Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

Based FE design and performance enhancement of a PMSM intended

for a leisure electric vehicle

Radhia JEBAHI Nadia CHAKER Helmi ALOUI Moez Ayadi

[email protected] [email protected] [email protected] [email protected]

Laboratory of Advanced Electronic Systems and Sustainable Energy, ENET’Com, University of Sfax, Tunisia

Abstract-- The increase of vehicular traffic is one of the 2. INTRODUCTION

main causes of the high rate of pollution and increased
energy consumption. For that, researchers and industrials Along several years, researches were focused on the
are continuously working on environmentally friendly reduction of problems caused by vehicular traffic such as
solutions, such as electric and hybrid vehicles. The electric pollution, energy consumption and long-term severe
vehicles are equipped with rechargeable batteries intended to effects on the ecosystem. Retained solutions were mainly
the supply of the traction motor. Thanks to their higher cleaner vehicles such as hybrid and electric ones. In front
performances, permanent magnet synchronous motors
of the fuel's prices rise and the frequent encouragement to
(PMSM) became the main types of motors insuring electric
traction. The present work deals with a based 2D finite use the environmentally friendly vehicles, the electric
elements design of a synchronous motor, where PMs are vehicle market doubles every year. Besides, driving
managed to insure flux concentration, considering well- motors characteristics are increasingly improved [1-3].
defined specifications of a leisure electric vehicle. It has been
found that obtained structure gather reduced energy Design and control of electric traction motors was
consumption to decreased losses. presented in several works. In [4], authors studied the
performances of different radial flux surface-mounted
Index Terms--Electric vehicle, Specifications, PMSM,
Finite Element Calculation, Output torque. permanent magnet motors designed for an electric vehicle
motor application (Inner rotor, Inner rotor segmented
magnet, Outer rotor and Outer rotor segmented magnet).
1. NOMENCLATURE They proved that the outer rotor topology has the
Br: remanent induction (T) smoother and the higher output torque, but it has also the
Bds: induction in stator tooth (T) highest iron losses. Moreover, in [5] the operational
characteristics, design features, and control requirements
Bc: induction in stator yoke (T) for induction machines, switched reluctance machines, and
f: frequency (Hz) permanent-magnet brushless machines for vehicle
propulsion systems have been reviewed, with emphasis on
J: current density (A/m2) their low-speed torque and high-speed power capability.
Km: error coefficient made by model Given that they offer a higher efficiency and torque
density, particular emphasis has been given to permanent-
Kb: winding coefficient
magnet brushless machines. Finally, it is clear that, due to
Lcu: copper length (m) their high performance and effectiveness, the main used
Mds: stator tooth mass (kg) motors for studied electric vehicles are the permanent
magnet ones [4-8].
Mc: stator yoke mass (kg)
In the present work, our study targets the design and the
mvfer: density of the iron (kg/m3) sizing of a concentrated flux PMSM intended to the
Pfs: iron losses (W) traction of an electric vehicle where thermal behavior is
taken into account. In fact, information about copper and
Pjs: copper losses (W) iron losses could be used to elaborate a predictive rapid
q: sheets quality model providing real-time information about the thermal
state of the motor permitting to perform advanced and
ρcu : copper resistivity (Ω.m)
complete control schemes taking into account the
Scu: copper surface (m2) evolution of the machine parameters and the prevention of
Ta : ambient temperature (°C) its components damages.

Tc : coil temperature (°C) On the other hand, Tunisia is known as great touristic
destination where leisure vehicles are widely needed,

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 Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

which explains the choice of such application in these

works.
To do so, this manuscript is organized as follows: In
first, the motor topology and composition are defined.
Then, the second part is intended to study the effects, on
cogging torque and electromagnetic one, of the variation
of motor’s components dimensions. Finally, the last part of
this work presents and discusses motor’s performances
from the points of view of energy consumption and
effectiveness.
Fig. 1. Studied topology.
3. SPECIFICATIONS
TABLE II
The analysis of specifications allows us to identify the
Machine’s initial dimensions
needed characteristics to insure motor functionality and
retrieve geometric, electrical, mechanical and thermal Symbol Quantity value
constraints.
Rexts outer stator diameter 133 mm
- Geometric constraints: They present the external
dimensions of the machine taking into account the Rints inner stator diameter 101 mm
cooling system and carter: external length Rextr outer rotor diameter 100 mm
Lext=200mm and external Diameter Dext=.280mm. Rintr inner rotor diameter 25 mm
- Electrical and mechanical constraints: they are given hcs stator yoke height 14 mm
in TableI. hds stator tooth height 18 mm
- Thermal constraints: the maximum temperature of the lds stator tooth width 20 mm
hottest point must not exceed Tmax=200°C.
Haim magnet height 40 mm
Moreover, in case of overheating, an indicator
should be turned on and the vehicle must be Eaim magnet thickness 8 mm
operated for a sufficient period of time with Her1 width chamfer1 0.6*Her2
degraded performance before stopping. Her2 width chamfer2 0.65*Eaim
TABLE I
ler1 height chamfer1 2 mm
Electrical and mechanical constraints ler2 height chamfer2 13 mm

