Radial force F r is the main cause of electromagnetic vibration and noise in motors. In this study, the vibration and noise characteristics of a permanent magnet synchronous motor (PMSM) with consideration of rotor-step skewing are investigated. Firstly, the analytical model of F r considering rotor-step skewing is deduced based on the Maxwell stress tensor method. The influence of rotor-step skewing on F r of the PMSM is then analysed and summarised. Taking a 65 kW PMSM commonly used in electric vehicles as an example, combined with electromagnetic finite element analysis, F r is then evaluated. Secondly, an electromagnetic vibration and noise simulation analysis is conducted based on a multi-physical field joint simulation platform, from which the influence of rotor-step skewing on the vibration and noise is then summarised. Finally, a noise experiment is then carried out. The results obtained from the multi-physical analysis and the tests conducted are presented to validate the precision of the simulation models, and the accuracy of the analytical model of F r. 2 Structure of rotor-step-skewed PMSM 2.1 Structure features of rotor-step-skewed PMSM The rotor-skewing structure has been considered as an effective measure to suppress the electromagnetic vibration noise of PMSMs. The rotor structure with step skewing is shown in Fig. 1b. The rotor is divided into several segments equably in the axial direction, and each segment is shifted sequentially at the same angle in the circumferential direction. 2.2 Specifications of prototype The cross-sectional view of the prototype studied in this paper is shown in Fig. 2. The motor is an 8-pole 48-slot PMSM with a rated power of 65 kW. The specification of which is shown in Table 1.
Interior permanent magnet synchronous machines (IPMSMs) with V‐shaped permanent magnet (PM) rotors are widely used as traction motors in electric vehicles because of their high torque density and high efficiency. However, the V‐shape IPMSMs have the disadvantages of inevitable torque ripple due to the non‐sinusoidal air‐gap flux density distribution and the utilisation of the reluctance torque. In this study, with the aim of improving the torque ripple characteristics, a modified V‐shaped IPMSM rotor configuration with bridges extended inwards towards the pole centre is proposed to generate a more sinusoidal air‐gap flux density waveform. The proposed topology, referred to as ‘Type C’ within this study, is compared with baseline rotor configuration references, namely ‘Type A’ which is a conventional V‐shaped PM rotor, as well as ‘Type B’ which is a related configuration with a mechanically non‐uniform air gap. The analysis results show that the rotor ‘Type C’ exhibits significant advantages in terms of reducing cogging torque, torque ripple and radial force, without incurring additional air‐gap friction losses. Finally, a prototype of the IPMSM with the proposed rotor configuration is manufactured and tested, verifying the predicted benefits experimentally.
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