electronics

Article
Design of A Novel Line Start Synchronous
Motor Rotor
Berkan Zöhra 1, * , Mehmet Akar 2 and Mustafa Eker 2
1 Department of Electronics and Automation, Merzifon Vocational School, Amasya University,
Amasya TR 05300, Turkey
2 Department of Mechatronics Engineering, Faculty of Engineering and Natural Sciences, Gaziosmanpaşa
University, Tokat TR 60150, Turkey; [email protected] (M.A.); [email protected] (M.E.)
* Correspondence: [email protected]; Tel.: +90-358-513-5103/2744




Received: 29 November 2018; Accepted: 21 December 2018; Published: 26 December 2018


Abstract: Line start permanent magnet synchronous motors (LS-PMSM) are preferred more and more
in industrial applications, because they can start on their own and because of their high efficiency.
In this study, a new LS-PMSM rotor typology is suggested, which is modelled using surface mount
permanent magnets, in which two different slot types have been used together. The rotor of an
asynchronous motor on the industrial market in the IE2 efficiency segment has been remodeled in
the study, resulting in an increase in motor efficiency from 85% to 91.8%. A finite elements software
was used for determining motor design and performance, in addition to analytical methods.

Keywords: line start; permanent magnet; synchronous motor; efficiency motor; rotor design

1. Introduction
Electrical motors have the highest share in electrical consumption for industrial and home
applications. Therefore, there are many studies in literature that focus on making electrical motors
more efficient. In addition to the electricity consumed by the electrical motors used in all fields,
the resources used for motor manufacture are also another significant issue [1,2]. The use of a motor
with a large core for obtaining the desired shaft power increases the material used for producing the
motor, thereby directly affecting production cost [3].
There are many products that can respond to the operating conditions in the current electrical
motors market. A necessity has emerged for regulating the electrical motor market with various
standards, as there are many different products in the market with different brands that can replace
one another. Many regulations are ongoing regarding the frame dimensions, operating characteristics,
and operating conditions for these electrical motors, which are put on the market with standards that
are also accepted by electrical motor producers [4]. Many standards, such as EPAct (1992), CEMEP
(1998), and IEC 60034-2-1/60034-30-1 (2008), until now, have been suggested to arrange the market and
increase product mobility [4,5]. Moreover, now, more efficient motors with a higher performance can be
put on market, with the developing technology and the revisions that are made in the standards subject
to these changes. According to the widely accepted IEC electrical motor standards, motor efficiencies
are classified as IE1 for standard efficiency, IE2 for high efficiency, IE3 for premium efficiency, and IE4
for super premium efficiency [6].
Induction motors (IMs), which are preferred because of their robustness and requirement for
less maintenance are put on the market with an efficiency of IE3 and below. It is not possible to
produce these motors with an efficiency above IE3 because of technological and material limitations [7].
However, high-power electrical motors can be produced, which provide a higher efficiency and power
factor by placing high performance permanent magnets on the IM rotor, the cost of which continues

Electronics 2019, 8, 25; doi:10.3390/electronics8010025 www.mdpi.com/journal/electronics

Electronics 2019, 8, 25 2 of 18

to decrease every day [8]. These motors with a permanent magnet in their rotor and an IM squirrel
cage are known in the literature as line start permanent magnet synchronous motors (LS-PMSM).
In addition to being robust and requiring less maintenance, like IMs, LS-PMSMs are also able to
Electronics 2018, 7, x FOR PEER REVIEW 2 of 19
provide efficiencies of above IE3, thanks to the permanent magnets in their rotor [9].
Whilefactor
power the LS-PMSM
by placingmay highstart asynchronously
performance permanent via direct
magnetspower from
on the IMthe line,the
rotor, like IMs,
cost of because
which
of the squirrel
continues tocage in their
decrease every rotors, contrary
day [8]. These to IMs, with
motors which generate variable
a permanent magnet rpm subject
in their rotorto andload,
an IM they
cansquirrel
continue to operate
cage are known at ainconstant speed after
the literature as linereaching a synchronous
start permanent magnet speed. A rotor motors
synchronous current (LS-is not
PMSM).
induced on Intheaddition
cage, as to thebeing robust
squirrel cageand requiring
does not cut less maintenance,
off the like IMs,
stator magnetic fieldLS-PMSMs
in the motor, are which
also
able to provide
continues to rotateefficiencies
at a constant of above
speed IE3, thanks to the
(synchronous permanent
speed) because magnets in their
of the effect of rotor [9]. magnetic
the extra
While the
flux generated byLS-PMSM
the permanent may start asynchronously
magnets, which leads viatodirect powerthe
reducing from the line, like IMs,
electromagnetic because
losses on the
of the squirrel cage in their rotors, contrary to IMs, which
rotor to an almost non-existing level (when harmonics are considered) [10,11]. generate variable rpm subject to load, they
can continue to operate at a constant speed after reaching a synchronous
The LS-PMSMs, which can run up with the cage torque generated by the aluminum start winding speed. A rotor current is not
induced
(squirrel on the
cage) cage,rotor,
in their as thearesquirrel cage
able to does not
generate ancut off the stator
opposite magnetic
braking torquefield
thanksin the
to motor, which
the permanent
continues to rotate at a constant speed (synchronous speed) because of
magnets placed on the rotor. Thus, the electromagnetic torque generated by the motor during thethe effect of the extra magnetic
flux generated by the permanent magnets, which leads to reducing the electromagnetic losses on the
synchronization period is comprised of two torques, as the cage torque (Tc ) and magnet torque, which
rotor to an almost non-existing level (when harmonics are considered) [10,11].
is in the opposite direction (Tpm ). The Tc and Tpm torque components generated at the time of starting
The LS-PMSMs, which can run up with the cage torque generated by the aluminum start
are expressed by Equations (1) and (2), respectively [12–14].
winding (squirrel cage) in their rotor, are able to generate an opposite braking torque thanks to the
permanent magnets placed on the rotor. ( Thus, the electromagnetic

torque
) generated by the motor
p m X2d − X2q I2d I2q +
during the synchronization Tcperiod
= is comprised of two torques, as the cage torque (𝑇 ) and magnet(1)
2 ws Xmd Id I2q − Xmq Iq I2d + E0 I2d
torque, which is in the opposite direction (𝑇 ). The 𝑇 and 𝑇 torque components generated at
the time of starting are expressed pbymEquations n (1) and (2), respectively

[12–14].
o
Tpm = Xmd I f m Imd + Xd − Xq Imd Imq (2)
2 ws 𝑋 −𝑋 𝐼 𝐼 + (1)
𝑇 =
The total electromagnetic torque (Te ) can 𝑋 be 𝐼 𝐼determined
− 𝑋 𝐼 𝐼 using + 𝐸 𝐼Equation (3).

