Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications
Abstract
1. Introduction
- Design of segmented delta-shaped PMs.
- Integration of a three-notched rotor pole shape with two different notch specifications.
- An intermediate flux bridge between the bar-type magnets.
- Embedding of circular flux barriers within the rotor poles.
- Improved magnetic field shifting due to segmented PMs.
- Insertion of flux barriers between the PM segments.
2. Design Topology and Torque Capability
3. Evaluation of Electromagnetic Performance
3.1. No-Load Characteristics
3.2. On-Load Characteristics
3.3. High-Speed Operation
3.4. Thermal Analysis
4. Performance Comparison with State-of-the-Art Designs
- Comparison of the proposed SΔ-IPM with HA shows a 27.84% reduction in PM weight and 2.33- and 2.71-fold increases in torque and power density, respectively. Furthermore, torque ripples are suppressed by 72.38%, and cogging torque is reduced by 94.80%.
- Quantitative study of the proposed SΔ-IPM compared with HC shows a 27.84% reduction in PM weight and enhanced torque and power density by 1.81- and 1.88-fold, respectively. Additionally, cogging torque is reduced by 93.64% at the cost of a 45.29% increase in torque ripples.
- Comparative study of the proposed SΔ-IPM with TP1 shows a 58.99% reduction in PM weight, whereas torque density is improved by 2.62% at the cost of a 20.64% reduction in power density. In addition, cogging torque is reduced by 43.45%, and torque ripples are suppressed by 47.9%.
- Comparative analysis of the proposed SΔ-IPM with TP2 shows a 13.63% reduction in PM weight, 7.45% reduction in cogging torque and 83.65% suppression in torque ripples. Consequently, torque density improves by 2.62%, while power density reduces by 25.62%.
- Analysis of the proposed SΔ-IPM with CV1 exhibits an 86.42% reduction in PM weight and an 82.93% reduction in cogging torque, along with a 92.45% increase in torque ripples. Moreover, torque density increases by 18.9%, while power density decreases by 3.3%.
- Comparison with CV2 demonstrates a reduction of the PM weight by 36.6% and an enhancement of torque density by 84.19%, whereas power density reduces by 18%. In addition, cogging torque is reduced by 26.6%, and torque ripples are reduced by 82.27%.
- Quantitative comparison of the proposed SΔ-IPM with BI shows a 71.5% reduction in PM weight and enhanced torque and power density by 83.91% and 23%, respectively. Furthermore, cogging torque is reduced by 78.07%, and torque ripples are reduced by 79.6%.
- Comparative analysis of the proposed SΔ-IPM with NL shows a 66.47% reduction in PM weight and an 82.93% decrease in cogging torque, and torque ripples are reduced by 96.96% and 53.21%, respectively. Additionally, torque density improves by 28.54% at the expense of a 31.22% reduction in power density.
- Finally, a comparison of the proposed SΔ-IPM with RZ and TS was conducted. Since RZ and TS adopt traditional wound-field design, comparisons of PM usage are excluded. It is important to note that RZ uses a DC rotor (wound-field, WF), while TS adopts an induction machine. Based on the available performance data, it is evident that the proposed SΔ-IPM offers 96.47% lower cogging torque and 81.13% lower torque ripple than RZ, and 43.27% lower torque ripple than the TS design. Moreover, torque and power density are 75.20% and 72.86% higher than the RZ model, respectively. Additionally, compared with the TS model, a 2.23 increase in torque density is achieved at the cost of a 22% reduction in power density.
