Search Results (66)

This paper investigates the impact of segmented permanent magnet (PM) configurations on torque production, eddy current loss, and demagnetization in spoke-type flux-intensifying interior permanent magnet (FI-IPM) motors. While PM segmentation has been explored in conventional interior permanent magnet synchronous motors (IPMSMs) for reducing losses, its effect in flux-intensifying (FI) motors, characterized by reverse saliency, remains underexplored. To address this, five rotor designs with segmented PMs are analyzed against a baseline model using finite element analysis, maintaining identical stator and PM volume. Results show that segmentation increases reluctance torque, compensating for reduced PM torque, while simultaneously lowering eddy current loss and enhancing demagnetization resistance. These improvements validate segmented PMs as a viable strategy to enhance the durability and efficiency of FI-IPM motors for electric vehicle applications. Full article

The paper deals with a finite element analysis (FEA) of the occurrence of an inflection point in the power loss vs. torque curve of permanent magnet synchronous machines (PMSM), related to optimal torque distribution in multi-motor all-wheel drive electric vehicles. Simplified, analytical power-loss models of the electric motor suggest that the power loss curve is convex, and consequently, the equal front/rear torque distribution is optimal. On the contrary, experimental studies usually point to a non-convex power loss curve containing an inflection point, which leads to more complex torque distribution laws. With the aim of explaining the experimentally observed effects, a first-principle, FEA approach is applied to PMSMs of different types (interior vs. surface permanent magnets, IPM vs. SPM) and different vector control strategies (maximum torque per ampere vs. maximum efficiency). Additionally, the impact of vehicle transmission losses on the power loss curve inflection point occurrence is analyzed. The results demonstrate that in the IPM motors, the inflection point occurs more readily than in the SPM motors due to the greater reluctance torque capabilities, which can strongly saturate the q-axis even under flux-weakening conditions, thus creating a highly nonlinear iron loss torque dependency. Also, the rising transmission efficiency vs. torque curve contributes to the occurrence of an inflection point. Full article

Due to the widespread adoption of high-performance electric vehicles (EVs), Interior Permanent Magnet (IPM) machines have achieved significant advancement in the field of electric motors due to their high torque density and efficiency. However, research has been ongoing for many decades to suppress the rare-earth permanent magnet (PM) usage without sacrificing electromagnetic performance while still achieving the required torque, power, and efficiency. In this regard, various EV manufacturers, such as Honda, Toyota, Chevrolet, BMW, and Nissan, have developed different types of IPM topologies; however, the rare-earth PM usage is extensively high, and the torque density is lower. Thus, to reduce the PM consumption and improve the electromagnetic performance, especially torque density, this paper proposes a novel segmented delta-shaped IPM (SΔ-IPM) with a three-notched rotor pole shape having two different specifications and featuring embedded circular flux barriers and an intermediate flux bridge. Secondly, torque performance is analytically discussed, and electromagnetic performance has been evaluated using 2D finite element analysis (FEA). Due to its unique design featuring improved magnetic field shifting, an average torque of 393.7 Nm with torque ripples of 5.1% and a cogging torque of 0.57 Nm has been achieved. Finally, an extensive comparative analysis of the aforementioned ten state-of-the-art industry models has been conducted, which confirms the effectiveness of the proposed design for high torque density with minimum PM usage. Full article

This paper investigates the feasibility of an interior permanent magnet (IPM) rotor for 1 MW-class high-speed permanent magnet synchronous machines (PMSMs) in a hybrid propulsion system of electrified aviation. A double-layer IPM machine and a surface-mounted PM (SPM) benchmark machine with Halbach-array PMs, which are typically employed in aviation applications; are designed using the same design specifications, the same stator, double-three-phase winding layout, physical air-gap length, outer and inner diameters of rotor; and the same materials. The rotor robustness of the IPM machine using high-strength iron material has been verified through mechanical strength analysis with an outstanding safety factor margin. The electromagnetic performances of IPM and SPM benchmark machines are compared. It is found that the IPM design can achieve similar high torque/power density and high efficiency to the SPM benchmark machine, using 48% less rare-earth PM materials and a simpler rotor structure without a carbon fiber sleeve for easy manufacturing. The investigation confirms the feasibility of IPM topology for MW-class high-speed aviation propulsion machines for lower cost and more sustainable purposes. Full article