𝑝𝑚
(
)
p
𝑇 = m X − X
𝑋 𝐼 𝐼 + 𝑋 −𝑋 𝐼 𝐼
d q Id Iq +
Te = (2)(3)
2 ws2 𝑤 Xmd I2d Iq − Xmq I2q Id + E0 Iq

Figure 1 shows the torque components of the LS-PMSM. The dotted curve in the figure represents
The total electromagnetic torque (𝑇 ) can be determined using Equation (3).
the torque generated by the start cage without a permanent magnet (Tc ), and the dashed line represents
𝑝𝑚 𝑋 −𝑋
the braking torque generated by the permanent 𝐼 𝐼 + (Tpm ). The asynchronous torque (Tasyn )
magnets
𝑇 = (3)
𝑋 𝐼is 𝐼the
generated by electromagnetic torque (T2e ),𝑤which − sum
𝑋 𝐼of𝐼Tc+and𝐸 𝐼 Tpm , is represented by a normal
line. The cage torque (Tc ) should overcome the braking torque (Tpm ) generated by the permanent
magnets, the load torque (TL ), and motor inertia (Jm ) in order for the synchronization process in
LS-PMSM to be successful.

Figure 1. Torque
Figure components
1. Torque componentsofofthe
theline
linestart
startpermanent
permanent magnet synchronousmotors
magnet synchronous motors(LS-PMSM).
(LS-PMSM).

Figure 1 shows the torque components of the LS-PMSM. The dotted curve in the figure
represents the torque generated by the start cage without a permanent magnet (𝑇 ), and the dashed
Electronics 2019, 8, 25 3 of 18

The successfully synchronized motor passes on to a steady state operation in order to continue
rotating at a synchronous speed. The torque generated because of the currents during the steady state
operation is as given in Equation (4).
p m

Tsyn = E0 Iq + Id Iq Xd − Xq (4)
2 ws

In addition, if the angle between the EMF and terminal voltage is denoted by β, the synchronous
torque when the resistances are neglected can be expressed as in Equation (5).
2 
 
p m E0 Vph1 Vph1 1 1

Tsyn = 2 ws Xd sin β + 2 Xq − Xd sin 2β
(5)
= T1 sin β + T2 sin 2β

There are many studies in the literature for improving the start performance of LS-PMSMs under
different loads and line voltages, and for ensuring that the motor operates more efficiently after
synchronization. It is observed that these studies have focused on improving the motor dynamic
model, which expresses the operating characteristic of the motor better, as well as the determination
and optimization of the design parameters with an impact on the synchronization performance of the
motor [15–19].
A new LS-PMSM rotor design is presented in this study, with a high producibility, low cost,
high efficiency, and with low maintenance requirement. A new squirrel cage using two different
slot structures for improving motor run up and synchronization performance, along with surface
mount permanent magnets, have been used in this suggested rotor design for increasing performance.
The purpose of the study is to remodel the rotor of an already existing IM with IE2 1500 rpm 5.5 kW
rated power. The ANSYS® Electromagnetics Suite finite elements software environment, which has
proven itself in academic studies, was used for modelling the motor, in addition to the analytical
models. The MathWorks Inc. MATLAB® development environment was also used in addition to
Electromagnetics Suite for determining the motor performance characteristics, as well as for the
optimization studies.

2. LS-PMSM Design
The IM design process is quite complex, but it has been discussed many times in the literature.
LS-PMSMs are structurally similar to IMs to a great extent; however, their design process is more
complex because of the inclusion of permanent magnets in their structure. It is a preferred method of
LS-PMSM design to initially design the IM that will provide the desired power, and then placing the
permanent magnets to the rotor [19–22]. Works for improving the slot and magnet design should be
carried out in order to reach the desired motor design. Figure 2 shows the optimal LS-PMSM design
algorithm [20,23].
It is very practical to start the design process by first determining the main dimensions of the
motor (stator outer diameter, Dso ; stator inner diameter, Dsi ; stack length, l; and air gap, δ). The air
gap power of the motor can be determined subject to the output power of the motor, after the main
dimensions of the motor have been determined. Stator winding and slot design can be carried out
using the determined airgap power (SGAP ). Finally, the rotor design is carried out to complete the
design process.
The primary goal in LS-PMSM design is to ensure that the motor can synchronize by itself.
The synchronization performance should be reevaluated by updating the permanent magnet and
starting the winding design of the motor, which failed in the synchronization process. The shaft
torque characteristic and efficiency during the steady state operation are controlled for the motor,
which provides a satisfactory synchronization performance. The design process should be repeated
by updating the main dimensions of the motor and/or the permanent magnet design for the motor
designs with an unsatisfactory torque characteristic or efficiency.
Electronics
Electronics 2018,
2019, 7,
8, x25FOR PEER REVIEW 4 4ofof19
18

Figure2.
Figure OptimalLS-PMSM
2.Optimal LS-PMSMdesign
designalgorithm.
algorithm.

2.1. Determining the Main Dimensions of the Machine

It is very practical to start the design process by first determining the main dimensions of the
motorDetermining
(stator outerthe diameter, 𝐷 ; statorofinner
main dimensions the LS-PMSM
diameter, should 𝐷 ; stackbe carried 𝑙; and
length, out in an gap, 𝛿). manner.
airattentive The air
It becomes
gap power veryof theeasy
motorto place
can bethedetermined
permanent subject
magnetstoand the slots
outputto the
powermainofmotor core when
the motor, after the
the motor
main
core is selected as larger than necessary. However, this preference leads
dimensions of the motor have been determined. Stator winding and slot design can be carried out to the use of more production
(lamination
using steel, aluminum,
the determined airgap copper,
power etc.),
(𝑆 ). thereby
Finally, resulting
the rotor in adesign
motorisdesign
carriedwithouta to
heavier core and
complete the
a larger production
design process. cost. It may become a problem to fit a slot design and permanent magnet that will
meetThe theprimary
desired goal
airgap in power
LS-PMSM if the motoris core
design is selected
to ensure that theas motor
being smaller than necessary.
can synchronize When
by itself. The
it is considered that
synchronization the motorshould
performance core isbeaffected by theby
reevaluated magnetic
updatingfield in addition magnet
the permanent to the magnetic flux
and starting
generated by the permanent magnets, especially the stator yoke, the
the winding design of the motor, which failed in the synchronization process. The shaft torque saturation increases excessively,
thereby leading
characteristic andtoefficiency
a significant decrease
during in motor
the steady stateefficiency.
operationFinally, the accordance
are controlled for the of the selected
motor, which
motor core
provides dimensions synchronization
a satisfactory with the standardperformance.
frame dimensions is important
The design processfor the compliance
should be repeated of the
by
design with the standards.
updating the main dimensions of the motor and/or the permanent magnet design for the motor
designs In this
withstudy, the stator design
an unsatisfactory torque was obtained from
characteristic a current industrial IEC standard compliant
or efficiency.
IM. Thus, the main dimensions of the motor were determined by taking the stator design as reference.
2.1. Determining
Therefore, it wasthe Main Dimensions
ensured that the newof the Machine
design is compliant with the IEC motor standards. The main
reference motor dimensions in the study have been given in Table 1.
Determining the main dimensions of the LS-PMSM should be carried out in an attentive manner.
It becomes very easy to place the permanent magnets and slots to the main motor core when the
Table 1. Main dimensions of the reference motor.
motor core is selected as larger than necessary. However, this preference leads to the use of more
production
Frame (lamination
Output steel,
Power,aluminum,
Pn Stackcopper,
Length,etc.),
l thereby resulting
Stator Outer Dia, Din
so a Stator
motorInner
design
Dia,with
Dsi a
heavier 132core
s4 and a larger 5.5production
kW cost. It125
maymmbecome a problem 200 mmto fit a slot design 125andmmpermanent
magnet that will meet the desired airgap power if the motor core is selected as being smaller than
necessary. When it is considered that the motor core is affected by the magnetic field in addition to
Dso , Dsi , and l are already known in the study, as the stator design has been directly taken from
the magnetic flux generated by the permanent magnets, especially the stator yoke, the saturation
a standard IM (Table 1). Additionally, the air gap has to be re-determined for the new rotor design.
increases excessively, thereby leading to a significant decrease in motor efficiency. Finally, the
Electronics 2019, 8, 25 5 of 18