Parameter value La active machine length 70 mm

Power (kW) 33 (30 seconds) Ne slot number 18

30 (300 seconds) p number of pole pairs 6

15 (permanent)
Voltage (V) DC supply Nominal: 200 5. NO-LOAD STUDY
Variation range 90 → 220 This part focuses the machine cogging torque. First, we
torque (Nm) 145 (30 seconds) choose the remnant induction, then following studies are
130 (300 seconds) performed:
65 (permanent) - Variation of magnets thickness, where magnets
basic Speed (tr/min) 2250
height is fixed.

operating speed limit (tr/min) 8000 - Variation of magnets height, where magnets
thickness is fixed.
- Variation of magnets thickness where volume
4. MOTOR TOPOLOGY
magnets is fixed.
In this work, we propose a design procedure of a
A. Choice of magnets remnant induction
permanent magnet synchronous motor with flux
concentration arrangement. Considered topology is Fig.2 shows the output cogging torque when we used
illustrated in Fig.1. Besides, the initial dimensions of the respectively ferrite magnets (Br=0,37T) and Neodymium
machine are shown in Table II. Those dimensions will be Iron Boron magnets “NdFeB” (Br=1T). According to this
varied during the next studies in order to respond as best figure we can find that the use of ferrite magnets is not a
to required specifications. good solution despite of its low price. In fact, the output

ISBN: 978-9938-14-953-1 (49) Editors: Tarek Bouktir & Rafik Neji

 Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

torque in this case is almost zero, while the use of a TABLE III
NdFeB magnets give to machine the power to produce a Cogging torque (Haim=40mm)
cogging torque reaching 10 Nm.
Eaim=6mm Eaim=8mm Eaim=10mm
Moreover, Fig.2 and Fig.3 show that the angular period
of cogging torque is 10°. Max cogging 6.31Nm 10.27Nm 14.85Nm
torque

C. Variation of magnets height

In this part, the magnet height is varied from 35 to
45mm, where the magnet thickness is fixed to Eaim=8mm.
According to Fig.5 and table IV, the cogging torque
increases with the magnet height rise. In fact, a rise of
magnet height by 10mm leads to a rise of cogging torque
by 9.26Nm and of magnets volume by 5600mm3.

Fig. 2. Cogging torque versus angular position.

Fig. 5. Cogging torque versus angular position.

TABLE IV
Fig. 3. Angular period of cogging torque.
Cogging torque (Eaim=8mm)
B. Effect of the variation of magnets thickness
Haim=35mm Haim=40mm Haim=45mm
In this part, the magnet thickness is varied from 6 to
10mm, where the magnet height is fixed to Haim=40mm. Max cogging torque 6.08 Nm 10.27 Nm 15.34 Nm
According to Fig.4 and Table III, the cogging torque
increases with the magnet thickness rise. In fact, a rise of
magnet thickness by 4mm leads to an increase of the D. Effect of the variation of magnets thickness for a fixed
maximum cogging torque by 8.54Nm and also of magnets volume
volume by 11200mm3.
Fig.6 and table V show that when the magnet volume is
fixed, the cogging torque decreases with the magnet
thickness rise. In fact, the raise of magnets thickness leads
to the growth magnets short circuits, which fallouts a
reduction of generated torque as shown in Fig. 7
The main objective of this part is to determine an
optimal value Eaimoptimal where the torque is maximum.
Beyond this value, cogging torque decreases with the
magnet height.
The analytical expression (1) gives Eaimoptimal ≈ 7mm.
while the finite element results show that Eaimoptimal should
be ≤ 6mm.

Fig. 4. Cogging torque versus angular position. (1)

ISBN: 978-9938-14-953-1 (50) Editors: Tarek Bouktir & Rafik Neji

 Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

At this stage, we have tested the effect of the variation concentrated winding and distributed winding [10-11],
of the magnets dimensions on cogging torque. The Fig.8.
obtained resultants show that the analytical expression (1)
used in [9] to determine Eaimoptimal is false. Besides, we Fig.9 shows an output torque comparison of two
can find that a rise of magnet dimensions leads to an PMSM with flux concentration arrangement. The first
increase of the maximum cogging torque and also of encloses a concentrated winding and the second is a
magnets volume consequently a rise of magnet price, but classical one with a distributed winding. According to
to deciding about final dimensions of the magnets and find obtained curves, the concentrated winding should be the
a compromise between it and "J", load studies have to be best choice in our case. In fact, when J=10A/mm2, the
performed. output torque in case of concentrated windings can reach
108 Nm, while in case of distributed windings the output
torque cannot exceed 23Nm.

