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TABLE I TABLE IV
0.25-kW DESIGN 5.0-kW DESIGN
TABLE II TABLE V
1.0-kW DESIGN 10.0-kW DESIGN
TABLE III in most industries. The rated speed is chosen to be 1000 r/min
3.0-kW DESIGN
with a no-load maximum speed of 2000 r/min for all the ma-
chines except the 1/4-kW machines. 2000 r/min was the rated
speed for these machines, with a 3000 r/min no-load speed at
375-V dc. All the designs used high-energy rare-earth sintered
NdFeB magnets. The winding currents are assumed to be lim-
ited at rated speed. The no-load speed of 2000 r/min corresponds
to a motor back-EMF constant of about 187 V/kr/min, line
to line. This parameter is also chosen so that the sizing com-
parison can be made for machines that can be replaced for a
certain application making the replacement transparent to the
5) Type E, Axial Field Slotless Dual Air Gap: This is an axial
motor drive electronics. All the performance calculations are
field slotless motor with two air gaps. The only steel in the
made using a three-phase six-step drive and the back EMFs of
motor is that of the two stator back irons (yokes). This de-
all the machines are assumed to be trapezoidal. The 1/4-kW ma-
sign also cancels out the attractive forces that exist even in
chines used a 12slot eight-pole combination while all the other
the slotless single-air-gap axial field machine. The mag-
slotted designs used a 24-slot eight-pole design.
nets used here are also high-energy rare-earth magnets.
Tables IV give the values of the six parameters that are held
There is no back iron in the rotor and the magnet flux
more or less a constant for each of the five different output power
crosses two air gaps.
levels. The slot fill is calculated assuming a fixed slot insulation
thickness and using square cross-sectional wire even though the
II. BASIS FOR COMPARISON
actual wire being used is circular. The flux densities in the steel
To make the comparison, several parameters are held constant and air gap represent peak values. The magnet thickness is de-
or very near to each other. The radial field machine is designed fined in the direction of magnetization and, hence, radial in the
first to provide the benchmark and then the design of the axial case of the conventional motor and axial in all other designs. It
field machines is attempted. is also assumed that the machines are cooled adequately such
The slot fill for all the slotted machines is kept constant with that there is no possibility of demagnetization due to excessive
a small variation for each of the power ratings. The slotless ma- temperature. The magnets of all the machines are dimensioned
chines have different slot fills but they are made consistent with such that the considered stator currents do not demagnetize the
the values obtained for each of the different ratings. The air gap, magnets. The three-phase windings are star connected. As the
yoke, and tooth flux densities are kept constant with some small power output gets larger, multiple strands of copper wire is used
variation for each of the slotted designs. Tables IV give the pa- in the stator coils. In actuality, the number of strands is usually
rameters forming the basis for the design of machines for five increased while decreasing the wire diameter so that forming
power levels. The following power ratings are chosen: 1/4, 1, the conductors in the slots and the end turns becomes easier.
3, 5, and 10 kW for the shaft output power. All the machines In each case except for the two smallest machines, the magnet
are designed using 375 V dc as the rated supply voltage. This thickness in the direction of magnetization had to be increased
value corresponds to the dc voltage obtained when single-phase for the slotless machines due to the larger air gap created to
440-V ac rms is rectified and this ac voltage is readily available accommodate the windings. The cross section of the copper wire
SITAPATI AND KRISHNAN: RADIAL AND AXIAL FIELD, PERMANENT-MAGNET, BRUSHLESS MACHINES 1221
is increased with power output to reduce copper losses. All the TABLE VI
designs require forced cooling for continuous operation at rated OUTER DIAMETER IN MILLIMETERS
output power as indicated by the total power loss. The phase
resistance for each of the designs varies as a result of making
other parameters equal.
The air-gap flux density is nearly the same for all of the
slotted designs but falls sharply for the slotless designs due to
the large air gap. This drop would be even greater if the magnet
thickness were not increased. The dual-gap axial field motor has
a higher air-gap flux density than the single-gap slotless motor
because of the smaller air gap per side. In this case, the turns
required per slot pitch are almost half because of two stator as- TABLE VII
LENGTH IN MILLIMETERS
semblies.