Equation (6) is used in the literature [20] for determining the air gap in the machines with two or
more poles.  √ 
δ = 0.1 + 0.012 3 Pn 10−3 m (6)

The air gap, δ, stated here, is the ideal value required for the modeling of standard IM. As surface
mount permanent magnets are used in this study, the risks for braking the torque generated by the
magnets and the demagnetization of the permanent magnets increase when the air gap that is selected
is very small. Therefore, it may be necessary to select this value as greater than the analytical values.
Another parameter that should be set during the design process is the targeted flux density for the
air gap (Bδ ). It is suggested [24] that the air gap flux density should be between (0.7–0.9 T). This value
is taken into consideration when modeling the rotor cores and determining the dimensions of the
permanent magnets.

2.2. Stator Design

This study aims to make an industrial asynchronous motor more efficient only by redesigning its
rotor. For this purpose, the stator design was taken from a 5.5 kW IE2 asynchronous motor. Details
regarding the 36-slot stator design have been given in Table 2.

Table 2. Stator design details.

Winding Winding Conductor Number Number

Coil Pitch Wire Size Steel Type
Layer Type per Slots of Strands of Slots
2 Whole-Coiled 28 7 3 0.9116 M330 50A 36

The label information for the standard IE2 IMs taken as reference have been given in Table 3.

Table 3. Label information for the reference motor.

Output Rated R.P.M. Power Starting Rated Starting

Eff. % Weight
Power Current min−1 Factor Current Torque Torque
5.5 kW 11.8 A 1440 0.83 85 7 p.u. 36.5 Nm 2.3 p.u. 63 kg

2.3. Rotor Design

The rotor design for LS-PMSM can be examined under the two main headings of slot design and
permanent magnet design. Determining the preferred rotor topology first, during the design process,
followed by the design of start windings, and finally the placement of the required permanent magnets
to the rotor core, makes the design process very practical. Many different rotor designs have been
presented for LS-PMSM development until today [25–28]. It can be observed in the studies carried out
that surface PM or interior PM type designs may be preferred [29,30]. Placing the slots on the regions
left over from the permanent magnet may be problematic in designs, such as in interior PMs, where
permanent magnets are placed away from the air gap. It may be necessary to readjust the slot design
so as to reduce the slot height, especially in designs where permanent magnets are positioned behind
the slot. In addition, part of the magnetic field generated by the permanent magnets placed away from
the air gap only close in the rotor, thereby resulting in losses in the magnet magnetic field leading to an
overheating of the rotor. This undesired situation is overcome by placing a flux barrier at the magnet
tip. This brings forth the necessity to leave an additional space on the rotor core for the flux barrier.
Placing the permanent magnet on the rotor core without deforming is another problem that needs to
be overcome. However, it has been observed in the studies carried out that interior PM typologies are
preferred more, as there is a lower risk for the permanent magnets to be deformed while the motor is
in operation [25–28].
Electronics 2019, 8, 25 6 of 18

A new surface permanent magnet topology has been preferred in this study, which is to place the
desired number of permanent magnets on the rotor. Also, it is more flexible with regard to the slot
design. Thanks to this preference, it has been possible to place the permanent magnets on the rotor
core without any deformation. In addition, the permanent magnet magnetic flux losses have been
minimized and they have been directed to the airgap. Of course, this has led to giving more attention
to the rotor cage design in order to ensure that the permanent magnets that are closer to the air gap
do not have an adverse impact on the motor start. The torque fluctuations due to the impact of the
permanent magnets are another issue that should be taken into consideration [31,32].
The most important issue that requires attention in the design of the surface mount permanent
magnets is to select the magnet dimensions (thickness and height) properly. While a very thin
permanent magnet preference leads to an increased risk of demagnetization, a thick permanent magnet
preference results in the braking torque generated by the permanent magnet to have an adverse impact
on the motor start [22,33].
The leakage flux and fringing effects may be neglected when it is taken into consideration that the
flux generated by the permanent magnets in the surface mount permanent magnet motors directly
passes onto the air gap, thus it is accepted that φδ = φ pm . Thereby, Equations (7) and (8) can be
written [33].
( H δ)
hmag = − δ (7)
Hmag
Bδ
µr µ0 δ
tmag = (8)
Hmag
The rotor bar and end ring circuits to be used in dimensioning the motor start windings can be
determined by way of Equations (9) and (10) [24].

z Qs Qs
Ir = Is cos ϕ (9)
a Qr

Ir
Iring =   (10)
πp
2 sin Qr

where
Pn
Is = (11)
mηVph1 cos ϕ
As a result, the acquired rotor bar and end ring area can be calculated via Equations (12) and (13),
respectively.
Ir
Scr = (12)
Jr
Iring
Scring = (13)
Jring
where Jr and Jring indicate the rotor bar and end ring current densities, respectively. It is suggested
in the literature [24] that this value should remain between the 3–6.5 A/mm2 interval for aluminum
rotor cages.
In light of the acquired data, the rotor tooth width, btr , can be calculated as given in
Equation (14) [20].
Bδ
btr ≈ τr (14)
K Fe Btr
The LS-PMSM’s may start by overcoming the motor inertia and the braking torque generated
by the permanent magnets. This puts forth the necessity for a high-performance cage design in order
to prevent the motor from having synchronization problems. In addition, the start windings have
 𝐵
𝑏 ≈ 𝜏 (14)
𝐾 𝐵

Electronics 2019, 8, 25 7 of 18
The LS-PMSM’s may start by overcoming the motor inertia and the braking torque generated by
the permanent magnets. This puts forth the necessity for a high-performance cage design in order to
prevent the motor from
to re-synchronize having
the motor insynchronization
case the motor problems. In addition,
speed is below the start windings
the synchronous speed at have
the to re-
time
synchronize
of starting. the motor in case the motor speed is below the synchronous speed at the time of starting.
The slot structures
The slot structuresthat
thatdetermine
determine the
the motor
motor torque
torque characteristic
characteristic are standardized
are standardized by NEMA
by NEMA with
with class A, B, C and D [34]. According to the NEMA standard classes A and B
class A, B, C and D [34]. According to the NEMA standard classes A and B are used in general are used inpurpose
general
purpose motors.
motors. Also, Also,
Class Class
C and C and
D are D are in
preferred preferred in applications
applications requiring
requiring higher higher
starting starting
torque. As atorque.
result,
As a result, a new rotor typology making use of both of the slot types is suggested in
a new rotor typology making use of both of the slot types is suggested in this study, to ensure that this study, to
ensure that both the motor start and synchronization performances
both the motor start and synchronization performances are high (Figure 3). are high (Figure 3).

Figure 3. Suggested rotor design.

