitched concentrated coils. (c) Trapezoidal 120-electrical-degree
three-phase current set. (d) Three-phase back EMF with short-pitched wind- The type of magnet used will have a great effect on the
ings. (e) Electromagnetic torque with short-pitched winding. (f) Three-phase motor performance and cost. The increased cost of high-energy
back EMF with fully pitched windings. (g) Electromagnetic torque with fully magnets may be offset by the fact that less magnet material
pitched winding.
is required and the motor will be more compact. Typical
is smooth, as shown in Fig. 5(e). The efficiency is only 85%, remanent magnetism and recoil permeability values at 25 C
but at 6000 r/min with eight poles, the frequency in the iron is for various magnets are listed Table III. Further details are
400 Hz. This may require high-grade aerospace steel, although put forward in [7] and [8]. The nonlinear characteristics of the
this was not used in this instance (Losil 800 was used), and specific magnets should be inspected. The magnets should not
therefore, the iron loss dominated the loss components. be used in the nonlinear area, as shown in Fig. 9, and sufficient
2) DC Winding: DC machines require a different winding design tolerance should be built in so that the magnets are not
strategy with the aim of obtaining a trapezoidal back-EMF demagnetized even under overload. The operating point can be
waveform. This will interact with the trapezoidal current (with found by calculating the permeance coefficient (PC) and also
120 conduction period) to produce a smooth torque. This the electric loading effects. For ferrite-magnet motors, a PC of
requires fully pitched concentrated windings. Fig. 6 shows the at least eight is usually required, but for rare-earth magnets, this
winding layout for one phase of a three-phase set for a 12-slot can be lower since the magnets are much stronger and linear.
4-pole machine. The first simulation uses a short-pitched dis- The PC can be improved by the use of a narrow air gap and
tributed winding, while the second uses a fully pitched concen- shorter flux path lengths and wide teeth and stator yoke. Lower
trated winding. The waveforms illustrate the torque production flux-density levels also improve the PC.
and the fact that there is inherent torque ripple with the short- The thermal performance of the magnet material also has
pitched winding. This is very much an idealized waveform. The to be considered, as shown in Fig. 10. While this paper is
back EMF usually has some distortion to produce ripple, and mostly concerned with rare-earth magnet machines, it is worth
this arrangement would have substantial cogging torque since considering ferrite-magnet material for completeness. The
DORRELL et al.: REVIEW OF DESIGN ISSUES AND TECHNIQUES FOR PERMANENT-MAGNET MOTORS 3747
Fig. 8. Zero-order 3rd time harmonics in delta-connected brushless PM motor. (a) 3-phase current and 3rd time harmonics. (b) Circulating zero-order set.
TABLE III
TYPICAL MAGNET DATA
Fig. 9. Second quadrant operation for ferrite (grades 1 and 5) and NdFeB
(Crumax 2830) magnets.
Fig. 12. Comparison of B/H and frequency/iron-loss curves for Losil 800/65 and Transil 35 steels (B = 1.7 T for loss data).
TABLE IV 4) What is the duty cycle?
INSULATION CLASSIFICATIONS [NEMA MG 1-2006]
(AMBIENT BELOW 40 C) 5) How effectively can we cool the machine?
The latter two points will affect the thermal rating of the
machine, and this is addressed in the next section.
Fig. 14. Thermal circuits and winding model of machine. (a) Lumped thermal model (part model) with heat sources, thermal resistances, and thermal
capacitancessurface-magnet rotor. (b) Multilayer winding representation when there is a high temperature gradient. Traditional winding for random-wound
coils and 54% slot fill.
Fig. 16. Prius PM-motor cross section in SPEED PC-BDCthis shows two
Fig. 15. Comparison of IPsi loops for dc and ac controls. magnets per pole and high saliency.
