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Electrical Machine Systems with High Efficiency, Reliability and Integration

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A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "F: Electrical Engineering".

Deadline for manuscript submissions: closed (25 August 2025) | Viewed by 7388

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Special Issue Editors

Prof. Dr. Tao Wang

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Guest Editor

College of Electrical Engineering, Zhejiang University, Hangzhou 310058, China
Interests: wind power generation; motor drive and advanced control

Dr. Chenwen Cheng

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Guest Editor

School of Electrical Engineering, Southeast University, Nanjing 210018, China
Interests: motor control; wireless power transfer; high-frequency converter

Dr. Yang Xiao

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Guest Editor

School of Engineering, University of Leicester, Leicester LE1 7RH, UK
Interests: advanced electrical machine design and control for electrified transportation, energy storage, humanoid robots, and large scale power generation; AI-assisted design and optimization of electrical machine systems
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Special Issue Information

Dear Colleagues,

In recent decades, significant advancements have been achieved in electrification, sustainability, and automation across many industries. Global electrification efforts to tackle carbon emissions and other environmental challenges will surely continue; therefore, the development of advanced electrical machines, which work as critical components in electrical propulsion and drive systems, is valuable for both academia and the industry sectors. To address the ever-increasing demands for electrical generation and propulsion systems in different applications, advanced electrical machines are required to provide high efficiency, high reliability, and the integrated design of machine drives.

The development of advanced electrical machines and drives, via the integration of electrical machine and power electronics devices, requires innovative approaches and efforts at both the component level and systematic level. Additionally, novel designs, optimization, and new techniques for manufacturing electrical machine and power electronics converters can facilitate the development of ground-breaking, high-performance machine and drive systems, thereby enabling high efficiency and high reliability. On the control side, cutting-edge control methods and algorithms, including predictive control, fault-tolerant control, and sensorless control, are being explored to enhance the performance of machine drive systems. Moreover, the integration of electrical machines and drives may also inspire further performance improvements from the systematic perspective. Thus, it is advantageous to promote the research and application of advanced electrical machines.

This Special Issue is dedicated to providing a platform for researchers to share their research and advancements in electrical machines and drives related to high efficiency, high reliability, and integrated machine drive systems, as well as to contribute to ongoing progress in this dynamic field.

In this Special Issue, original research articles and reviews are welcome. Research areas may include (but are not limited to) the following:

Multi-phase electrical machines and drives;
Fault diagnosis and fault-tolerant control of electrical machines and converters;
Advanced linear motors and drives;
High-speed electrical machines and drives;
Non- or less permanent magnet machines (switched reluctance machine, hybrid excited machine, etc.);
Sensorless control of electrical machines;
High-power density motors and converters;
Motor and drive integrated system;
Loss modeling and high efficiency design of electrical machines and converters;
High reliability topology, structure, and assembly of electrical machines;
Multi-physics design of electrical machines;
Artificial-intelligence-assisted design of electrical machines and drives.

We look forward to hearing from you.

Prof. Dr. Tao Wang
Dr. Chenwen Cheng
Dr. Yang Xiao
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Energies is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

multi-phase electrical machines and drives
fault diagnosis and fault-tolerant control of electrical machines and converters
advanced linear motors and drives
high speed electrical machines and drives
non- or less permanent magnet machines (switched reluctance machine, hybrid excited machine, etc.)
sensorless control of electrical machines
high-power density motors and converters
motor and drive integrated system
loss modeling and high efficiency design of electrical machines and converters
high reliability topology, structure, and assembly of electrical machines
multi-physics design of electrical machines
artificial-intelligence-assisted design of electrical machines and drives

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Published Papers (9 papers)

