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Abstract This paper introduces a performance comparison of the problem of selecting fractional slot motor geometry and the
different permanent magnet motor structures equipped with windings properly remains still partly unsolved it is important
fractional slot windings in which the number of slots per pole and to study the fractional slot machines carefully. That is also why
phase q < 1. Such a PM machine is an attractive solution for low- it was concerned to manufacture a real prototype machine of
speed applications in which copper losses often dominate as iron considerable power. [1,2,5]
losses are of less importance. It was in the authors interest to
have a low speed motor to a specific application, in which high The windings layout and the copper amount of a fractional
torque and 45 kW output power at 420 rpm can be achieved slot machine were studied and the results were compared to
using a restricted motor volume. These demands lead to study integer slotted machine. First the 45 kW fractional wound (q =
multi-pole machines with fractional slot windings. One of the 0.4) prototype motor with 12 slots and 10 poles was compared
designs studied was verified via a prototype machine. to a motor with q = 1. A fractional motor with q = 0.4 can have
at least three different winding constructions:
Keywords; permanent magnet motor; fractional slot three-
phase windings, finite element analysis one-layer winding
two-layer winding, where slots are divided horizontally
I. INTRODUCTION
two-layer winding, where slots are divided vertically.
In low speed applications a high pole number is often a
good selection. The advantage is a low iron mass per rated +A +A
-A
torque due to rather low flux per pole. A high pole number in -A +A
-A
-A
conventional wound machines leads also to a high slot number,
which increases costs and in the worst cases leads to a low
copper fill factor (the amount of insulation material compared
to the slot area is big). The fractional slot winding solution
instead does not require many slots although the pole number is
high, which reduces both the iron and the copper mass in the
machine. The fractional winding allows a longer stator stack in
the same frame length than conventional windings since the a) b) c)
axial length of end winding is typically smaller. As the stator
Figure 1. Windings of one phase of a 10-pole-machine: a) a traditional one-
yoke may be manufactured very thin, the maximum air gap layer winding with Q = 30 and q = 1, b) a one-layer fractional winding Q = 12
diameter in a certain limited stator external diameter is and q = 0.4 and c) a two-layer fractional winding with Q = 12 and q = 0.4,
available with this machine type leading to high torque. where the slot is divided vertically.
Compared to conventional windings (q 1) it can be shown
that the length of the end winding is less than one third of the The end windings of phase A of a 10-pole-machine with
total copper length in concentrated fractional wound machines. different winding constructions are shown in Fig. 1. From this
This forms a remarkable potential to reduce the portion of figure it can be easily seen that the length of the end windings
copper losses considerably. Less copper means also less total of the motor a) are definitely at least three times longer than in
material cost, because copper is much more expensive than motors b) or c). In concentrated winding, structure c), each of
iron. the coils is wound around one tooth. Therefore it is possible to
use automatic winding of the machine. An attractive solution
Some fractional slot machine alternatives have relatively would be, if the coils of the phases could be separately wound
low fundamental winding factors, and they create harmonics and then installed to the stator lamination pack. Having a
and sub-harmonics causing extra heating, additional losses and totally open slot structure enables this option. It can be useful
vibration. These machine types have been studied for small in some cases to manufacture machines with totally open slots
power and sometimes for 1 or 2 phase systems, so they have to have a simpler stator structure, which can of course also
not yet been commonly used at higher power ratings. Because reduce production costs. [7]
1000
1
Torque (p.u.)
28 poles
20 poles
1
500
0.5
0 0
0 45 90 135 180 0 45 90 135 180
Current angle (deg)
Load angle (deg)
Figure 2. The developed torque of fractional slot machines as a function of Figure 4. Torque as a function of the load angle for 12-slot stator with rotors
the current angle. The current density in copper is 5.2 A/mm2. having 10 and 14 poles. Magnet material 10.5 kg.
U s EPM
P=m sin , (6)
Ld
where Us is the supply phase voltage, EPM is the induced back
EMF, is the load angle and Ld is the direct axis inductance.
It was also noticed that a 12-slot-10-pole-motor with a Figure 5. A surface magnet motor and a V-magnet motor (mass of magnets
permanent magnet mass of 10.5 kg could achieve almost the 12.5 kg) with formed pole shoe at load situation.
same peak torque as the 24-slot-20-pole-motor with 9.5 kg of
magnets. According to the FE analysis the 24-slot-20-pole- In Fig. 6, are shown the results of static FE analysis of 12-
machine (q = 0.4) seems to be an interesting selection for the slot-10-pole-machines: The surface magnet motor with 10.7 kg
prototype machine. However, it was decided to manufacture of the magnet material is compared to a V-magnet motor which
the prototype motor with lower pole and slot number, but with has a normal pole shoe (smooth rotor) and also 10.7 kg of the
the same number of slots per pole and phase, i.e. q = 0.4 with magnet material.
only 12-slots and 10-poles.
1.2
IV. 12-SLOT-10-POLE-MOTOR 1
45 KW PROTOTYPE PARAMETERS
Figure 8. The no-load voltage wave forms from measurement and from FE
Magnet V-magnet
computation.
Slots/poles 12 / 10
Winding factor 0.933
Rated current [A] 86 B. Generator test
Pout [kW] 45 The 45 kW PM machine was driven against resistive load
Speed [rpm] 420 to achieve an output power half of the rated power 22.5 kW. A
Efficiency 0.915 DC-motor was used to run the PM machine in this test. The
Up [V] 368 heat of the machine was measured with Pt-100 temperature
Winding turns per phase, Nph 104 sensors. Transient FEA was carried out to see, if the same
Rphase [] 0.114 values are achieved by computation. The motor winding was
Current density [A/mm2] 5.4 star connected. The speed was fixed to 420 rpm. FE
Magnets [kg] 12.5 computation results showed that the current, power and voltage
Air gap flux density created by magnets [T] 0.935 values are similar to the measurement results as is shown in
table VI. The computed voltage 139.6 V is less than the
measured 144.7 V, which is because the magnet material used
0.6
0.4
Measurement
trendline of FEA
0
0 45 90 135 180
Load angle (deg)