This paper presents a design environment for permanent-magnet synchronous motors (PMSMs). Two design examples for electric vehicle (EV) traction are presented: one interior PM machine of the PM-assisted synchronous reluctance (PM-SyR) type and one concentrated-winding surface-mounted PM motor (CW-SPM). The parametric design software used in the paper includes design equations, finite element analysis (FEA) and multi-objective optimization algorithms for the design of PMSMs. The paper presents two possible design methodologies, for the two mentioned test cases. EV application was chosen for its many challenging aspects, involving flux weakening for extended speed range, discontinuous duty cycles, high transient overload requirements, high efficiency over a large area of operation, and so forth. The design examples are compared to selected benchmark designs in terms of operating range in the torque versus speed domain and efficiency maps, all FEA evaluated. Besides magnetics, thermal and structural aspects are included in the study.
This paper investigates the applicability of fractional-slot concentrated windings to Synchronous Reluctance Motors for industry applications. Tooth-wound winding arrangements are attractive for the industry due to their lower cost of manufacturing, but when associated to a synchronous reluctance rotor they tend to lower the output torque and power factor of the machine significantly, and to excite high values of torque ripple. The proposed analysis shows that after design optimization one synchronous reluctance machine with concentrated windings can reach the IE4 (super-premium) efficiency class within the same frame of a distributed-winding synchronous reluctance machine of the same size. Moreover, the paper demonstrates that the synchronous reluctance rotor must be purposely redesigned for the new stator, when passing from distributed to concentrated windings, for the sake of torque ripple mitigation. A step by step design procedure is provided, supported by finite-element analysis and experimental results.
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