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Research

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14 pages, 2203 KB

Open AccessArticle

Design and Analysis of an IE6 Hyper-Efficiency Permanent Magnet Synchronous Motor for Electric Vehicle Applications

by Hayatullah Nory, Ahmet Yildiz, Serhat Aksun and Cansu Aksoy

Energies 2025, 18(17), 4684; https://doi.org/10.3390/en18174684 - 3 Sep 2025

Viewed by 190

Abstract

In this study, a high-efficiency permanent magnet synchronous motor (PMSM) was designed for a geared electric vehicle. The motor was developed for use in an L-category electric vehicle with four wheels and a two-passenger capacity. During the design process, application-specific dimensional constraints, electromagnetic requirements, and material limitations were taken into consideration. A spoke-type rotor structure was adopted to achieve both mechanical robustness and high efficiency with minimized leakage flux. In addition, the combination of a 12-stator slot and a 10-rotor pole was selected to suppress low-order harmonic components and improve torque smoothness. The motor model was analyzed using Siemens Simcenter SPEED software (Product Version 2020.3.1), and an efficiency above 94% was achieved, meeting the IE6 efficiency class. Magnetic flux analysis results showed that the selected core material operated within the magnetic saturation limits. The findings demonstrate that a compact and high-efficiency PMSM design is feasible for electric vehicle applications. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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16 pages, 5272 KB

Open AccessArticle

Performance Comparison of Coreless PCB AFPM Topologies for Duct Fan

by Seung-Hoon Ko, Min-Ki Hong, Na-Rim Jo, Ye-Seo Lee and Won-Ho Kim

Energies 2025, 18(17), 4600; https://doi.org/10.3390/en18174600 - 29 Aug 2025

Viewed by 260

Abstract

Duct fan motors must provide high torque within limited space to maintain airflow while requiring low vibration characteristics to minimize fluid resistance caused by fan oscillation. Axial Flux Permanent Magnet Motor (AFPM) offers higher torque performance than Radial Flux Permanent Magnet Motor (RFPM) due to their large radial and short axial dimensions. In particular, the coreless AFPM structure enables superior low-vibration performance. Conventional AFPM typically employs a core-type stator, which presents manufacturing difficulties. In core-type AFPM, applying a multi-stator configuration linearly increases winding takt time in proportion to the number of stators. Conversely, a Printed Circuit Board (PCB) stator AFPM significantly reduces stator production time, making it favorable for implementing multi-stator topologies. The use of multi-stator structures enables various topological configurations depending on (1) stator placement, (2) magnetization pattern of permanent magnets, and (3) rotor arrangement—each offering specific advantages. This study evaluates and analyzes the performance of different topologies based on efficient arrangements of magnets and stators, aiming to identify the optimal structure for duct fan applications. The validity of the proposed approach and design was verified through three-dimensional finite element analysis (FEA). Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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14 pages, 9427 KB

Open AccessArticle

Optimal Split Ratio in Double-Stator Permanent-Magnet Motors Considering Loss Limitations for Robot Joint Applications

by Tianran He, Yang Shen, Wei Li and Dawei Liang

Energies 2025, 18(14), 3594; https://doi.org/10.3390/en18143594 - 8 Jul 2025

Viewed by 342

Abstract

Recently, humanoid robots with personification behavior and high working efficiency have received significant attention. Meanwhile, high-torque-density motors, which serve as the core power source for robot joints, have also been widely researched. In this paper, a high-torque-density double-stator permanent-magnet (DSPM) motor is designed for robot joint applications, and its outer stator (OS) split ratio (the ratio between the inner and outer diameters of the OS) and inner stator (IS) split ratio (the ratio between the inner and outer diameters of the IS) are analyzed and optimized. Since the DSPM motor has different heat dissipation capabilities for the OS and IS, their different loss limitations should be considered to avoid the risk of local overheating, especially for the IS. This paper shows that the loss limitations affect the optimal OS and IS split ratios, as well as the maximum average torque. The IS loss limitation increases the optimal OS split ratio and decreases the optimal IS split ratio; however, the OS loss limitation has the opposite effect. Additionally, an investigation into the electromagnetic characteristics of the optimized DSPM motor was conducted using the finite element method. Finally, a prototype was manufactured, and the results of the temperature rise experiments verified the feasibility of the proposed DSPM motor and the effectiveness of the optimal method. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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23 pages, 7419 KB