The peak current for both simulations was 15 A, and the same torques [62]. This technique is used in an FEA, and many
short-pitched winding in Fig. 6(a) was utilized. Interestingly, packages allow this function. To summarize, using a magne-
in the Appendix, the theoretical ac/dc control rating ratio was tostatic model, a full nonlinear solution is carried out, and the
calculated to be 1.5. Here, by simply changing from sine- total torque can be obtained from this solution. The saturated
to square-wave control, the torque increases by 1.15. If the magnetic permeances are then locked. If the magnets are then
winding is fully pitched for the dc control, then the torque is switched off (by setting the remanent magnetism Br to zero)
1.07 so that the ratio is 1.23. However, the rms current with and the solution restarted with the locked permeances from the
the dc control is higher. Using the same rms currents and fully full solution, then the reluctance torque can be calculated. This
pitched winding in the dc simulation gives a torque ratio of reluctance torque includes the saturation effects from the full
1.07. These results were obtained in the SPEED PC-BDC and solution. An example is shown in Fig. 16, which is a SPEED
PC-FEA environments. simulation of the Toyota Prius machine in [30]. This machine
operates at a high phase advance to allow for a very wide
field-weakening range (from 1500 to 6000 r/min) and relies on
B. Frozen Permeability Method
substantial reluctance torque. This is an eight-pole machine.
This method is a very powerful tool for separating out the The peak current occurs at the base speed of 1500 r/min.
different torque components due to excitation and reluctance This is a transient point, and the current density (over
3752 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 58, NO. 9, SEPTEMBER 2011
C. Efficiency Plots This paper has described the design philosophy for dc and ac
PM machines. It goes on to discuss many of the modern-day
Efficiency is becoming a more important factor in machine analysis techniques that can be used to assess the performance
design and is indeed crucial in many designs. Computational of a machine. Many of the techniques are illustrated with
design solutions are becoming increasingly rapid, and it is now examples, and the need to consider the electromagnetic design,
possible to scan a range of operating points and produce a thermal analysis, and manufacturing techniques in conjunction
plot of the efficiencies over a 2-D array of torques and speeds. is stressed. This paper will be very useful to an electrical ma-
In [30], measured efficiency plots were used to illustrate the chine designer who requires more detailed information about
motor operation, and these can be obtained from simulations the steps necessary to analyze and improve a motor design of
too. Fig. 20 shows the efficiency plot for the machine in the this ilk.
previous section using SPEED PC-BDC. For a brushless PM
motor, there are several parameters that can be set. In this A. Further Literature
case, at each load point, the phase angle advance was set at
0 , 30 , and 60 , and the current varied until the correct torque There are many sources of design method information from
was obtained. The highest efficiency was then selected as the many researchers. In terms of further texts, [65] gives a treatise
operating point. The selected phase angle is shown in the top specific to PM motor design, while general ac machine design
chart, while the efficiencies are shown as colored regions and and operation are considered in [66] and [67], which can
contour lines in the bottom plot. be very helpful in terms of winding theory and practice and
other aspects of machine operation. The technology is rapidly
developing due to new material design refinement. There are
D. Fractional-Slot Design-Size Rationalization
continuing developments of algorithms that are aimed at the
Here, an example is put forward for the rationalization of automated and precise design of an electrical machine; [68]
a motor design by consideration of the thermal design [63]. and [69] are illustrations of these, and a literature review would
DORRELL et al.: REVIEW OF DESIGN ISSUES AND TECHNIQUES FOR PERMANENT-MAGNET MOTORS 3753
Fig. 18. Separation of torque at 1500 r/min with 190.9-A loadingvariation of current phase with respect to q-axis.
Fig. 19. Separation of torque at 6000 r/min with 35.4-A loadingvariation of current phase with respect to q-axis.
Comparison of Stresses: Comparing (A3)(A9) shows that, and fluid-dynamical finite-element analysis, IEEE Trans. Ind. Electron.,
for a given phase current (whether sinusoidal or trapezoidal), vol. 55, no. 10, pp. 35913601, Oct. 2008.
[17] A. Di Gerlando, G. Foglia, and R. Perini, Permanent magnet machines
dc control gives higher stress density than ac control for a given for modulated damping of seismic vibrations: Electrical and thermal
peak flux density in the ratio 0.82/0.55 = 1.5. However, dc modeling, IEEE Trans. Ind. Electron., vol. 55, no. 10, pp. 36023610,
control tends to give more torque ripple and is more suitable Oct. 2008.