Figure 3. Suggested rotor design.
A total of 16 NEMA D class upper slots have been placed near the permanent magnets in the
suggested model, by taking into consideration the speeding characteristic of LS-PMSM. In addition,
12 NEMA B class lower slots have been placed under the permanent magnets, in order to help
re-synchronization in case the motor drops below the synchronous speed during steady state operation,
and also in order to support the motor start. Care was also given to ensure that the cross-sections of
both slot types are as close to each other as possible, for ensuring the homogeneous distribution of the
rotor current induced on the start windings to the rotor bars. As was the case for the stator, M330 50A
steel material was used for the rotor as well during the design procedure. Also, N45SH neodymium
magnets are preferred for PM design.

2.4. Optimization of the Suggested Design

The motor operating characteristic in the LS-PMSM design depends to a large extent on the
permanent magnet and slot design. So much so that a significant increase in the motor performance
can be attained with a permanent magnet design with the correct geometrical position and geometry,
in addition to reducing the cogging. In addition, determining the proper rotor slot geometry is another
important issue to ensure that the motors start themselves.
It can be seen in Figure 4a that the analytically designed model has been synchronized successfully
at 150 ms. The shaft torque generated by the motor during starting (0–150ms) and steady state
(150–200 ms) periods can be seen in Figure 4b. The Tripple = 19.98 (SI) generated during the steady
state operation indicates that an excessively vibratory shaft torque has been generated (the SI unit
corresponds to TRMS /Tmean ). The stator current and motor efficiency were determined during the
in addition to reducing the cogging. In addition, determining the proper rotor slot geometry is
another important issue to ensure that the motors start themselves.
It can be seen in Figure 4a that the analytically designed model has been synchronized
successfully at 150 ms. The shaft torque generated by the motor during starting (0–150ms) and steady
state (150–200 ms) periods can be seen in Figure 4b. The 𝑇
Electronics 2019, 8, 25
= 19.98 (SI) generated during8 of the
18
steady state operation indicates that an excessively vibratory shaft torque has been generated (the SI
unit corresponds to 𝑇 /𝑇 ). The stator current and motor efficiency were determined during the
steady state
steady state operation 𝐼 9.6
operationasasIs = A and
= 9.6 A and η = 91.14%,
η = 91.14%, respectively. When this
respectively. efficiency
When value is compared
this efficiency value is
compared with the 85% value obtained with the standard IM rotor, it can be observed increase
with the 85% value obtained with the standard IM rotor, it can be observed that an efficiency that an
of 6.14% has
efficiency been attained.
increase of 6.14%IE3
hasefficiency levels have
been attained. IE3 been reached
efficiency withhave
levels this efficiency value,with
been reached obtained
this
using the value,
efficiency analytically modelled
obtained design
using the without modelled
analytically any optimization.
design without any optimization.

(a) (b)
Figure4.4. 𝑇TL==35
Figure Nm;𝐽Jm= =1 1p.u.
35Nm; p.u.Starting
Startingprocess
processofofthe
theanalytical
analyticalmodel:
model:(a)
(a)speed
speedcharacteristic
characteristicand
and
(b) torque characteristic.
(b) torque characteristic.

Theobjective
The objectivewith withthetheoptimization
optimizationstudies
studiescarried
carriedout
outwas
wasto
toensure
ensurethat
thatthe
themotor
motorefficiency
efficiency
exceeds91.9%
exceeds 91.9%(IE4),
(IE4),by bydetermining
determiningthe
theproper
properdesign
designparameters.
parameters.The
Theoptimized
optimizeddesign
designparameters
parameters
Electronics 2018, 7, x FOR PEER REVIEW 9 of 19
can be seen in Figure
can be seen in Figure 5. 5.
𝑀 and 𝑀 in Figure 5 stand for the magnet thickness and width, respectively; 𝐵𝑠0 denotes
the slot gap for the rotor upper slots; 𝐻 represents the slot depth; and 𝐵𝑠1 denotes the slot
diameter. Finally, the rotor diameter ( 𝑅𝑂 ) was also included in the optimization studies for
determining the optimum air gap value. The parameters used in the optimization study are shown
in Table 4 together with their min. and max. values.

Figure5.5.Design
Figure Design optimization.
optimization.

Mt and Mw in FigureTable
5 4. Design
stand parameters
for used thickness
the magnet for the optimization of therespectively;
and width, model. Bs0 denotes the
slot gap for the rotor upper slots; Hs represents
Design the slot depth; and Bs1 denotes the slot diameter.
Initial
Min. Max.
Finally, the rotor diameter (RO) Parameters
was also includedValue in the optimization studies for determining the
optimum air gap value. The parameters𝑀 used in the41°optimization36° study 42°are shown in Table 4 together
with their min. and max. values. 𝑀 4.7 mm 4 mm 5 mm
𝐵𝑠0 1.5 mm 1 mm 2 mm
𝐵𝑠1
Table 4. Design parameters used9 mm 8 mm
for the optimization 9of
mm the model.
0.25 1.2
𝐻
Design Parameters Initial0.5 mm
Value Min.
mm mm Max.
Mw ◦
41 61.5 36 ◦ 62 42◦
𝑅𝑂 61 mm
Mt 4.7 mm 4 mm mm 5 mm
Bs0 1.5 mm 1 mm 2 mm
Bs1
2.4.1. Optimization of the 9 mm
Model Suggested via 8 mm
Genetic Algorithm 9 mm
Hs 0.5 mm 0.25 mm 1.2 mm
It can be observed RO
when studies on geometric
61.5 optimization 61 mm are examined,
62 mmthat, in general, the
genetic algorithm (GA) is used for determining the optimum data from among large data sets. GA
has also been preferred in this study during the optimization work carried out for determining the
motor design parameters with the targeted efficiency characteristics.
 𝑀 41° 36° 42°
𝑀 4.7 mm 4 mm 5 mm
𝐵𝑠0 1.5 mm 1 mm 2 mm
𝐵𝑠1 9 mm 8 mm 9 mm
Electronics 2019, 8, 25 0.25 1.2 9 of 18
𝐻 0.5 mm
mm mm
62
2.4.1. Optimization of the Model𝑅𝑂 61.5 Algorithm
Suggested via Genetic 61 mm
mm
It can be observed when studies on geometric optimization are examined, that, in general,
2.4.1.
the Optimization
genetic algorithm of the
(GA)Model Suggested
is used via Genetic
for determining theAlgorithm
optimum data from among large data sets.
GA has alsobe
It can been preferred
observed in this
when studyonduring
studies the optimization
geometric optimizationwork carried out that,
are examined, for determining
in general, the
the
motor design parameters with the targeted efficiency characteristics.
genetic algorithm (GA) is used for determining the optimum data from among large data sets. GA
The been
has also cost function
preferredobtained
in this as a result
study of optimization
during via thework
the optimization genetic algorithm
carried hasdetermining
out for been presented
the
in Figure
motor 6 as aparameters
design graph. As with
can be seen
the from the
targeted graph, characteristics.
efficiency the targeted efficiency (92%) was reached after
383 evolutions.

Figure 6. Cost function.

Figure 6.