This paper presents a novel integrated gear drive unit (IGDU), which integrates a high torque density flux-focusing magnetic gear with a V-shaped interior permanent magnet (IPM) motor into a compact structure. The proposed configuration enables direct torque amplification and efficient low-speed, high-torque operation, addressing the inherent torque limitations of conventional electric motors. Critical design parameters, including pole-pair selection, modulation ring dimensions, and stator slot openings, are optimized to enhance torque performance and minimize cogging torque. Finite element analysis (FEA) verifies a maximum torque output of 43.7 Nm. A prototype of the proposed IGDU was fabricated, and experimental validation confirms the effectiveness of the design, with a good match between the measured back-EMF and the simulated one. The results highlight the potential of the proposed machine for compact, high-performance applications such as electric vehicles and industrial drives. Full article

Permanent magnet synchronous machines (PMSMs) are the preferred choice for electric vehicles (EVs), hybrid EVs, and wind turbines because of their high torque density, efficiency, and wide constant-power speed range. Conventional PMSMs rely heavily on rare-earth (RE) permanent magnets like Nd-Fe-B, which offers high remanence and coercivity but comes with high costs, supply chain issues, and environmental concerns. To address these challenges, this paper explores the potential of tetragonal Fe₂Ni₂N, a newly developed RE-free permanent magnet, as a replacement for commercial Nd-Fe-B (N35) in high-performance PMSMs. Fe₂Ni₂N shows a remanent flux density of 1.2 T and coercivity of 0.957 MA/m, closely matching those of commercial N35 magnets. Finite element analysis (FEA) in Ansys Maxwell was performed on both surface-mounted (SPM) and interior-mounted (IPM) PMSMs under EV-representative operating conditions. Results demonstrate that Fe₂Ni₂N-based machines have similar demagnetization resistance, torque, and efficiency to those with N35 magnets, with slight performance advantages at low speeds and nearly identical performance at high speeds. Furthermore, system-level parameters such as DC bus voltage and stator current were analyzed, showing that increased voltage extends the constant torque region while higher current enhances torque output but can slightly reduce efficiency at elevated speeds. These findings confirm that Fe₂Ni₂N is a promising RE-free alternative to Nd-Fe-B for sustainable, high-performance PMSMs. Results show that Fe₂Ni₂N-based machines have similar demagnetization resistance, torque, and efficiency to those with N35 magnets, with slight performance benefits at low speeds and nearly identical results at high speeds. Furthermore, system-level parameters, such as DC bus voltage and stator current, were analyzed. The results show that increased voltage extends the constant-torque region, while higher current enhances torque output but can slightly reduce efficiency at elevated speeds. These findings confirm that Fe₂Ni₂N is a promising RE-free alternative to Nd-Fe-B for sustainable, high-performance PMSMs. Full article

Inter-turn short-circuit (ITSC) faults in motor drives can induce substantial circulating currents and localized thermal stress, ultimately degrading winding insulation and compromising torque stability. To enhance the operational reliability of open-winding (OW) five-phase fault-tolerant fractional-slot concentrated-winding interior permanent-magnet (FTFSCW-IPM) motor drive systems, this paper proposes a real-time fault-tolerant control strategy that provides current suppression and torque stabilization under ITSC conditions. Upon fault detection, the affected phase is actively isolated and connected to an external dissipative resistor, thereby limiting the fault-phase current and inhibiting further propagation of insulation damage. This reconfiguration allows the drive system to uniformly accommodate both open-circuit (OC) and ITSC scenarios without modification of the underlying control architecture. For OC operation, an equal-amplitude modulation scheme based on carrier-based pulse-width modulation (CPWM) is formulated to preserve the required magnetomotive-force distribution. Under ITSC conditions, a feedforward compensation mechanism is introduced to counteract the disturbance generated by the short-circuit loop. A principal contribution of this work is the derivation of a compensation term that can be estimated online using zero-sequence voltage (ZSV) together with measured phase currents, enabling accurate adaptation across varying ITSC severities. Simulation and experimental results demonstrate that the proposed method effectively suppresses fault-phase current, maintains near-sinusoidal current waveforms in the remaining healthy phases, and stabilizes torque production over a wide range of fault and load conditions. Full article