[18] D. G. Dorrell, Combined thermal and electromagnetic analysis of
for power drives. If a surface-magnet rotor is used, then (A4) permanent-magnet and induction machines to aid calculation, IEEE
can be compared with (A9), and this time, the theoretical stress Trans. Ind. Electron., vol. 55, no. 10, pp. 35663574, Oct. 2008.
limits are in the ratio 0.82/0.7 = 1.17, which is much closer. [19] L. Parsa and L. Hao, Interior permanent magnet motors with reduced
torque pulsation, IEEE Trans. Ind. Electron., vol. 55, no. 2, pp. 602609,
Relationship Between DC Link Voltage and Power Con- Feb. 2008.
version: Assume that the machines operate with unity power [20] K. I. Laskaris and A. G. Kladas, Internal permanent magnet motor design
factor. In a three-phase ac machine where the phase voltages for electric vehicle drive, IEEE Trans. Ind. Electron., vol. 57, no. 1,
pp. 138145, Jan. 2010.
and currents are sinusoidal and where there is 180 conduction [21] N. P. Shah, A. D. Hirzel, and B. Cho, Transmissionless selectively
in the inverter, the voltages and currents can be related to each aligned surface-permanent-magnet BLDC motor in hybrid electric ve-
other where Idc = Ipk and Vdc = 3Vpk /2. Therefore hicles, IEEE Trans. Ind. Electron., vol. 57, no. 2, pp. 669677,
Feb. 2010.
Vpk Ipk [22] K. Yamazaki and H. Ishigami, Rotor-shape optimization of interior-
Vdc Idc = 3 = 3Vrms Irms . (A10) permanent-magnet motors to reduce harmonic iron losses, IEEE Trans.
2 Ind. Electron., vol. 57, no. 1, pp. 6169, Jan. 2010.
[23] J. Hur, Characteristic analysis of interior permanent-magnet synchronous
For a dc machine, where the waveforms are trapezoidal and motor in electrohydraulic power steering systems, IEEE Trans. Ind. Elec-
where there is 120 conduction in the inverter, Idc = Ipk and tron., vol. 55, no. 6, pp. 23162323, Jun. 2008.
Vdc = 2Vpk . The rms-to-peak values are [24] P.-D. Fister and Y. Perriard, Very-high-speed slotless permanent-magnet
motors: Analytical modeling, optimization, design, and torque measure-
ment methods, IEEE Trans. Ind. Electron., vol. 57, no. 1, pp. 296303,
2 2 Jan. 2010.
Vrms = Vpk and Irms = Ipk (A11) [25] M. Andriollo, M. De Bortoli, G. Martinelli, A. Morini, and A. Tortella,
3 3
Design improvement of a single-phase brushless permanent magnet mo-
so that the relationship between the dc link and ac rms values is tor for small fan appliances, IEEE Trans. Ind. Electron., vol. 57, no. 1,
pp. 8895, Jan. 2010.
[26] J. F. Gieras, R.-J. Wang, and M. J. Kamper, Axial Flux Permanent Magnet
Vdc Idc = 2Vpk Ipk = 3Vrms Irms . (A12) Brushless Machines. New York: Springer-Verlag, 2008.
[27] E. A. Mendrela, R. Beniak, and R. Wrobel, Influence of stator struc-
Comparing (A10) and (A12) shows that the same relationship ture on electromechanical parameters of Torus-type brushless dc mo-
tor, IEEE Trans. Energy Convers., vol. 18, no. 2, pp. 231237,
holds whether it is ac or dc. Jun. 2003.
[28] B. J. Chalmers, A. M. Green, A. B. J. Reece, and A. H. Al-Badi,
Modelling and simulation of the Torus generator, Proc. Inst. Elect.
R EFERENCES Eng.Electr. Power Appl., vol. 144, no. 6, pp. 446452, Nov. 1997.
[1] J. R. Hendershot and T. J. E. Miller, Design of Brushless Permanent- [29] E. Muljadi, C. P. Butterfield, and Y.-H. Wan, Axial-flux modular
Magnet Motors. Oxford, U.K.: Clarendon, 1994. permanent-magnet generator with a toroidal winding for wind-turbine
[2] J. R. Ireland, Ceramic Permanent-Magnet Motors. New York: McGraw- applications, IEEE Trans. Ind. Appl., vol. 35, no. 4, pp. 831836,
Hill, 1968. Jul./Aug. 1999.
