Aspects of Permanent Magnet Machine Design

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1 Aspects of Permanent Magnet Machine Design Christine Ross February 7, 2011 Grainger Center for Electric Machinery and Electromechanics

2 Outline Permanent Magnet (PM) Machine Fundamentals Motivation and Application Design Aspects PM Material PM Rotor Configurations Manufacturing Processes Design Tools 2

Permanent Magnet (PM) Machine Fundamentals Focus on electronically controlled PM AC synchronous machines Rotor magnetic field is supplied by PMs Stator windings are sinusoidally

3 Permanent Magnet (PM) Machine Fundamentals Focus on electronically controlled PM AC synchronous machines Rotor magnetic field is supplied by PMs Stator windings are sinusoidally distributed windings, excited by sine-wave currents Brushless DC machines can also use PMs 3-phase stator windings Laminated stator 4-pole PM rotor Cross-section of surface-mounted PM machine 3

4 PM Machine Theory Output torque is proportional to power Control instantaneous torque by controlling magnitude of phase currents N f 60 RPM p speed N in RPM supply frequency f number of pole pairs p T P rm output torque T output power P rotor speed rm in rad/s 4

5 PM Machine Control Instantaneous torque control Servo performance kw Fast dynamic response Smooth output torque Accurate rotor position sensor information needed Back-emf e ωrm Single-phase equivalent circuit 5

PM Machine Control Flux-weakening control Constant power drives Traction, washing machines, starter/alternators Require constant output power over a speed range To operate above rated speed while

6 PM Machine Control Flux-weakening control Constant power drives Traction, washing machines, starter/alternators Require constant output power over a speed range To operate above rated speed while maintaining rated terminal voltage, reduce flux by controlling magnetizing current T Iarm V [1] Soong Ideal flux-weakening characteristics torque T magnetic flux armature current Iarm terminal voltage V magnetic flux angular speed in rad/s 6

7 Motivation for PM Machine Motivation for PM machines: High efficiency (at full load) High power density Simple variable-frequency control Rotor excited without current No rotor conductor loss and heat Magnet eddy current loss is lower than iron loss and rotor cage loss 7

8 PM Machine Disadvantages Magnet cost New magnet manufacturing processes Magnet sensitivity to temperature and demagnetization Little control of magnet field Always have no-load spinning losses Without control, over speed means over voltage fault management issues 8

PM Machine Applications AC PM machines Servo control systems Precision machine tools IPM washing-machines, air conditioning compressors, hybrid vehicle traction DC PM machines Lower cost

9 PM Machine Applications AC PM machines Servo control systems Precision machine tools IPM washing-machines, air conditioning compressors, hybrid vehicle traction DC PM machines Lower cost variable-speed applications where smoothest output torque is not required Computer fans, disk drives, actuators Industrial applications where constant speed is necessary IPM washing-machine motors [5] Hendershot and Miller 9

10 Design Specifications Electrical Environmental Ambient temperature Cooling system Structure Vibration Mechanical outputs Torque Speed Power Key features of machines Flux linkage Saliency, inductances Assembly process Magnet cost Number of magnets Simplicity of design Field weakening Reluctance torque Field control Line start, no inverter 10

11 PM Material Soft magnetic material (steel) small B-H loop Hard magnetic material (PM) large B-H loop Remnant Flux Density B r Coercivity H c Choose magnets based on high B r and H c 11

PM Material PM B r (T) H c (ka/m) Cost Resistivity (µω-cm) Max. Working Temp. (ºC) Alnico 5-7 1.3 60 47 > 500 Curie Temp. (ºC) Ferrite 0.

12 PM Material PM B r (T) H c (ka/m) Cost Resistivity (µω-cm) Max. Working Temp. (ºC) Alnico > 500 Curie Temp. (ºC) Ferrite low >10, NdFeB (sintered) Sm 2 Co 7 (sintered) medium Higher than NdFeB [2] Miller [3] Hendershot and Miller Arnold Magnetics

13 PM Material Chinese dependency No shortage Mountain Pass, CA Idaho Nd is about as common as Cu Arnold Magnetic Technologies 13