Figure
The cost7 shows the design
function parameters
obtained processed
as a result via GA and
of optimization viathe
thedistribution of the parameters.
genetic algorithm has been
It can be understood upon examining the graph that the values of Bs1, H , RO, M , and
presented in Figure 6 as a graph. As can be seen from the graph, the stargetedt efficiency M do not have
w (92%) was
areached
homogeneous
after 383distribution,
evolutions. and the optimization study has focused more on certain value intervals.
In addition, the graph presented indicates that the impact of the Bs0 value on motor performance is
quite low. In conclusion, the targeted efficiency was reached as a result of GA optimization at around
Bs1 = 8.5 mm, Hs = 1 mm, Bs0 = 1.79 mm, Mt = 4.48 mm, Mw = 40.5◦ , and RO = 61.30 mm. Moreover,
the torque ripples generated by the motor have been decreased down to about Tripple = 7.09 (SI), and
the motor rated current was determined as I A = 9.26 A. Table 5 summarizes the change in the design
parameters and motor operating characteristic as a result of the GA optimization.

Table 5. Change in design parameters and motor efficiency after genetic algorithm (GA) optimization.

Design Parameters Before GA Optimization After GA Optimization

Mw 41◦ 40.5◦
Mt 4.7 mm 4.48 mm
Bs0 1.5 mm 1.79 mm
Bs1 9 mm 8.5 mm
Hs 0.5 mm 1 mm
RO 61.5 61.30 mm
η 91.14% 92%
Tripple 19.98 (SI) 7.09 (SI)
IA 9.6 A 9.26 A

A significant number of analyses were carried out during the optimization studies for reaching
an optimum rotor design with a high efficiency. The motor design was evaluated as being two
dimensional during the analyses carried out, as it delivers faster solutions, and the analyses were
finalized with a Maxwell 2D Transient solver. A Maxwell 3D Transient solver was used during the
next stages of the study for a more detailed examination of the model obtained with a high efficiency
via GA.
optimization at around 𝐵𝑠1 = 8.5 mm, 𝐻 = 1 mm, 𝐵𝑠0 = 1.79 mm, 𝑀 = 4.48 mm, 𝑀 = 40.5°, and
𝑅𝑂 = 61.30 mm. Moreover, the torque ripples generated by the motor have been decreased down to
about 𝑇 = 7.09 (SI), and the motor rated current was determined as 𝐼 = 9.26 A. Table 5
summarizes the change in the design parameters and motor operating characteristic as a result of the
Electronics 2019, 8, 25
GA optimization. 10 of 18

Figure 7. Distribution of genetic algorithm (GA) analysis parameters according to the number
Figure 7. Distribution of genetic algorithm (GA) analysis parameters according to the number of
of evolutions.
evolutions.
The torque ripples in the motor shaft torque resulted in Tripple = 19.98 (SI) in the model, whereas
A significant number of analyses were carried out during the optimization studies for reaching
this value was decreased to Tripple = 7.08 (SI) in the new design. Optimization works were carried
an optimum rotor design with a high efficiency. The motor design was evaluated as being two
out for the optimization of this value, which was still quite high in the later stages of the study.
dimensional during the analyses carried out, as it delivers faster solutions, and the analyses were
The component generated especially in the pole transitions generates ripples in the torque, because
finalized with a Maxwell 2D Transient solver. A Maxwell 3D Transient solver was used during the
of the interactions between the permanent magnets and the stator tooth in LS-PMSM’s [35]. It was
next stages of the study for a more detailed examination of the model obtained with a high efficiency
observed that when the studies for reducing the ripples in the torque were examined, the focus was
via GA.
on the optimization of the stator tooth and/or permanent magnets, production of the skewed stator,
or rotors [36–40].
Table 5. Change in design parameters and motor efficiency after genetic algorithm (GA)
Embedding the permanent magnets to the rotor core in order to decrease their interaction with
optimization.
the stator tooth is a widely used method for optimizing the permanent magnets so as to reduce
Design cannotBefore
torque ripples. However, this method GA on rotor
be applied After GA
topologies with a surface mount PM.
Parameters
In addition, it is not possible Optimization
to update the stator slot andOptimization
tooth structure, as the stator design was
taken from an already existing IM.𝑀 41° 40.5°
On the other hand, producing 𝑀 skewed permanent
4.7 mm magnet 4.48 mmmakes it more difficult to place
rotors
the magnets inside the rotor core,𝐵𝑠0 1.5 mm
which increases 1.79 mm
the production costs. Therefore, the focus was on
𝐵𝑠1
producing a skewed stator core for reducing 9ripples
mm in torque. 8.5 Thus,
mm it was aimed at reducing the
ripples in the torque by only producing a skewed core without any changes in the stator slot and
tooth design.

2.4.2. Reducing Ripples in the Torque Using Skewed Stator

The graph in Figure 8 shows the Tripple values generated by the motors modelled with different
stator skew angles. It can be seen in the graph that there is no linear relationship between the
Tripple values, however the lowest Tripple values could be generated as Tripple (skew9)= 4.48 (SI),
Tripple (skew13) = 2.9 (SI), and Tripple (skew15) = 4.39 (SI). It can also be seen from the graph
 Electronics 2019, 8, 25 11 of 18

Electronics
that the 2018, 7, x FOR
highest PEER REVIEW
efficiency 12 of
values were obtained as η (skew7) = 91.33%, η(skew8) = 91.29%, and19
η (skew13) = 91.28%.

Electronics 2018, 7, x FOR PEER REVIEW 12 of 19

Figure 8. Ripple and efficiency obtained for different stator

stator skew
skew angles.
angles.

As can be seen in Figure 9, showing the impact of s stator skew angle on the motor synchronization
performance, the motor has the highest synchronization performance at angles of skew0 and skew8.
However, the high torque ripples of around Tripple = 7 (SI) are generated for both skew angles, which
results in an unacceptable decrease in the motor shaft torque quality. In addition, it was also observed
that motor efficiency
Figure 8.and performance
Ripple decreased
and efficiency significantly
obtained forstator
for different skew15 at angles.
skew which a satisfactory
decrease in the torque ripple was obtained. In conclusion, skew13 was preferred as the stator skew
angle, because of its satisfactory synchronization performance and lowest torque ripples.

Figure 9. Motor synchronization performance for different stator skew angles.