Fig. 6. Cogging torque versus angular position.

TABLE V

Cogging torque (Haim=Vaim/Eaim)

Eaim=6mm Eaim=7mm Eaim=8mm Eaim=10mm

Max 17.34Nm 13.4 Nm 10.27 Nm 6.33 Nm

cogging
torque

Fig. 8. Concentrated and classical distributed windings

Fig. 7. Field vectors at no-load (J=0A/mm2)

6. LOAD STUDY
Before deciding about final dimensions of the magnets,
the following studies have to be conducted: Fig. 9. Output torques versus current density
- Choice of winding type B. Needed current density
- Investigation of needed current density In order to find out the current density "J" needed to
A. Windings choice produce the desired electromagnetic torque and find a
compromise between J and magnet dimensions, following
There are two windings types for the electric motors, studies are performed:

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 Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

- Variation of magnets thickness, where magnets (respectively thickness) is high, more the
height is fixed (Haim=40mm), Fig. 10. current densities giving the required torques is
low.
- Variation of magnets height, where magnets
thickness is fixed (Eaim=8mm), Fig. 11. - The rise of magnets height (respectively
thickness) make the machine less susceptible
- Variation of magnets thickness where volume to saturation
magnets is fixed, Fig. 12.
Table VI and VII show the required currents density.
According to Fig.12 and TABLE VIII we can see that
the required current density increases with magnet
thickness when magnet volume is fixed, as a result of the
growth magnets short circuits, Fig.13.
TABLE VI

Required current density (A/mm2)

Eaim=6mm Eaim=8mm Eaim=10mm

65 Nm 7.8 5.67 4.51

130 Nm 19.2 13.48 10.76
145 Nm 23.06 15.64 12.46
Fig. 10. Electromagnetic torque versus current density, for Eaim
from 6 to 10mm
TABLE VII

Required current density (A/mm2) FOR HAIM FROM 35 TO 45MM.

Haim=35mm Haim=40mm Haim=45mm

65 Nm 7.78 5.67 4.29

130 Nm 18.11 13.48 10.53
145 Nm 21.26 15.64 12.25

TABLE VIII

Required current density (A/mm2) FOR EAIM FROM 6 TO 9MM

Eaim=6mm Eaim=7mm Eaim=8mm Eaim=9mm

Fig. 11. Electromagnetic torque versus current density for Haim 65 Nm 4.42 5.47 6.57 8.72
from 35 to 45mm.
130 Nm 11.44 13.7 15.88 19.99
145 Nm 13.44 15.93 18.31 23.32

C. The final dimensions of magnets

According to the obtained results during load and no-
load studies, we can conclude that:
§ The rise of magnets volume can reduce the heat
produced by electrical currents and make
machine less susceptible to saturation, but it
will cause a rise of magnet price.
§ It is better to increase magnets height than
Fig. 12. Electromagnetic torque versus current density for E aim magnets thickness.
from 6 to 9mm Before deciding about final dimensions of the magnets
Referring to Fig. 10 and 11, one can notice that: we have to see the effect of a Haim rise on Field vectors for
the required torque, Fig.13.Finally, the retained magnet's
- For a constant thickness (respectively height) of sizes are: Eaim = 10 mm and Haim= 45mm.
magnets, more the magnets height

ISBN: 978-9938-14-953-1 (52) Editors: Tarek Bouktir & Rafik Neji

 Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

deciding about final value of lds, in order to find a

compromise between torque ripple, saturation and the
required current density.

Fig. 13. Field vectors for the required torque (145Nm)

While the magnet dimensions affect only the cogging
torque, the stator tooth dimensions affect also the copper
surface, consequently, it affects the electromagnetic torque Fig. 15. Field vectors no-load operation (lds=20mm).
and the copper losses. For this raison, we are interested in
the next part to the stator tooth sizing.
7. STATOR TOOTH SIZING
During the following studies the stator tooth width is
varied where the stator tooth height is fixed to hds=18mm.
According to the equation (2), [9], we can see that the
decrease of stator tooth width can help to reduce the iron
losses but we have to know the impact of this action in
order to choose the right dimensions of the stator tooth.

