Permanent-magnet excited synchronous motor servo drives are increasingly employed in industrial applications. During mass production, deviations from the ideal machine occur. Thereby, parasitic effects such as cogging torque and torque ripple are influenced in particular. For permanent-magnet excited machines, the magnet's quality is important. There are many possible failure configurations requiring the study of their influence on the machine's behavior. In this paper, an approach for the estimation of cogging torque considering magnetization faults is presented. This approach is applied to determine crucial configurations of permanent-magnet faults. The intent is to evaluate the influence of the faulty magnetic materials with its asymmetries on the later produced machine. In the process, analytical and numerical methods are combined whereby finally a small computational effort with accurate results is achieved.Index Terms-Cogging torque, electrical machine, estimation of manufacturing fault tolerance, magnetization fault, permanent-magnet motor, servo-drive.
PurposeDisturbing vibrations and noise of electrical machines are gaining impact. The paper aims to focus on the necessity of estimating the electromagnetic, structure‐dynamical, and acoustic behaviour of the machine during designing and before proto‐typing.Design/methodology/approachAn adequate tool is numerical simulation applying the finite‐element method (FEM) and the boundary‐element method (BEM) allowing for the structured analysis and evaluation of audible noise also caused by manufacturing tolerances.FindingsThe simulated results show good accordance to measurement results. The methods and simulation tools allow the analysis and evaluation of every type of energy converter with respect to its electromagnetic, structure‐dynamical and acoustic behaviour.Originality/valueThe methods developed and proved can be applied to any electromagnetic device in general.
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