[3] T. Kenjo and S. Nagamori, Permanent-Magnet and Brushless DC Motors. [30] M. Olszewski, Evaluation of the 2007 Toyota Camry hybrid synergy
Oxford, U.K.: Clarendon, 1994. drive system, Oak Ridge Nat. Lab., U.S. Dept. Energy, Oak Ridge, TN,
[4] J. F. Gieras and M. Wing, Permanent Magnet Motor Technology. 2009.
New York: Marcel Dekker, 2002. [31] T. J. E. Miller, SPEEDs Electrical Motors. Glasgow, U.K.: SPEED
[5] D. C. Hanselman, Brushless Permanent Magnet Motor Design. Lab., Univ. Glasgow, 2006.
Lebanon, OH: Magna Physics, 2006. [32] Z. Q. Zhu, D. Ishak, D. Howe, and J. Chen, Unbalanced magnetic forces
[6] N. Bianchi, M. D. Pr, L. Alberti, and E. Fornasiero, Theory de- in permanent-magnet brushless machines with diametrically asymmetric
sign of fractional-slot PM machines, Tutorial Course Notes, IEEE phase windings, IEEE Trans. Ind. Appl., vol. 43, no. 6, pp. 15441553,
IAS2007 Annu., Meeting, Sep. 23, 2007, CLEUP editor (Padova, Italy); Nov./Dec. 2007.
New Orleans: USA. [33] M. S. Ahmad, N. A. A. Manap, and D. Ishak, Permanent magnet brush-
[7] P. Campbell, Permanent Magnet Materials and Their Applications. less machines with minimum difference in slot number and pole number,
Cambridge, U.K.: Cambridge Univ. Press, 1994. in Proc. IEEE Int. PECon, Johor Baharu, Malaysia, Dec. 13, 2008,
[8] L. R. Moskowitz, Permanent Magnet Design and Application Handbook. pp. 10641069.
Melbourne, FL: Krieger, 1995. [34] D. G. Dorrell, M. Popescu, and D. Ionel, Unbalanced magnetic
[9] P. Beckley, Electrical Steels for Rotating Machines. London, U.K.: IEE, pull due to asymmetry and low-level static rotor eccentricity in
2002. fractional-slot brushless permanent-magnet motors with surface-magnet
[10] P. Beckley, Electrical Steels. Newport, U.K.: Eur. Elect. Steels, 2000. and consequent-pole rotors, IEEE Trans. Magn., vol. 46, no. 7, pp. 2675
[11] G. C. Stone, E. A. Boulter, I. Culbert, and H. Dhirani, Electrical Insulation 2685, Jul. 2010.
for Rotating Machines. Piscataway, NJ: IEEE Press, 2004. [35] J. Kolehmainen, Optimal dovetail permanent magnet rotor solutions for
[12] S. J. Yang and A. J. Ellison, Machinery Noise Measurement. Oxford, various pole numbers, IEEE Trans. Ind. Electron., vol. 57, no. 1, pp. 70
U.K.: Clarendon, 1985. 77, Jan. 2010.
[13] P. L. Timr, Noise and Vibration of Electrical Machines. Amsterdam, [36] Z. Q. Zhu, Z. P. Xia, L. J. Wu, and G. W. Jewell, Influence of slot and
The Netherlands: Elsevier, 1989. pole number combination on radial force and vibration modes in fractional
[14] M. A. Valenzuela and J. A. Tapia, Heat transfer and thermal design slot PM brushless machines having single- and double layer windings, in
of finned frames for TEFC variable-speed motors, IEEE Trans. Ind. Proc. IEEE ECCE, Sep. 2024, 2009, pp. 34433450.
Electron., vol. 55, no. 10, pp. 35003508, Oct. 2008. [37] J. F. Gieras, Analytical approach to cogging torque calculation of PM
[15] J. Nerg, M. Rilla, and J. Pyrhonen, Thermal analysis of radial-flux elec- brushless motors, IEEE Trans. Ind. Appl., vol. 40, no. 5, pp. 13101316,
trical machines with a high power density, IEEE Trans. Ind. Electron., Sep./Oct. 2004.
vol. 55, no. 10, pp. 35433554, Oct. 2008. [38] N. Bianchi and S. Bolognani, Design techniques for reducing the cogging
[16] F. Marignetti, V. Delli Colli, and Y. Coia, Design of axial flux PM torque in surface-mounted PM motors, IEEE Trans. Ind. Appl., vol. 38,
synchronous machines through 3-D coupled electromagnetic thermal no. 5, pp. 12591265, Sep./Oct. 2002.