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
| EV | Electric Vehicles |
| IPM | Interior Permanent Magnet |
| PM | Permanent Magnet |
| FEA | Finite Element Analysis |
| SΔ-IPM | Segmented delta-shaped IPM |
| HEVs | Hybrid EVs |
| ICE | Internal Combustion Engines |
| FSPM | Flux Switching Permanent Magnet |
| FRPM | Flux Reversal Permanent Magnet |
| SPM | Surface-mounted Permanent Magnet |
| PMSM | Permanent Magnet Synchronous Machines |
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| Symbol | Value (mm) | Symbol | Value (mm) |
|---|---|---|---|
| 75 | 19 | ||
| 120 | 45 | ||
| 74.3 | 31.3 | ||
| 43 | 2 | ||
| 120 | 4 | ||
| 24 | 2 | ||
| 0.81 | 10 | ||
| 6 | 45° | ||
| 36.72° | 3 | ||
| 11 | 8 | ||
| 5 | 3.68 |
| Performance | Value | Unit | |
|---|---|---|---|
| 2D FEA | 3D FEA | ||
| Average torque | 393.7 | 391.4 | Nm |
| Torque ripple ratio | 5.1 | 5.4 | % |
| Output power | 103.073 | 102.416 | kW |
| Machine weight | 32.23 | 32.23 | Kg |
| Copper losses | 1.0789 | 1.365 | kW |
| PM eddy current losses | 1.795 | 1.859 | W |
| Core losses | 3.719 | 3.787 | kW |
| Efficiency | 93.98 | 93.59 | % |
| Specification | HA | HC | TP1 | TP2 | CV1 | CV2 | BI | NL | RZ | TS | Proposed |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Topology | SPM | SPM | IPM | IPM | IPM | PMSM | PMSM | IPM | FW | IM | IPM |
| Winding type | C-DL | C-DL | D-SL | D-SL | D-SL | D-SL | D-SL | D-SL | D-SL | D-DL | D-SL |
| Coil per phase | 8 | 8 | 8 | 8 | 12 | 12 | 12 | 8 | 8 | 12 | 9 |
| Peak phase current | 225 | 250 | 235 | 700 | 325 | 325 | 400 | 480 | 480 | 900 | 600 |
| Stator slots | 24 | 24 | 48 | 48 | 72 | 72 | 72 | 48 | 48 | 60 | 48 |
| Rotor pole pairs | 8 | 8 | 8 | 8 | 12 | 12 | 6 | 4 | 8 | 4 | 8 |
| Stator outer diameter (mm) | 335 | 265 | 264 | 214 | 340 | 340 | 242 | 198.12 | 250 | 254 | 240 |
| Axial length (mm) | 40 | 40 | 50.8 | 60 | 51.5 | 31.5 | 132 | 151.16 | 155 | 152 | 120 |
| PM weight (kg) | 0.79 | 0.79 | 1.39 | 0.66 | 4.2 | 0.9 | 2 | 1.7 | - | - | 0.57 |
| Total motor weight (kg) | 22.86 | 18.22 | 19.08 | 15.9 | 30.15 | 19.6 | 42 | 33.1 | 48.6 | 60.3 | 32.23 |
| Performance | HA | HC | TP1 | TP2 | CV1 | CV2 | BI | NL | RZ | TS | Proposed |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Cogging torque (pk-pk) (Nm) | 10.97 | 8.97 | 1.31 | 0.53 | 3.34 | 0.45 | 2.6 | 18.8 | 16.19 | - | 0.57 |
| Torque ripples at peak current | 18.47 | 3.51 | 9.79 | 31.2 | 2.65 | 28.78 | 25 | 10.9 | 27.03 | 8.99 | 5.1 |
| Average torque at peak current | 119.5 | 122.8 | 227.9 | 191 | 309.8 | 130.1 | 300 | 314.7 | 339 | 330 | 393.709 |
| Torque density (Nm/kg) | 5.22 | 6.73 | 11.9 | 12 | 10.27 | 6.63 | 6.64 | 9.5 | 6.97 | 5.47 | 12.212 |
| Torque per PM weight (Nm/kg) | 151.2 | 155.4 | 163.9 | 289 | 73.76 | 118.2 | 93.75 | 185 | - | - | 683.64 |
| Maximum output power (kW) | 27.2 | 31 | 77 | 68.4 | 100.4 | 78.2 | 121 | 154 | 90.2 | 250 | 103.073 |
| Power density (kW/kg) | 1.18 | 1.7 | 4.03 | 4.3 | 3.3 | 3.9 | 2.6 | 4.65 | 1.85 | 4.1 | 3.198 |
| PM weight (kW/kg) | 34.4 | 39.2 | 55.39 | 103.6 | 23.9 | 86.8 | 37.8 | 90.5 | - | - | 178.977 |
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© 2026 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license.
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Ullah, W.; Fatima, M.; Abido, M.A.; Akuru, U.B.; Samkari, H.S.; Allehyani, M.F.; Junejo, A.K. Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications. Machines 2026, 14, 530. https://doi.org/10.3390/machines14050530
Ullah W, Fatima M, Abido MA, Akuru UB, Samkari HS, Allehyani MF, Junejo AK. Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications. Machines. 2026; 14(5):530. https://doi.org/10.3390/machines14050530
Chicago/Turabian StyleUllah, Wasiq, Mehroz Fatima, Mohammad A. Abido, Udochukwu B. Akuru, Husam S. Samkari, Mohammed F. Allehyani, and Abdul Khalique Junejo. 2026. "Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications" Machines 14, no. 5: 530. https://doi.org/10.3390/machines14050530
APA StyleUllah, W., Fatima, M., Abido, M. A., Akuru, U. B., Samkari, H. S., Allehyani, M. F., & Junejo, A. K. (2026). Design Analysis and Comparison of a Novel IPM Synchronous Machine with Minimum Rare-Earth PM Usage for EV Industrial Applications. Machines, 14(5), 530. https://doi.org/10.3390/machines14050530