Cogging torque is a torque effect that is generated in the motor shaft, which prevents the rotation
of the motor shaft—the impact of which is felt when the motor is idle. This torque component
generated because of the permanent magnets on the rotor core is a factor that results in the decrease
in the quality of the shaft torque generated by the motor. Figure 10 shows the cogging torque for the
skew0 and skew13 angles, which is generated during the 30º rotation of the motor. As can be seen
in the graph, the cogging
Figure torque
9. Motor is reduced significantly
synchronization (67.7%)
performance for with
different a skewed
stator stator motor design.
skew angles.
The graph in Figure
Figure9. 11
Motorshowssynchronization
the electromagneticperformance
torquefor differentbystator
generated skew angles.
the motor for skew angles of
skew0 and skew13.
Cogging torqueAs is acantorque effect
be seen that
from is graph
the generated in the motor
a significant shaft, which
improvement prevents
in motor the rotation
torque quality
Cogging
of
hasthe motor
been torque is
byapreferring
shaft—the
attained torque
impact effect
of whichthat
skew13 is
is feltgenerated in theismotor
when the motor
angle. shaft,
idle. This which
torque prevents
component the rotation
generated
of the motor
because of shaft—the
the permanent impact
magnets of onwhich is felt
the rotor corewhen thethat
is a factor motor is in
results idle. This torque
the decrease in thecomponent
quality
generated because
of the shaft of the
torque permanent
generated by themagnets on the10rotor
motor. Figure showscoretheiscogging
a factortorque
that results
for the in the decrease
skew0 and
in the quality
skew13 of thewhich
angles, shaftistorque generated
generated during by 30◦ motor.
the the rotationFigure 10 shows
of the motor. As canthebecogging
seen in torque for the
the graph,
skew0 and skew13 angles, which is generated during the 30º rotation of the motor. As can be seen
the cogging torque is reduced significantly (67.7%) with a skewed stator motor design. The graph
ingraph,
in the Figure 11
theshows
coggingthe electromagnetic
torque is reduced torque generated by
significantly the motor
(67.7%) withfor skew angles
a skewed of skew0
stator motoranddesign.
skew13. As can be seen from the graph a significant improvement
The graph in Figure 11 shows the electromagnetic torque generated by the motor for skew in motor torque quality has angles
been of
attained by preferring skew13 angle.
skew0 and skew13. As can be seen from the graph a significant improvement in motor torque quality
has been attained by preferring skew13 angle.
 in the quality of the shaft torque generated by the motor. Figure 10 shows the cogging torque for the
skew0 and skew13 angles, which is generated during the 30º rotation of the motor. As can be seen
in the graph, the cogging torque is reduced significantly (67.7%) with a skewed stator motor design.
The graph in Figure 11 shows the electromagnetic torque generated by the motor for skew angles of
skew0 and skew13. As can be seen from the graph a significant improvement in motor torque quality
Electronics
has been 8, 25
2019,attained by preferring skew13 angle. 12 of 18

Electronics 2018, 7, x FOR PEER REVIEW 13 of 19

Electronics 2018, 7, x FOR PEER REVIEW 13 of 19

Figure 10. The cogging torque generated during a 30º rotation of the motor for skew0 and skew13
Figure 10. The cogging torque generated during a 30º rotation of the motor for skew0 and skew13
skew angles.
skew angles.
Figure 10. The cogging torque generated during a 30◦ rotation of the motor for skew0 and skew13
skew angles.

Figure 11. Change

11. Change in electromagnetic torque subject
in electromagnetic subject totorotor revolution generated by theby
motor
thefor
Figure
Figure 11. Change in electromagnetictorque
torque subject to rotor
rotor revolution
revolution generated
generated motor
by the motor for for
skew0 skew0
and and skew13
skew13 angles.angles.
skew0 and skew13 angles.
2.5. Analysis
2.5. Analysis of the of The Suggested Model
2.5. Analysis of Suggested Model
The Suggested Model
At this stage of the study, the performance characteristic will be examined for the motor design
At this stage
Atathis of the
stage study,
of the study,thetheperformance
performance characteristic
characteristic willbebe
will examined
examined for for
the the motor
motor design
design
with stator having a skew angle of skew13, modelled using the suggested rotor topology. The most
with with
a stator
a having
stator a
having skew
a skew angle
angle of
of skew13,
skew13, modelled
modelled using
using the
the suggested
suggested
important problem with LS-PMSM’s is the braking torque generated during operation, because of rotor
rotor topology.
topology. The The
most most
important problem
important problem with
withLS-PMSM’s
LS-PMSM’s is
is the
the braking
braking torque
torque generated
generated during
during
the permanent magnets. This results in issues such as the LS-PMSM’s becoming too sensitive to operation,
operation, because
because of of
the permanent
the permanent magnets.
magnets.
circumstances, This
such as This results in
results inofissues
the overloading issues such
such
the motor. as the
as the
Figure LS-PMSM’s
LS-PMSM’s
12 shows becoming
becoming
the starting too
performancesensitive
toounder to
sensitive to
circumstances,
different such
circumstances, motorsuch
as as the
loads
the foroverloading
the skewedof
overloading ofthe
the motor.
stator motor.suggested.
model Figure
Figure1212shows
As canthe
shows starting
bethe
seen fromperformance
starting the graph, under
the under
performance
different motor
motor can reachloads for the
a synchronous skewed
speed of stator
1500 model 0.3 s at 𝑇 = As
rpm in suggested. can
35 Nm be
(Full seen
Load).from the graph,
An overloading themotor
different motor loads for the skewed stator model suggested. As can be seen from the graph, the
of 14%
motor can(𝑇reach
= 40 aNm) results in the
synchronous failure
speed of therpm
of 1500 motor s at 𝑇 = 35 Nm
synchronization
in 0.3 process.
(Full Load). An overloading
can reach a synchronous speed of 1500 rpm in 0.3 s at TL = 35 Nm (Full Load). An overloading of 14%
of 14% (𝑇 = 40 Nm) results in the failure of the motor synchronization process.
(TL = 40 Nm) results in the failure of the motor synchronization process.

Figure 12. Starting performance for the suggested model with skewed stator under different motor
loads.
Figure
Figure 12. 12. Startingperformance
Starting performance for
forthethe
suggested model
suggested with skewed
model stator under
with skewed different
stator undermotor
different
The graph in Figure 13 shows the current and efficiency values subject to load torque. It can
loads.
motor loads.
clearly be seen from the graph that the current drawn when the motor is idle is around 𝐼 = 2.3 A.
This
Thevalue increases
graph up to13𝐼 shows
in Figure =9.84 Athe
at an overloading
current of 40 Nm.values
and efficiency The current drawn
subject at ¼torque.
to load of the load
It can
clearly be seen from the graph that the current drawn when the motor is idle is aroundto𝐼91%
is 2.8 A and 4.3 A at ½ loading. Motor efficiency at ¼ loading increased up to 86% and up at A.
= 2.3
½, whereas a maximum value of 91.28% was reached at full load.
This value increases up to 𝐼 =9.84 A at an overloading of 40 Nm. The current drawn at ¼ of the load
is 2.8 A and 4.3 A at ½ loading. Motor efficiency at ¼ loading increased up to 86% and up to 91% at
½, whereas a maximum value of 91.28% was reached at full load.
Electronics 2019, 8, 25 13 of 18

The graph in Figure 13 shows the current and efficiency values subject to load torque. It can
Electronics
clearly 2018, 7,
be seen x FORthe
from PEER REVIEW
graph 14 of
that the current drawn when the motor is idle is around I A = 2.3 A.19
1
This value increases up to I A = 9.84 A at an overloading of 40 Nm. The current drawn at 4 of the load
Electronics 2018, 7, x FOR PEER REVIEW 14 of 19
is 2.8 A and 4.3 A at 12 loading. Motor efficiency at 14 loading increased up to 86% and up to 91% at 12 ,
whereas a maximum value of 91.28% was reached at full load.