Open AccessArticle

Improved Discrete-Time Active Disturbance Rejection Control for Enhancing Dynamics of Current Loop in LC-Filtered SPMSM Drive System

by Zibo Li, Haitao Yang, Jin Wang, Yali Wang and Libing Zhou

Energies 2025, 18(11), 2894; https://doi.org/10.3390/en18112894 - 30 May 2025

Viewed by 578

Abstract

Active disturbance rejection control is implemented in a LC-filtered surface-mounted permanent magnet synchronous motor (SPMSM) drive system to enhance current control dynamics. However, the combined effects of computation one-beat delay and the pulse-width modulation zero-order hold (ZOH) effect significantly degrade system stability and dynamic performance. To address these limitations, an improved predictive extended state observer (ESO) with an accurate ZOH discretization method is proposed to ensure fast and robust dynamic performance. The predictive ESO predicts one beat to compensate for the delay effect, while the ZOH discretization yields a more precise discrete dynamic model of the system. These combined improvements substantially enhance the system’s phase and gain margins, leading to superior dynamic performance. Furthermore, a discrete-domain transfer function of the control system is analytically derived, with the control parameters systematically designed using frequency-domain analysis to guarantee robust performance. Experimental validation on a LC-filtered SPMSM drive system demonstrates remarkable enhancement in current control dynamics while maintaining sufficient robustness. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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15 pages, 7886 KB

Open AccessArticle

Optimal Rotor Design for Reducing Electromagnetic Vibration in Traction Motors Based on Numerical Analysis

by Seung-Heon Lee, Si-Woo Song, In-Jun Yang, Ju Lee and Won-Ho Kim

Energies 2024, 17(23), 6206; https://doi.org/10.3390/en17236206 - 9 Dec 2024

Cited by 1 | Viewed by 1000

Abstract

Interior permanent magnet synchronous motor (IPMSM) for traction applications have attracted significant attention due to their advantages of high torque and power density as well as a wide operating range. However, these motors suffer from high electromagnetic vibration noise due to their complex structure and structural rigidity. The main sources of this electromagnetic vibration noise are cogging torque, torque ripple, and radial force. To predict electromagnetic vibration noise, finite element analysis (FEA) with flux density analysis of the air gap is essential. This approach allows for the calculation of radial force that is the source of the vibration and enables the prediction of vibration in advance. The data obtained from these analyses provide important guidance for reducing vibration and noise in the design of electric motors. In this paper, the cogging torque and vibration at rated and maximum operating speed are analyzed, and an optimal cogging torque and vibration reduction model, with rotor taper and two-step skew structure, is proposed using the response surface method (RSM) to minimize them. The validity of the proposed model is demonstrated through formulations and FEA based entirely on numerical analysis and results. This study is expected to contribute to the design of more efficient and quieter electric motors by providing a solution to the electromagnetic vibration noise problem generated by IPMSM for traction applications with complex structures. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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17 pages, 8568 KB

Open AccessFeature PaperArticle

Influence of Winding Configurations and Stator/Rotor Pole Combinations on Field Back-EMF Ripple in Switched Flux Hybrid Excited Machines

by Zhiyu Yang, Xiaoyong Sun, Ruizhao Han, Ruyu Shang, Zhen Chen and Xiangdong Liu

Energies 2024, 17(23), 5906; https://doi.org/10.3390/en17235906 - 25 Nov 2024

Viewed by 940

Abstract

Similar to armature back electromotive force (armature back-EMF), the back-EMF also exists in the field winding of hybrid excited machines. However, the existence of field back electromotive force (field back-EMF) is harmful to the safe and stable operation of machine systems, e.g., higher losses, lower efficiency, higher torque ripple, and reduced control performance. This paper systematically investigates the influence of armature/field winding configurations together with stator/rotor pole combinations on the field back-EMF ripple in hybrid excited machines with switched-flux stators. The two-dimensional (2D) time-stepping finite element modeling and prototyping experiments are used for the research. The investigated field and armature coil pitches equal to 1, i.e., non-overlapped windings. The influential factors that are investigated in this paper mainly include the number of layers of field/armature windings, the number of field/armature coils, and the stator/rotor pole combinations. The results show that the field back-EMF’s harmonic order and peak-to-peak value are closely associated with field/armature winding configurations and stator/rotor pole combinations under various conditions. Finally, for validation of the results predicted by the finite element method, a prototype machine is built and tested. Overall, non-overlapped double-layer armature and field windings are recommended for the hybrid excited switched flux machines with various stator/rotor pole combinations to realize relatively lower field back-EMF under different conditions. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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Review