The steel flux density is always kept below 1.2 T so the loss
per unit weight is nearly the same. Due to the absence of teeth,
the slotless machines have a much higher slot fill than the slotted
ones. The active iron volume is taken to be the volume of the
stator teeth, stator back iron, and rotor back iron. The active
weight is considered to be the weight of the active volume. This
approach neglects additional material required for the housing,
shaft, bearings, and cooling fan as they are specific to a given
application.
In summary, assumptions made for the comparison are as fol-
lows:
phase resistance kept nearly the same for each design;
wire size kept the same;
air-gap flux density kept nearly the same;
steel flux density kept nearly the same;
slot fill kept nearly the same;
shaft diameter is 20 mm;
shaft extension is 30 mm;
end-turns extension fixed at 10 mm per side;
bearings and end bells contained within 20 mm per side in
radial machines;
bearings contained inside the inner diameter of the stator
in axial machines;
package volume consists of active volume plus the addi-
tional space required for bearings, end bells, and end turns;
Fig. 1. Active volume versus output power.
active volume is the volume of stator teeth, yoke, and rotor
yoke;
active weight is the weight of the active volume; five topologies are similar, the length is very different. The axial
motor has a trapezoidal back-EMF wave shape and is com- field motor has a very small axial profile when compared to the
mutated by a six-step drive; radial field motor.
magnets never demagnetized by temperature rise as ade- The axial field motor topology is best suited in applications
quate cooling is provided. where the axial space is limited and a very flat profile is re-
quired. The slotless machines require a larger diameter due to
III. RESULTS OF THE COMPARISON the additional turns present. The space required for the end turns
also grows with the number of turns that are wound in each coil.
The results of the comparison are given in graphical form. For
The tables indicate that even though the diameter of the slotless
each of the power ratings, the comparisons consist of physical
machines are larger when compared to the slotted axial field ma-
size (diameter, length, and volume), moment of inertia, weight
chines, the length in the axial direction is smaller, offering the
of copper and iron, weight of magnet material, copper and iron
flattest profile of the five different topologies.
loss, power per unit moment of inertia, power per unit active
Fig. 1 shows the variation of total volume required for the five
weight, and power per unit active volume.
power ratings. It can be seen that the volume required for the radial
field motor is much larger than any of the axial field machines.
A. Volume This difference widens with increasing output. The slotless
Tables VI and VII show the motor outer diameter and length dual- and single-gap axial field machines have similar volumes.
for the five power ratings chosen. While the diameters of the The slotted axial field machines also have similar volumes.
1222 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 37, NO. 5, SEPTEMBER/OCTOBER 2001
Fig. 2. Moment of inertia versus output power. Fig. 3. Steel weight versus output power.
B. Moment of Inertia
Fig. 2 shows the variation of moment of inertia.
For any power rating, the radial field motor has the largest
moment of inertia. This is due to the longer rotor length as well
as the assumption that the rotor is solid. The longer motor length
is required because the torque is produced at a fixed air-gap di-
ameter which is effectively smaller than the axial field motor
where the torque-producing diameter grows radially for a fixed
air-gap length. In applications where rapid acceleration and de-
celeration are required, the axial field motor is the better choice.
All of the axial field topologies have a similar moment of inertia.
For the single-gap machines, the rotor contains both the magnets
as well as the magnet back iron constituting the return path for
the magnet flux.
For the dual-gap units, the magnet thickness is larger, but the
densities of steel and magnet are very similar. This makes the Fig. 4. Copper weight versus output power.
moment of inertia of the axial field machines more or less equal.