3756 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 58, NO. 9, SEPTEMBER 2011
[39] D. G. Dorrell, Tolerance variations and magnetization modelling in [64] R. V. Major, Development of high strength soft magnetic alloys for high
brushless permanent magnet machines, in Proc. IEE Int. Conf. Power speed electrical machines, in Proc. IEE Colloq. New Magn. Mater.
Electron., Mach. Drives, Bath, U.K., Jun. 47, 2002, pp. 398403. Bonded Iron, Lamination Steels, Sintered Iron and Permanent Magnets
[40] M. S. Islam, S. Mir, and T. Sebastian, Issues in reducing the cogging (Digest No. 1998/259), London, U.K., May 28, 1998, pp. 8/18/4.
torque of mass-produced permanent-magnet brushless dc motor, IEEE [65] R. Krishnan, Permanent Magnet Synchronous and Brushless DC Motor
Trans. Ind. Appl., vol. 40, no. 3, pp. 813820, May/Jun. 2004. Drives. Boca Raton, FL: CRC, 2010.
[41] F. Magnussen and H. Lendenmann, Parasitic effects in PM machines [66] J. Pyrhonen, T. Jokinen, and V. Hrabovcova, Design of Rotating Electrical
with concentrated windings, IEEE Trans. Ind. Appl., vol. 43, no. 5, Machines. Chichester, U.K.: Wiley, 2007.
pp. 12231232, Sep./Oct. 2007. [67] T. A. Lipo, Introduction to AC Machine Design. Madison, WI: Univ.
[42] D. M. Ionel, M. Popescu, M. I. McGilp, T. J. E. Miller, and S. J. Dellinger, Wisconsin Press, 2004.
Assessment of torque components in brushless permanent-magnet ma- [68] W. Ouyang, D. Zarko, and T. A. Lipo, Permanent magnet machine design
chines through numerical analysis of the electromagnetic field, IEEE practice and optimization, in Conf. Rec. 41st IEEE IAS Annu. Meeting,
Trans. Ind. Appl., vol. 41, no. 5, pp. 11491158, Sep./Oct. 2005. Tampa, FL, Oct. 812, 2006, pp. 19051911.
[43] D. G. Dorrell, M. Popescu, and M. I. McGilp, Torque calculation in [69] S. Huang, M. Aydin, and T. A. Lipo, Torque quality assessment and
finite element solutions of electrical machines by consideration of stored sizing optimization for surface mounted permanent magnet machines,
energy, IEEE Trans. Magn., vol. 42, no. 10, pp. 34313433, Oct. 2006. in Conf. Rec. 36th IEEE IAS Annu. Meeting, Chicago, IL, Sep. 30Oct. 4,
[44] D. A. Staton, R. P. Deodhar, W. L. Soong, and T. J. E. Miller, Torque 2001, pp. 16031610.
prediction using the flux-MMF diagram in ac, dc, and reluctance motors, [70] S. Huang, M. Aydin, and T. A. Lipo, Electromagnetic vibration and noise
IEEE Trans. Ind. Appl., vol. 32, no. 1, pp. 180188, Jan./Feb. 1996. assessment for surface mounted PM machines, in Proc. IEEE Power
[45] R. P. Deodhar, D. A. Staton, T. M. Jahns, and T. J. E. Miller, Prediction Eng. Soc. Summer Meeting, Vancouver, BC, Canada, Jul. 1519, 2001,
of cogging torque using the flux-MMF diagram technique, IEEE Trans. pp. 14171426.
Ind. Appl., vol. 32, no. 3, pp. 569576, May/Jun. 1996.
[46] A. M. EL-Refaie, Fractional-slot concentrated-windings synchronous
permanent magnet machines: Opportunities and challenges, IEEE Trans. David G. Dorrell (M95SM08) is a native of
Ind. Electron., vol. 57, no. 1, pp. 107121, Jan. 2010. St. Helens, U.K. He received the B.Eng. (Hons.)