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29 pages, 1990 KB

Open AccessReview

Real-Time Digital Twins for Intelligent Fault Diagnosis and Condition-Based Monitoring of Electrical Machines

by Shahin Hedayati Kia, Larisa Dunai, José Alfonso Antonino-Daviu and Hubert Razik

Energies 2025, 18(17), 4637; https://doi.org/10.3390/en18174637 - 31 Aug 2025

Viewed by 362

Abstract

This article presents an overview of selected research focusing on digital real-time simulation (DRTS) in the context of digital twin (DT) realization with the primary aim of enabling the intelligent fault diagnosis (FD) and condition-based monitoring (CBM) of electrical machines. The concept of standalone DTs in conventional multiphysics digital offline simulations (DoSs) is widely utilized during the conceptualization and development phases of electrical machine manufacturing and processing, particularly for virtual testing under both standard and extreme operating conditions, as well as for aging assessments and lifecycle analysis. Recent advancements in data communication and information technologies, including virtual reality, cloud computing, parallel processing, machine learning, big data, and the Internet of Things (IoT), have facilitated the creation of real-time DTs based on physics-based (PHYB), circuit-oriented lumped-parameter (COLP), and data-driven approaches, as well as physics-informed machine learning (PIML), which is a combination of these models. These models are distinguished by their ability to enable real-time bidirectional data exchange with physical electrical machines. This article proposes a predictive-level framework with a particular emphasis on real-time multiphysics modeling to enhance the efficiency of the FD and CBM of electrical machines, which play a crucial role in various industrial applications. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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36 pages, 9026 KB

Open AccessReview

Review on Research and Development of Magnetic Bearings

by Yuanhao Du, Gan Zhang and Wei Hua

Energies 2025, 18(12), 3222; https://doi.org/10.3390/en18123222 - 19 Jun 2025

Viewed by 1621

Abstract

This paper reviews the research advancements and development in magnetic bearings. Firstly, from the technical principle, the design differences and application areas of active magnetic bearings, permanent magnetic bearings and hybrid structures are clarified. At the key technology level, focusing on electromagnetic design optimization, control strategy innovation and power-driven energy management, the breakthrough points of multi-physics coupling modeling, vibration suppression and energy efficiency improvement are revealed. Through the analysis of its engineering cases in the fields of high-speed motors, flywheel energy storage, aerospace and so on, the feasibility and economy of the technical scheme are verified. Further, the technical bottlenecks that need to be broken through are pointed out. For the future trend, this paper suggests that integration of interdisciplinary high-precision modeling, intelligent control algorithm and miniaturized integrated design should be deeply integrated to promote the large-scale application of magnetic bearing in frontier fields. This paper provides theoretical reference and engineering practice guidance for the technology iteration and cross-field integration of magnetic bearings. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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25 pages, 5162 KB

Open AccessReview

Analysis and Compensation of Current Measurement Errors in Machine Drive Systems—A Review

by Pingyue Song, Tao Wang, Lijian Wu, Hao Li, Xiang Meng and Cheng Li

Energies 2025, 18(6), 1367; https://doi.org/10.3390/en18061367 - 11 Mar 2025

Cited by 1 | Viewed by 1198

Abstract

The rapid development of machine drive systems is closely tied to advancements in signal sampling technology. Accurate measurement results, especially current measurement results, are crucial for high-performance machine drive systems. However, current measurement errors (CME) caused by circuit parameter inconsistencies, aging, and temperature variations can significantly affect the control performance of drive systems, thus necessitating compensation. To better understand the mechanisms of CME in drive systems, this paper reviews existing research on CME analysis and compensation techniques. Based on the source of CME, this paper classifies CME into high-frequency and low-frequency components and discusses their causes and compensation methods, respectively. Additionally, the influence of different types of CME on other control strategies, such as sensorless and model predictive control, is discussed. The characteristics of CME compensation strategies for special current sensor installation positions are also explored. Finally, the paper summarizes the state of the art in CME analysis and compensation and discusses future trends in this field. Full article

(This article belongs to the Special Issue Electrical Machine Systems with High Efficiency, Reliability and Integration)

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