The dual-gap slotless machine has the lowest moment of inertia volume of the axial field machines is generally smaller than
as it does not contain any steel in the rotor and the density of the the radial field motor. This means that the weight will also be
magnet material is slightly lower than that of steel. Additional smaller and this agrees with the calculated parameters shown in
material that is used to retain the magnets and couple them to the Fig. 3.
shaft has been ignored. It is valid to do this because of the vast
difference in the moment of inertia between the axial and radial D. Copper Weight
field machines as shown in Fig. 2. This difference in moment of Fig. 4 shows the variation of the required copper in each of the
inertia of the rotor is singularly the biggest difference between machines. The maximum copper is required by the single-gap
the radial and axial field machines. slotless motor (type D). This is due to the fact that the flux den-
sity is low in the air gap and there is space in only one stator for
C. Steel Weight the winding. This motor also requires a larger number of turns
Fig. 3 shows the variation of the weight of iron required for per coil to match the back-EMF constant value that was speci-
each of the power ratings. It can be seen that as the power rating fied earlier.
increases, the slotless machines require less iron than the radial The copper required by the radial field and single-gap axial
field machines. They are similar in value at lower ratings with field slotted machines is almost identical. Both the dual-gap
the radial field motor requiring the least iron. The lowest iron slotless and slotted axial field machines require less copper than
weight is in the single-gap slotless motor that does not have any the radial field machine due to the presence of a larger magnet
teeth or tooth tips. The only iron in the electromagnetic circuit area. This also indicates that for a given value of output power,
is in the stator and rotor yokes. The next higher weight is in the the single-gap slotless motor will experience the largest copper
single-gap slotted motor followed by the dual-gap slotless and loss. The lowest weight in type C is due to the fact that the stator
the dual-gap slotted motor. teeth help to guide the flux across a small air gap, thus creating
Intuitively, it may be seen that as the total volume of the motor a better utilization of the air-gap flux density as well due to this
gets larger, the weight also increases. Fig. 1 shows that the total topology having two stators. In the case of the dual-gap slotted
SITAPATI AND KRISHNAN: RADIAL AND AXIAL FIELD, PERMANENT-MAGNET, BRUSHLESS MACHINES 1223
Fig. 5. Magnet weight versus output power. Fig. 6. Copper loss versus output power.
machine, there are two stators that can be wound and the gener-
ated back EMF is a result of contribution from both the wound
stators, thus almost halving the required turns. In the case of
the slotless machines, the thicker magnet and larger diameter
reduces the requirement for a large number of turns.
E. Magnet Weight
Fig. 5 shows the variation of the required magnet weight. The
pole span for all the machines is taken to be 170 electrical de-
grees. All the machines are designed using 35 MGOe energy
product sintered NdFeB material.
The two axial field slotless machines require the maximum
magnet volume and, hence, weight due to the large air gaps
present. The dual-gap slotless machine requirement is slightly
lower than the single-gap slotless machine due to two available
stators. It is to be noted that the slotted axial field motors re- Fig. 7. Iron loss versus output power.
quire less magnet material than the radial field machine for all
the power ratings. sistance as the number of turns reduces, but this increases the
cost of the magnets which can cost much more than the cost of
F. Copper Losses cooling.
The copper losses are in the same ratio as the weight of
copper. The current required by each of the machines at each G. Iron Losses
of the power ratings is the same and losses are directly propor- Fig. 7 shows the iron loss variation for each of the designs.
tional to the weight. At larger power outputs, the single-gap This is directly proportional to the weight of iron as the flux
slotless axial field motor has high copper losses and will require density is nearly the same for all cases. The commutation fre-
some form of forced cooling unless the duty cycle is very small. quency is also low, making the iron losses very low for all the
The radial field motor and the slotted single- and dual-gap machines at the power rating and speed chosen.
axial field machines have very similar copper losses and have The lowest iron loss is of the single gap slotless axial motor
the lowest values. It is applicable, as these are the three ma- which has the lowest iron weight. This is followed by the single
chines that have stators to help carry the magnet flux. Thus, they gap slotted motor. The radial field, dual gap slotted and the dual
require lower turns per coil for the same generated back EMF gap slotless machines have very similar iron loss because of
when compared to the machines without any stator slots. Then, their similar weights. If there is sufficient cooling available, the
the air gap becomes large, resulting in a larger number of turns single-gap slotless axial field motor can be used when minimum
per coil for the same induced EMF. The dual-gap slotless axial weight is required for a given power rating.