[47] T. J. E. Miller and M. I. McGilp, PC-BDC 8.0 for WindowsSoftware, degree in Electrical and Electronic Engineering from
SPEED Lab., Univ. Glasgow, Glasgow, U.K., 2008. The University of Leeds, Leeds U.K., in 1988,
[48] J. Reinert, A. Brockmeyer, and R. W. A. A. De Doncker, Calculation the M.Sc. degree in Power Electronics Engineering
of losses in ferro- and ferrimagnetic materials based on the modified from The University of Bradford, Bradford, U.K., in
Steinmetz equation, IEEE Trans. Ind. Appl., vol. 37, no. 4, pp. 1055 1989, and the Ph.D. degree from The University of
1061, Jul./Aug. 2001. Cambridge, Cambridge, U.K., in 1993.
[49] E. Peralta-Snchez and A. C. Smith, Line-start permanent-magnet ma- He has held lecturing positions with Robert
chines using a canned rotor, IEEE Trans. Ind. Appl., vol. 45, no. 3, Gordon University, Aberdeen, U.K., and the Univer-
pp. 903910, May/Jun. 2009. sity of Reading, Berkshire, U.K. He was a Senior
[50] E. C. Lovelace, T. M. Jahns, T. A. Keim, and J. H. Lang, Mechanical Lecturer with the University of Glasgow, Glasgow, U.K., for several years. In
design considerations for conventionally laminated, high-speed, interior 2008, he took up a post with the University of Technology Sydney, Sydney,
PM synchronous machine rotors, IEEE Trans. Ind. Appl., vol. 40, no. 3, Australia, where he was promoted to Associate Professor in 2009. He is
also an Adjunct Associate Professor with National Cheng Kung University,
pp. 806812, May/Jun. 2004.
Tainan, Taiwan. His research interests cover the design and analysis of various
[51] C. Bailey, D. M. Saban, and P. Guedes-Pinto, Design of high-speed
electrical machines and also renewable-energy systems with over 150 technical
direct-connected permanent-magnet motors and generators for the petro-
publications to his name.
chemical industry, IEEE Trans. Ind. Appl., vol. 45, no. 3, pp. 11551165,
Dr. Dorrell is a Chartered Engineer in the U.K. and a Fellow of the Institution
May/Jun. 2009.
of Engineering and Technology.
[52] D. M. Saban, C. Bailey, K. Brun, and D. Gonzalez-Lopez, Beyond IEEE
STC 115 & API 546: Test procedures for high-speed multi-megawatt
permanent-magnet synchronous machines, in Proc. IEEE IAS PCIC, Min-Fu Hsieh (M02) was born in Tainan, Taiwan,
Sep. 1416, 2009, pp. 19. in 1968. He received the B.Eng. degree in mechani-
[53] K. Yoshida, Y. Hita, and K. Kesamaru, Eddy-current loss analysis in PM cal engineering from National Cheng Kung Univer-
of surface-mounted-PM SM for electric vehicles, IEEE Trans. Magn., sity (NCKU), Tainan, in 1991 and the M.Sc. and
vol. 36, no. 4, pp. 19411944, Jul. 2000. Ph.D. degrees in mechanical engineering from the
[54] P. H. Mellor, R. Wrobel, and N. McNeill, Investigation of proximity University of Liverpool, Liverpool, U.K., in 1996
losses in a high speed brushless permanent magnet motor, in Conf. Rec. and 2000, respectively.
41st IEEE IAS Annu. Meeting, Oct. 812, 2006, vol. 3, pp. 15141518. From 2000 to 2003, he served as a Researcher
[55] K. Yamazaki, Torque and efficiency calculation of an interior permanent with the Electric Motor Technology Research Center,
magnet motor considering harmonic iron losses of both the stator and NCKU. In 2003, he joined the Department of Sys-
rotor, IEEE Trans. Magn., vol. 39, no. 3, pp. 14601463, Jul. 2003. tems and Naval Mechatronic Engineering, NCKU, as
[56] Test Procedure for Evaluation of Systems of Insulating Materials for an Assistant Professor. In 2007, he was promoted to Associate Professor. His
Random-Wound AC Electric Machinery, (revised, 1984), Std. 117-1974, area of interests includes renewable-energy generation (wave, tidal current, and
1974. wind), electric propulsors, servo control, and electric machine design.