PM Machine Rotor Configurations Surface-mounted PM rotor Maximum

low speeds, magnets are bonded to hub of soft magnetic steel Higher

demagnetization; wider speed range using flux-weakening; increases

14 PM Machine Rotor Configurations Surface-mounted PM rotor Maximum magnet flux linkage with stator Simple, robust, manufacturable For low speeds, magnets are bonded to hub of soft magnetic steel Higher speeds use a retaining sleeve Inset better protection against demagnetization; wider speed range using flux-weakening; increases saliency; but also increases leakage Inset magnets Surface bread-loaf magnets 14

with lower loss Increases saliency and reluctance

15 PM Machine Rotor Configurations Interior-mounted PM (IPM) rotor IPM Advantages Extended speed range with lower loss Increases saliency and reluctance torque Greater field weakening capability A. O. Smith 15

16 PM Machine Topology SMPM: More mechanically robust Magnet losses can be an issue (not shielded by rotor iron); reduce by segmenting magnets axially or radially or increasing magnet resistivity IPM: Better demagnetization withstand Characteristic SMPM IPM Saliency No Yes Field Weakening Some Good Controller Standard More Complex [4] Klontz and Soong 16

PM Manufacturing Practices Realistic manufacturing tolerances Key parameters stator inner diameter, rotor outer diameter, no load current, winding temperature Issues with core steels laser cutting,

17 PM Manufacturing Practices Realistic manufacturing tolerances Key parameters stator inner diameter, rotor outer diameter, no load current, winding temperature Issues with core steels laser cutting, punched laminations, lamination thickness Issues with magnets dimensions, loss of strength due to thermal conditioning Hybrid Camry PM synchronous AC motor/generator ecee.colorado.edu High speed practice and limits rotor diameter limits speed 17

PM Machine Design Process Design and simulate motor and driver Separately Combined Analytical, lumped-circuit, and finite-element design tools

18 PM Machine Design Process Design and simulate motor and driver Separately Combined Analytical, lumped-circuit, and finite-element design tools Different tools are used to trade-off understanding of the design, speed, and accuracy Finite element meshing, flux lines and B for SMPM machine A.O. Smith 18

19 Analytical Design Tools Broad simplifying approximations Equivalent circuit parameters Use for initial sizing and performance estimates Performance prediction Limitations Does not initially account for local saturation Requires tuning with FE results 19

20 Analytical Design Tools Core losses Hysteresis loss Eddy current loss Anomalous loss depends on material process, impurities Problems with core loss prediction Stator iron loss: based on knowledge of stator tooth flux density waveforms Usually assumes sinusoidal time-variation and one-dimensional spatial variation Flux waveforms have harmonic frequency and rotational component Use db/dt method for eddy-current term, frequency spectrum method Torque, efficiency, inductance [4] Klontz and Soong 20

21 Lumped-Circuit Design Tools Non-linear magnetic material modeling of simple geometries Need a good understanding of magnetic field distribution to partition Fast to solve, good for optimization Limitations Requires tuning with FE results Lovelace, Jahns, and Lang 21

22 Finite-Element Modeling and Simulation Tools Important aspects model saturation More accurate Essential when saturation is significant Limitations Meshing Only as accurate as model design 2D, 3D Not currently used as a design tool due to computational intensity y (m) Average Magnitude Magnetic Flux Density linear run x (m) Nonlinear magnetostatic FE average magnetic flux density solution for machine with solid rotor

23 Ideal Design Tool Easy to set up Models all significant aspects of machine that affect performance magnetic saturation Efficiently simulates transient conditions and steady-state operation 23

24 References [1] W.L. Soong, Design and Modeling of Axially-Laminated Interior Permanent Magnet Motor Drives for Field-Weakening Applications, Ph.D. Thesis, School of Electrical and Electronic Engineering, University of Glasgow, [2] T.J.E. Miller, Brushless Permanent-Magnet and Reluctance Motor Drives, Oxford Science Publications, [3] J.R. Hendershot and T.J.E. Miller, Design of Brushless Permanent-Magnet Motors, Magna Physics Publishing and Oxford University Press, [4] K. Klontz and W.L. Soong, Design of Interior Permanent Magnet and Brushless DC Machines Taking Theory to Practice course notes [5] J.R. Hendershot and T.J.E. Miller, Design of Brushless Permanent-Magnet Motors, Motor Design Books, Questions? 24

Design of Brushless Permanent-Magnet Machines. J.R. Hendershot Jr. T.J.E. Miller

Design of Brushless Permanent-Magnet Machines J.R. Hendershot Jr. T.J.E. Miller Contents 1 GENERAL INTRODUCTION l 1.1 Definitions and types of brushless motor 1 1.2 Commutation,. 4 1.3 Operation of 3-phase