This paper presents a comprehensive sensorless control approach for interior permanent magnet (IPM) motors, integrating high-frequency injection (HFI) and model-based observer techniques to ensure accurate rotor position estimation across a wide speed range. Two HFI strategies—pulsating and rotating—are investigated experimentally and compared in combination with two observer structures: the conventional Sliding Mode Observer (SMO) and Adaptive-Gain SMO (AG-SMO). The AG-SMO dynamically adjusts its observer gain according to the estimated back-electromotive force (back-EMF) amplitude, significantly reducing chattering and improving estimation performance under varying load and noise conditions. A Frequency-Adaptive Complex Coefficient Filter (FACCF) and an Orthogonal Phase-Locked Loop (PLL) are incorporated to eliminate phase delay and enhance demodulation accuracy. Simulation and experimental results obtained using a 30 W, 20 V IPM motor demonstrate that the pulsating HFI + AG-SMO configuration achieves superior stability and noise immunity, while the rotating HFI + AG-SMO provides smoother and more accurate estimation. Overall, the proposed hybrid control framework achieves robust, high-precision, and sensorless operation for IPM motors over the wide speed range, offering a practical solution for applications such as inverter-driven compressor systems operating in noisy environments. Full article

This paper presents a multiphysics, Life Cycle Assessment (LCA)-based design optimization framework for an interior permanent-magnet traction motor tailored to electric-vehicle duty. The workflow couples driving cycle realism, electromagnetic–thermal analysis, and life cycle assessment within a unified, computationally efficient process. Representative operating points are extracted from WMTC and ECE cycles using clustering, after which a multi-level Taguchi refinement searches the design space from coarse to fine. A weighted composite objective balances machine cost and life cycle cumulative emissions under hard constraints on torque capability and hotspot temperature. The optimized design satisfies performance and thermal limits while simultaneously reducing both cost and life cycle burden, as confirmed through phase-wise assessment of raw material, use-phase, and end-of-life contributions. Iterative improvements are accompanied by rising signal-to-noise ratios and reduced parameter-level spread, indicating greater robustness to operating variability. Overall, the study demonstrates that an LCA-driven, multiphysics-constrained optimization can deliver sustainable, high-performance IPM designs that are aligned with realistic vehicle operating conditions and readily adaptable to alternative motor and drive architectures. Full article

In this paper, the effects of asymmetric interior permanent magnet (AIPM) rotors on the torque characteristics in dual three-phase (DTP) permanent magnet synchronous machines (PMSMs) are investigated. The electromagnetic performances of DTP PMSMs with symmetrical and asymmetric IPM rotors are compared, including air-gap flux density, back EMF, cogging torque, torque, loss, and efficiency. It is found that in DTP PMSMs, the AIPM rotor can achieve significant torque improvement under both healthy and single three-phase open-circuit conditions. It is also found that performance enhancement in AIPM DTP machines is more remarkable across the constant torque region, particularly at high-load conditions, than in the constant power region, compared with the symmetrical IPM counterpart. A prototype is fabricated and tested to verify theoretical analyses. Full article

In addressing the challenges posed by the numerous rotor structure parameters and the difficulty in analyzing the air gap magnetic field distribution in interior permanent magnet (IPM) motors, and to enhance the performance of automotive IPM synchronous motors, this paper proposes a multi-objective optimization method based on sensitivity stratification. Firstly, sensitivity analysis is conducted on the positional and shape parameters of the rotor permanent magnets (PMs), and the parameters are stratified according to their sensitivity levels. Subsequently, distinct analysis and optimization methods are applied to parameters of different strata for dual-objective optimization, which aims to increase the amplitude of the air gap flux density and reduce its total harmonic distortion (THD). Moreover, the waveform of the air gap flux density is analyzed to propose a targeted arrangement of magnetic isolation slots, thereby further optimizing the magnetic field distribution. Meanwhile, the demagnetization conditions and influencing factors of the PMs under overload are analyzed to enhance their demagnetization resistance and determine the final structural parameters. Simulation results indicate that, with the application of the proposed optimization method, the fundamental amplitude of the air gap flux density is increased by 0.035 T and THD is decreased by 9.9% when the proposed optimization method is applied. This verifies the effectiveness and feasibility of the method. Full article