Figure 13. Current and efficiency values obtained from the motor subject to load torque.
Figure
Figure 13.13. Current
Current andand efficiencyvalues
efficiency valuesobtained
obtainedfrom
from the
the motor subject
subject to
toload
loadtorque.
torque.
Figure 14 shows the meshed model of the ¼ suggested LS-PMSM. The Tetrahedra mesh
Figure
Figure
structure 14
was shows
14used the
shows meshed
in the model
thesimulation
meshed of theof14 the
model
analyses. suggested
The¼number LS-PMSM.
suggested The
LS-PMSM.
of small Tetrahedra
regions The mesh
Tetrahedra
formed in thisstructure
mesh
structure
was structure
used in was
the used in
simulation the simulation
analyses. analyses.
The number Theof number
small of small
regions regions
formed informed
this
is directly related to the closeness to the correct result. A total of 173,665 regions were created as a in this
structure structure
is directly
is directly
related
result therelated
toofthe mesh to
closeness the closeness
to the
processing.correct toresult.
While the correctof result.
A total
a total A totalregions
of 173,665
35,569 regions ofexisted
173,665
wereinregions
created
each were
as acreated
stator; result of
26,133 as a
the
regions
mesh result
were of the mesh
processing.
consisted Whileprocessing.
in the arotor,
total ofWhile
anda regions
35,569
bar, total of existed
magnets. 35,569
The regions of existed
in each
rest stator;
the in each
26,133
regions stator;
regions
are located26,133
were regions
consisted
in the defined
were
in windings,
the consisted
rotor, bar, in the
and rotor, bar,
magnets. The and
rest magnets.
of the The rest
regions oflocated
are the regions
in aredefined
the locatedwindings,
in the definedband,
band, inner-outer regions, and shaft regions.
windings, band, inner-outer
inner-outer regions, and shaft regions. regions, and shaft regions.

(a)
(a) (b)(b)
Figure
Figure
Figure 14.
14.14.
TheThe
The meshed
meshed
meshed model
model ofof
model of the
thetheLS-PMSM
LS-PMSM
LS-PMSM with
with
with suggested rotor
suggested
suggested design:
rotor
rotor (a)
design:
design: rotor
(a)(a) and
rotor
rotor and (b)
(b)stator.
and (b) stator.
stator.

Figure 15a shows the flux densitiesininthe

Figure
Figure 15a
15ashows
shows thethe
flux
flux densities inthe
densities thestatorand
statorand
stator and rotor core
rotor core during
rotor during
core duringthe steady
thethe
steady
steadystate
state operation
operation
state operation
of ofof the
thethe motor.
motor. As
AsAscancan be
bebe understood
understood from
from the
thethe presented
presented figure,
figure, the
thethemagnetic
magnetic flux
flux can
can penetrate
penetrate deep
deep
motor. can understood from presented figure, magnetic flux can penetrate deep
into into
the the rotor
rotor core
core at at high
high speeds,
speeds, because
because of
of the
the low
low frequency
frequency of
of the
the rotor,
rotor, which
which results
results in
inan active
an active
into the rotor core at high speeds, because of the low frequency of the rotor, which results in an active
motor synchronization at lower slots. In addition, it also makes it more difficult for the motor to
motor
motor synchronization
synchronization at at
lower
lower slots.
slots.InInaddition,
addition,it italso alsomakes
makesit itmore
moredifficult
difficult forfor
thethe
motor
motorto to
decrease from a synchronous speed. Even though it is observed in the graph that the flux densities
decrease
decrease fromfroma synchronous
a synchronous speed.
speed. Even
Even though
though it it
is is
observed
observed inin
thethe
graph
graph that thethe
that flux densities
flux densities
remain in safe limits at the rotor and stator yokes, it can also be observed that the flux accumulations
remain
remain in in
safe limits
safe at at
limits the rotor and stator yokes, it can also bebeobserved that thetheflux accumulations
that develop during thethe rotor
steady and
state stator
period yokes,
do it can
not exceed also
the valueobserved
of 1.9–2that
T. flux accumulations
that develop
that develop during
during thethe
steady
steady state period
state period dodonotnot
exceed
exceed thethe
value
valueof of
1.9–2 T. T.
1.9–2
Also, Figure 15b shows the vector distribution of the ¼ suggested model in 2D. As can be seen
Also,
in the Figure
figure, 15b shows
the magnetic the
flux vectorthe
around distribution
upper slots,oflower the ¼slots,
suggested
permanentmodel in 2D.and
magnet, Asthecanrotor
be seen
inyoke
the figure, the
changes easily.magnetic flux around the upper slots, lower slots, permanent magnet, and the rotor
yoke changes easily.
 Electronics 2018, 7, x FOR PEER REVIEW 15 of 19

Electronics 2018,
Electronics 8, x25FOR PEER REVIEW
2019, 7, 1514ofof19
18

(a) (b)
Figure 15. Field (a)
reports of the LS-PMSM with suggested rotor design: (b) (a) flux distributions at the
stator and rotor cores in steady state operation and (b) vector distribution.
Figure
Figure 15. Field reports
reportsofofthe
theLS-PMSM
LS-PMSM with
with suggested
suggested rotor
rotor design:
design: (a) flux
(a) flux distributions
distributions at theatstator
the
and
stator
2.6. rotor
and cores
Analysis rotor in steady
cores
of The stateModel
in steady
Suggested operation and
state Under (b)
operation vector
and distribution.
(b) Load
Quadratic vector distribution.

TheFigure
Also,
2.6. Analysis starting
of The15b performance
shows Model
Suggested of
the vector the
Under model, which
distribution
Quadratic of theis14 suggested
Load suggested modelwith Figure
in 2D. As12 can
in the previous
be seen in
section, was discussed under a constant load; it has been observed that
the figure, the magnetic flux around the upper slots, lower slots, permanent magnet, and the rotor the suggested motor cannot
beThe
yoke
starting performance
changes
of the model, which is suggested with Figure 12 in the previous
easily.under a constant load of 𝑇 = 40 Nm. This result, which has been acquired from
synchronized
section, was discussed under a constant
analysis studies, is quite low if compared load; it has
to the 230% beenof observed
the starting that the suggested
torque generatedmotorby the cannot
reference
be synchronized
Analysis of theunder
2.6.motor. a constant
Suggested load of
Model Under 𝑇 = 40 Load
Quadratic Nm. This result, which has been acquired from
analysisThe studies,
loadisperformance
quite low
torque if compared
increases to theproportion
230% of theof starting torqueof generated by thespeed
reference
The starting of thewith
model,the which is suggested thewith
square
Figure 12 the
in rotation
the previous in the
section,
motor.
applications where the flow power is required, such as centrifugal pumps, fans, and blowers
was discussed under a constant load; it has been observed that the suggested motor cannot be
The load15)torque increases with the proportion of the square of the rotation speed in the
(Equation
synchronized under a constant load of T = 40 Nm. This result, which has been acquired from analysis
applications where the flow power isL required, such as centrifugal pumps, fans, and blowers
studies, is quite low if compared to the 230% of the
(Equation 15) 𝑇 starting
= 𝑘𝜔 torque generated by the reference motor. (15)
The load torque increases with the proportion of the square of the rotation speed in the applications
where the flow power is required, such as centrifugal 𝑇 = 𝑘𝜔 pumps, fans, and blowers (Equation (15)) (15)
A superior performance can be obtained in the applications that have a square load profile, by
2
using LM-PMSM, which offers a low starting TL = kω performance under a constant load. The starting (15)
A superior performance can be obtained in the applications that
performance under the 𝑇 = 35 Nm constant and square load of the suggested model in Figure have a square load profile, by 16
using A superior
wasLM-PMSM,
compared. Asperformance
which
it canoffers can be obtained
a low starting
be understood in
from the the applications
performance
figure, theunder that
motor awith have
constant a square
a low load. load profile,
The starting
performance under a
byconstant
using LM-PMSM,
performance under the 𝑇
which = offers
35 Nm a low
constantstarting
and performance
square load under
of the a constant
suggested
load can offer superior performance under a square load. It can be seen the suggested model load.
model The
in starting
Figure 16
performance
was compared. under
As it the
can Tbe = 35 Nm
understood constant
from and
the square
figure, theload of
motor
in Figure 17 can be synchronized in 200 ms up to 𝑇 = 87.50 Nm (250% rated torque) loads
L the suggested
with a low model
performance in Figure
under 16
a
was compared.
constant load can offer superior performance under a square load. It can be seen the suggested modela
successfully. As it can be understood from the figure, the motor with a low performance under
constant
in Figureload
17 can offer superior performance
be synchronized in 200 ms underup ato 𝑇 = load.
square 87.50ItNm can be seen rated
(250% the suggested
torque) model
loads
in Figure 17 can be synchronized in 200 ms up to TL = 87.50 Nm (250% rated torque) loads successfully.
successfully.