field motor copper loss lies in between these and the single-gap As with the case of the copper losses, iron losses can be re-
slotless motor. The copper loss variation is shown in Fig. 6 duced by increasing the amount of iron in the teeth and back
Copper losses can be reduced further by increasing the wire irons. This will lower the flux density, but will increase the
size, which will result in a larger machine size. The alternative package size and weight of the motor. The slotless machines
will be to increase the magnetic loading of the machine by in- do not have much loss in the rotor back iron, but undergo loss
creasing the air-gap flux density. This will result in a lower re- in the stator back iron where the flux from to the magnets and
1224 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 37, NO. 5, SEPTEMBER/OCTOBER 2001
Fig. 8. Total loss versus output power. Fig. 9. Torque/moment of inertia versus output power.
H. Total Losses
Fig. 8 shows the sum of the copper and iron losses. As the
iron losses are not as significant as the copper losses, the total
loss trend is to follow the copper loss. The radial field motor,
dual-gap, slotted, and slotless machines have very similar total
losses. The slotless single-gap motor has the highest loss with
the slotless dual-gap axial field machine in between.
It must be noted that the losses shown in Fig. 8 indicate only
the electromagnetic losses. There are other factors that add, such Fig. 10. Power/active weight versus output power.
as bearing friction and preload loss, loss due to air resistance,
and other stray losses which are not calculated in this paper. noted that there is little variation as the output power increases.
Some of these losses are highly dependent on the mechanical The single-gap slotless motor is next, as the rotor contains back
design of the motor and may also depend on the final configu- iron, making the weight higher than the other axial machines.
ration of the machine. Friction and preload losses will be sig- The larger magnet required to drive flux through the large air
nificantly lower in the dual-gap and radial field machines than gap requires a thicker back iron, making this motor have the
the single-gap axial field machines due to the attractive force be- lowest axial field machine torque per unit moment of inertia. By
tween the rotor and stator. In these machines, the force of attrac- the same argument, the dual-gap slotless motor has the largest
tion has to be canceled by a mechanical arrangement and there value, with the slotted axial machines in between.
is some friction loss associated with this and it is inevitable. The At lower power levels, all the axial field machines have mo-
magnitude of this loss is proportional to the force of attraction ment of inertia values that are similar, but as the power levels
which is a function of the magnet strength, air-gap length, and grow the differences between the axial machines provide an in-
the outer and inner diameters of the magnet and stator assem- dication of the motor best suited for an application. The axial
blies. Windage losses may be low due to the relatively low speed field dual-air-gap machine does not contain any rotor back iron,
of operation. which reduces the weight of the rotor. Also, the magnet mate-
rial density is assumed to be lower than that of steel, making this
I. Torque per Unit Moment of Inertia rotor have the lowest moment of inertia.
Fig. 9 shows the variation of the ratio of shaft torque per unit
moment of inertia for each of the designs. This is an important J. Power per Unit Active Weight
parameter as it gives an indication of the acceleration of the rotor Fig. 10 shows the variation of the ratio of power per unit active
and the mechanical response for any power rating. weight for each of the designs. The active weight consists of
The figure shows that the radial field motor has the lowest the copper and iron weight required by the magnetic circuit. At
torque for a given moment of inertia. This is because the rotor higher power levels, the radial field motor ratio drops away from
has the largest length for any given power rating. It is also to be the axial field machines.
SITAPATI AND KRISHNAN: RADIAL AND AXIAL FIELD, PERMANENT-MAGNET, BRUSHLESS MACHINES 1225
APPENDIX II
CORE LOSS CALCULATIONS
Core loss is calculated by using the loss versus flux density
data provided by the electrical grade steel manufacturer. It is
assumed that there are no rotor losses as well as all the core
losses are contributed only by the magnet flux. A cubic spline
algorithm is used to calculate the loss per kilogram at 60 Hz for
the flux density in the teeth and stator. The following equation
is used for the total loss in the stator teeth:
Fig. 11. Power/active volume versus output power.