Interior permanent magnet (IPM) synchronous motors have gained widespread adoption in electric vehicles (EVs) owing to their durable rotor configurations, expansive operational speed range, and superior efficiency. Nonetheless, typical IPM motor designs frequently exhibit high torque ripple and constrained torque density. To address these issues, a torque enhancement method is introduced by applying both filleting and notching techniques to the stator core. These techniques help reshape the magnetic field directly at the stator, allowing for more precise control of torque production and torque ripple reduction while keeping the rotor structure unchanged. Design variables of the stator in a 12-slot/8-pole fractional-slot V-shaped IPM motor are optimized using a multi-objective genetic algorithm based on a sensitivity constraint for unidirectional operation. The electromagnetic performance of the motor is analyzed through 2D finite element simulations for both no-load and loaded scenarios. The proposed motor increases average torque by 2.45% and significantly reduces torque ripple by 47.73% compared to the conventional motor. These reflect a significant advancement in torque capability. Furthermore, the efficiency of the proposed motor reaches 93.8%. The findings suggest the potential of the proposed filleting and notching techniques for torque capability improvement in EV applications. Full article

Interior-mounted permanent magnet (IPM) machines have been widely used in recent years due to their high efficiency, high torque/power densities, and so on. These machines can produce reluctance torque whereas their surface-mounted (SPM) counterparts cannot. Hence, IPMs are attractive in industrial applications that require high torque density. ${\mathrm{I}}_{\mathrm{d}}=0$ control is commonly adopted to drive permanent magnet (PM) machines, and the strategy is attractive due to its simplicity. However, although it is suitable for SPMs, adopting it in IPMs sacrifices the reluctance torque that can be obtained from the machine. Hence, it is vital to control IPMs using the maximum torque per ampere (MTPA) strategy. This paper adopts the MTPA strategy for a 4.1 kW prototype IPM machine. Test system configuration is discussed step by step by paying particular attention to potential practical issues and inspirational discussions on their solutions. The issues associated with misaligned rotor positions or whistling problems pertinent to inappropriate power conversion strategies are addressed to overcome such issues in practical IPM drives. Comprehensive discussions and extensive comparisons of well-matched simulation and experimental results of both ${\mathrm{I}}_{\mathrm{d}}=0$- and MTPA-controlled drives at different evaluation metrics will be quite insightful to achieve efficiency-optimized IPM drives. Full article

This paper proposes an anti-disturbance model predictive fault-tolerance control strategy for open-circuit faults of five-phase flux intensifying fault-tolerant interior permanent magnet (FIFT-IPM) motors. This strategy is applicable to electric agricultural equipment that has an open winding failure. Due to the rich third-harmonic back electromotive force (EMF) content of five-phase FIFT-IPM motors, the existing model predictive current fault-tolerant control algorithms fail to effectively track fundamental and third-harmonic currents. This results in high harmonic distortion in the phase current. Hence, this paper innovatively proposes a multi-plane virtual vector model predictive fault-tolerant control strategy that can achieve rapid and effective control of both the fundamental and harmonic planes while ensuring good dynamic stability performance. Additionally, considering that electric agricultural equipment is usually in a multi-disturbance working environment, this paper introduces an adaptive gain sliding-mode disturbance observer. This observer estimates complex disturbances and feeds them back into the control system, which possesses good resistance to complex disturbances. Finally, the feasibility and effectiveness of the proposed control strategy are verified by experimental results. Full article

Permanent-magnet losses in interior permanent-magnet (IPM) motors can result in high magnet temperatures and potential demagnetization. This study investigates using partially segmented magnets as an alternative to traditional segmented magnets to reduce these losses. Partial segmentation involves cutting slots into the magnet to redirect the eddy current path and reduce losses. The research explores analytical and finite element modeling of eddy current losses in partially segmented magnets in IPM machines. Various configurations and orientations of partial segmentation were examined to assess their impact on eddy current losses. Axial slots for the partially segmented magnets were found to be the most effective slotting direction for the baseline IPM motor’s aspect ratio. This study also explores several methods for measuring permanent-magnet loss in IPM machines. A locked rotor test fixture was designed to measure losses induced by switching harmonics. AC loss measurements for the test fixture were conducted to compare magnets with and without partial segmentation. The results showed a significant reduction in permanent-magnet loss for the partially segmented magnets, particularly at higher currents and across all the tested switching frequencies and phase angles. Additionally, the transient temperature of the partially segmented magnets was found to be 12 °C lower than without partial segmentation after a 30 min test. Full article