Figure 16. Starting performance under TL = 35 Nm constant and square load of the suggested model.
 Figure 16. Starting performance under 𝑇 = 35 Nm constant and square load of the suggested
model.

Electronics 2019, 8, 25 15 of 18

Figure 17. Starting performance under different square loads of the suggested model.
Figure 17. Starting performance under different square loads of the suggested model.
3. Conclusions
3. Conclusions
In this study, the rotor of a motor with a 5.5 kW power 4–pole IE2 efficiency class is remodeled
In this study,
using PM. Analytical the rotor
methods andoffinite
a motor with aanalysis
element 5.5 kW software
power 4–pole IE2 efficiency
environment were class
usedisinremodeled
the
modeling. As the stator section of the designed motor was obtained from an industrially marketed in the
using PM. Analytical methods and finite element analysis software environment were used
modeling.
product, the rotorAs thedesigned
was stator section
usingofanthe designedstator
accordant motorinner
was diameter
obtained and
fromstack
an industrially marketed
length values,
thereby resulting in the designed motor operating in accordance with the other asynchronous motorsvalues,
product, the rotor was designed using an accordant stator inner diameter and stack length
thereby
with the sameresulting in the designed
power. Works motor
were carried operating
out in accordance
during the with the other
study for improving theasynchronous
torque ripplesmotors
with the same power. Works were carried out during the study for improving
generated by the motor in LS-PMSM, which resulted in a significant decrease in the shaft torque the torque
quality.ripples
generated by the motor in LS-PMSM, which resulted in a significant decrease
The best design parameters were determined via GA. An increase in the motor efficiency (of 6.28%)
in the shaft torque
quality. The best design parameters were determined via GA. An increase in the motor efficiency (of
was obtained by redesigning the rotor of a motor in the moderate efficiency segment. A rotor design
6.28%) was obtained by redesigning the rotor of a motor in the moderate efficiency segment. A rotor
was suggested that can operate with IM, with the same power, as a result of using a compatible stator
design was suggested that can operate with IM, with the same power, as a result of using a compatible
inner diameter and stack length. A new rotor topology with two different slot types as an upper and
stator inner diameter and stack length. A new rotor topology with two different slot types as an upper
lower was suggested as a result of the design studies carried out. A satisfactory starting performance
and lower was suggested as a result of the design studies carried out. A satisfactory starting
was obtained with the suggested topology. A new rotor design was introduced in the industrial pump
performance was obtained with the suggested topology. A new rotor design was introduced in the
and fan applications. In addition, a surface mount PM was used in the design of the suggested model,
industrial pump and fan applications. In addition, a surface mount PM was used in the design of the
thereby eliminating problems such as the placement of the PM in the rotor core, which poses a difficult
suggested model, thereby eliminating problems such as the placement of the PM in the rotor core,
problem for motors with interior PMs.
which poses a difficult problem for motors with interior PMs.
Author Contributions: Formal analysis, B.Z. and M.E.; investigation, B.Z.; methodology, B.Z. and M.A.; resources,
M.E.; supervision,
AppendixM.A.; validation, B.Z.; writing (review and editing), B.Z.
NOMENCLATURE
Funding: This study was supported by the Gaziosmanpaşa University Scientific Research Projects Unit, project
number 2017/90.
𝑚, 𝑝: Number of phase and pole
𝑃 , 𝑤 : Output
Conflicts of Interest: The authors
powerdeclare
and no conflict
stator of interest.
angular speed
𝑋 , 𝑋 , 𝑋 , 𝑋 : Leakage reactances (the suffix “2” refers to the rotor)
Nomenclature
𝐼 , 𝐼 , 𝐼 , 𝐼 : Axis current (the suffix “2” refers to the rotor)
m, p: Number 𝑋 of ,phase
𝑋 :andMagnetizing
pole reactances
Pn , ws : Output 𝐼 power, 𝐼 :andRMSstator angular
of d- speedcurrents
and q-axis
Xd , Xq , X2q , X : Leakage reactances (the
𝐸 , 𝐼 , 𝑉 : Excitation voltage,
2q suffix “2” refers to the
excitation rotor) and phase voltage
current,
Id , Iq , I2d , I2q : Axis current (the suffix “2” refers to the rotor)
𝑇 , 𝑇 , 𝑇 : Cage torque, permanent magnet torque, and total electromagnetic torque
Xmd , Xqm : Magnetizing reactances
𝑇 , 𝑇 : Asynchronous torque and synchronous torque
Imd , Iqm : RMS of d- and q-axis currents
𝐽 , 𝑇 , 𝑘: Motor inertia, load torque, and square load profile coefficient
E , I , V : Excitation voltage, excitation current, and phase voltage
0 fm ph1
Tc , Tpm , Te : Cage torque, permanent magnet torque, and total electromagnetic torque
Tasyn , Tsyn : Asynchronous torque and synchronous torque
Electronics 2019, 8, 25 16 of 18

Jm , TL , k: Motor inertia, load torque, and square load profile coefficient

β: Angle between EMF and terminal voltage
Dso , Dsi , RO: Outer and inner diameter of stator, rotor diameter
l, δ: Stack length and air gap
Bδ , SGAP : Air gap flux density and air gap power
φδ , φ pm : Air gap flux and permanent magnet flux
hmag , tmag : Permanent magnet height and thickness (in calculations)
Mt , Mw : Magnet thickness and width (in optimization study)
Hδ , Hmag : Field strength of the air gap and field intensity of the permanent magnet
µ0 , µr : Permeability of air and relative recoil permeability
Is , Ir , Iring : Stator, rotor, and end ring current
Qs , Qr : Number of stator and rotor slots
zQs , a: Number of conductors in a slot and parallel paths in a stator winding
η, cos ϕ, I A : Efficiency, power factor, and rated current
Scr , Scring : Cross-sectional area of rotor bar and end ring
Jr , Jring : Rotor and end ring current densities
btr , τr , K Fe : The rotor tooth width, rotor slot pitch, and the stacking factor
Tripple , TRMS , Tmean : Torque ripple, RMS of motor torque, and mean of motor torque
Bs0, Bs1, Hs : Slot gap for upper slot, slot diameter, and rotor slot depth

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