(2)

A. no-load study
According to Fig.14 we can show that the decrease of
lds caused the rise of torque ripple. Besides, Fig.15 and 16 Fig. 16. Field vectors no-load operation (lds=10mm).
show that the decrease of lds causes a high saturation at the B. load study
stator tooth. In fact, when lds= 20mm the flux density does
not exceed 1.81T, while when lds= 10mm it reached 2.19T. Fig.17 and table IX show that the decreases of lds
causes the rise of required current density and it make the
machine more susceptible to saturation.

Fig. 14. Cogging torque versus angular position, for lds from 10
to 20mm
Fig. 17. Electromagnetic torque versus current density for lds
Despite the bad effects of lds decrease presented in the from 10 to 20mm
no-load study, load studies have to be performed before

ISBN: 978-9938-14-953-1 (53) Editors: Tarek Bouktir & Rafik Neji

 Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

TABLE IX

Required current density (A/mm2) FOR LDS FROM 10 TO 20MM

lds=20 mm lds=15 mm lds=10 mm

65 Nm 3.52 4.34 3.77

130 Nm 9.35 13.55 13.99
145 Nm 10.91 15.52 16.66

According to the previous obtained results, we can

conclude that the most convenient dimensions for magnets
and stator tooth are as shown in table X.
TABLE X
Fig. 18. Copper losses versus coil temperature for the required
Final dimensions torque.

Symbol Haim Eaim lds hds B. iron losses

Value (mm) 45 10 20 18 The iron losses in rotor are equal to zero because the
rotor’s magnetic material sees a fixed magnetic field.
However, the stator's magnetic material sees a magnetic
8. PERFORMANCE OF THE DESIGNED CONFIGURATION field turning to the electric rotation frequency, for this
reason iron losses in stator are the majority and it can be
At this level, we have achieved the studies of cogging calculated by the equation (6), (7), (8), (9).
and electromagnetic torques. According to the previous
obtained results the most convenient dimensions for
(7)
magnets and stator tooth are as shown in table X. Besides,
Fig.14 shows that the designed motor is able to produce
Where:
cogging torque higher than 20 (Nm). Thanks to this
property, the motor does not need a high current density to (8)
produce the electromagnetic torque required by
specifications, Fig.17 and Table IX shows the current (9)
density requested
(10)
In the next parts, we focus on the evolutions of iron
and copper losses which are the principal heat sources in Fig.19 shows the induction in a stator tooth versus
motor and can degrade her performances. angular position.
A. copper losses Fig.20 shows the iron losses versus speed, according to
Copper losses refer to the heat produced by electrical this figure we can find that the iron losses which dissipated
currents in the conductors of motor. as heat, increase with the speed rise.

For a SMPM with flux concentration the copper losses

are calculated through the equations (3), (4), (5) and (6).
Fig.18 shows that the copper losses increase
proportionally with the temperature rise. Besides, we can
see that copper losses converge more quickly with the
decreasing of electromagnetic torque.
(3)

Where:
(4)

(5)
Fig. 19. Induction in stator tooth versus angular position.
(6)

ISBN: 978-9938-14-953-1 (54) Editors: Tarek Bouktir & Rafik Neji

 Proceedings of the International Conference on Recent Advances in Electrical Systems, Tunisia, 2016

The present work covers the design and sizing of a

permanent-magnet synchronous motor, where PMs are
managed to insure flux concentration, considering well-
defined specifications of a leisure electric vehicle.
The performed load and no-load studies lead to an
improvement structure with reduced energy consumption
and decreased losses, which are the main heating sources
in electrical machines. In fact, the obtained structure offers
a reduction of required current density about 1 A/mm2 and
a reduction of iron losses exceeded 350 W. Besides, the
efficiency of the designed motor is around than 0.99 even
for high speed.
It is to be signaled that the information about copper
Fig. 20. Iron losses versus speed losses and iron losses obtained in the last part of this paper
Fig.18 and 20, show that the iron and copper losses in are currently being used to elaborate a predictive rapid
the designed motor during normal operation are model providing real-time information about the thermal
respectively equal to Pf=132.17W and Pjs=99.5W. state of the motor permitting to perform advanced and
Comparing to the final structure in [9]. We have found that complete control schemes taking into account the
the obtained structure gathers reduced energy consumption evolution of the machine parameters and the prevention of
to decreased losses. Table XI show a comparison between damages.
the two structures. Besides, Fig.21 shows that the designed
configuration is characterized by a very high efficiency. In
fact, the motor efficiency is greater than 0.99 even for high REFERENCES
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TABLE XI [3] Website: http://professionnel.peugeot.fr
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the pollution problem due essentially to the use of thermal
automotive, which explain that since several years
numerous research works were focused on the
improvement of the characteristics of different kinds of
motors intended for electric vehicles.

ISBN: 978-9938-14-953-1 (55) Editors: Tarek Bouktir & Rafik Neji