Static eccentricity (SE) is frequently generated by manufacturing processes. As the nonuniformity of the air-gap length is caused by the SE, the torque ripple and cogging torque increase in the motor. This study analyzes the distorted back electromotive force (EMF) and cogging torque due to SE. Further, a motor design considering SE is performed for stable back EMF and low cogging torque. First, the SE was diagnosed and analyzed using the back EMF and cogging torque measured from the test results of the base model. In addition, the rotor position was calculated using the unbalanced back EMF due to the SE. The calculated rotor position is used when analyzing phenomena due to SE and applied to robust design. Subsequently, robust design optimization was performed to improve the unbalanced back EMF and cogging torque due to SE. Using finite element analysis (FEA) considering SE, the shape of the stator was designed based on the base model. The estimated rotor position from the base model was applied to the optimum model to confirm its robustness from SE’s effects. Finally, the base and optimum models were compared through the test results.
In multi-pole permanent magnets (PMs) such a ring-type PMs, as multi-poles are magnetized in one segment, the ends of each pole are weakly magnetized, which is known as the dead zone. Thus, when analyzing characteristics of the motor with multi-pole PMs, accurate results can be obtained by considering the magnetization distribution. For this reason, this paper proposed an equivalent magnetic circuit (EMC) for external-rotor surface-mounted permanent magnet synchronous motors (SPMSMs) considering the dead zone to analyze the effects of the dead zone on the characteristics of the motor. As the magnetization in the dead zone gradually decreases toward the end of the pole, the magnetization distribution is assumed to have a trapezoidal shape. To describe the magnetization distribution, each pole was divided into several elements, and the equivalent residual magnetic flux density was applied to the elements of the dead zone. Finally, the validity of the proposed EMC was verified by comparing the back electro-motive force and air-gap magnetic flux density obtained by the EMC, finite-element analysis, and test.
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