[57] A. Boglietti, A. Cavagnini, and D. A. Staton, TEFC induction motors Dr. Hsieh is a member of the IEEE Magnetics, Industrial Electronics,
thermal models: A parameter sensitivity analysis, IEEE Trans. Ind. Appl., Oceanic Engineering, and Industrial Applications Societies.
vol. 41, no. 3, pp. 756763, May/Jun. 2005.
[58] D. A. Staton, A. Boglietti, and A. Cavagnini, Solving the more difficult
aspects of electric motor thermal analysis in small and medium size Mircea Popescu (M98SM04) received the D.Sc.
industrial induction motors, IEEE Trans. Energy Convers., vol. 20, no. 3, in electrical engineering from Helsinki University of
pp. 620628, Sep. 2005. Technology, Helsinki, Finland, in 2004.
[59] P. H. Mellor, D. Roberts, and D. R. Turner, Lumped parameter thermal He has more than 25 years of experience in electri-
model for electrical machines of TEFC design, Proc. Inst. Elect. Eng. cal motor design and analysis. He worked for the Re-
BElectr. Power Appl., vol. 138, no. 5, pp. 205218, Sep. 1991. search Institute for Electrical Machines, Bucharest,
[60] D. A. Staton, Motor-CAD V2. Shropshire, U.K.: Motor Design Ltd., Romania; Helsinki University of Technology; and
Oct. 2005. SPEED Laboratory, University of Glasgow,
[61] M. Olaru, T. J. E. Miller, and M. I. McGilp, PC-FEA 5.5 for Glasgow, U.K. In 2008, he joined Motor Design
WindowsSoftware, SPEED Lab., Univ. Glasgow, Glasgow, U.K., 2007. Ltd., Shropshire, U.K., as an Engineering Manager.
[62] J. A. Walker, D. G. Dorrell, and C. Cossar, Flux-linkage calculation He published over 100 papers in conferences and
in permanent-magnet motors using frozen permeabilities method, IEEE peer-reviewed journals.
Trans. Magn., vol. 41, no. 10, pp. 39463948, Oct. 2005. Dr. Popescu was the recipient of the first prize best paper awards from IEEE
[63] D. A. Staton, Servo motor size reductionNeed for thermal CAD, in Industry Applications Society Electric Machines Committee in 2002, 2006,
Proc. Drives Controls Conf., Mar. 1315, 2001, pp. 110. and 2008.
DORRELL et al.: REVIEW OF DESIGN ISSUES AND TECHNIQUES FOR PERMANENT-MAGNET MOTORS 3757
Lyndon Evans received the B.Sc. (Hons.) degree in Vic Grout (M01SM05) received the B.Sc.
computer networks from Glyndwr University, Wales, (Hons.) in Mathematics and Computing from The
U.K., in 2008. University of Exeter, Penryn, U.K., in 1984,
He qualified as a Television and Video Service and a Ph.D. in Communication Engineering from
Engineer in 1988 and worked in this field for over Plymouth Polytechnic, Devon, U.K., in 1988
15 years before returning to study and receiving his He is a Professor of Network Algorithms and the
B.Sc.(Hons.) degree. He is a Software Developer Director of the Centre for Applied Internet Research,
with Motor Design Ltd., Shropshire, U.K., in part- Glyndwr University, Wales, U.K. He has worked in
nership with Glyndwr University, and is studying for senior positions in both academia and industry for
a research degree. over 20 years and has published and presented over
Mr. Evans is a member of The Institution of En- 200 research papers and 4 books. He is an Electrical
gineering and Technology and an associate member of the British Computer Engineer, Scientist, Mathematician, and IT Professional.
Society. Mr. Grout is a Chartered Engineer and a Fellow of the Institute of Mathe-
matics and its Applications and British Computer Society and The Institution
of Engineering and Technology.
David A. Staton (M90) received the Ph.D. degree in
computer-aided design of electrical machines from
The University of Sheffield, Sheffield, U.K., in 1988.
Since then, he has worked on motor design and
particularly the development of motor design soft-
ware at Thorn EMI; the SPEED Laboratory, Uni-
versity of Glasgow, Glasgow, U.K.; and Control
Techniques, U.K. In 1999, he set up a new company,
Motor Design Ltd., Shropshire, U.K., to develop a
thermal analysis software for electrical machines. He
published over 50 papers in conferences and peer-
reviewed journals.