2017 IEEE Region 10 Humanitarian Technology Conference (R10-HTC)

21 - 23 Dec 2017, Dhaka, Bangladesh

Interior Permanent Magnet Synchronous Machine

(IPMSM) design for environment friendly Hybrid
Electric Vehicle (HEV) Applications
M. A. H. Raihan1, K. J. Smith1, A. A. Almoraya1, F. Khan2
School of Electrical and Electronic Engineering, Newcastle University Upon Tyne, Newcastle upon Tyne, NE17RU, UK
1
2
Department of Electrical, Electronic & Communication Engineering, Military Institute of Science &Technology, Bangladesh
[email protected]

Abstract— The Interior Permanent Magnet Synchronous density, torque derived with induced EMF, harmonic contents
Machine (IPMSM) is becoming an integral part in Hybrid Electric of flux linkage and back EMF and the mechanical design and
Vehicle (HEV) applications due to their excellent performance, winding configuration. It is advantageous to use PM machine
fast development and environment friendliness. While depending for high speed application due to their higher efficiency, greater
on the rare earth magnet materials and rotor structure for the torque and power density, simple and rigid construction, almost
dynamic characteristics, they are very useful in high speed no excitation losses and substantially superior dynamic
application especially for variable speed drives. This paper is performance [3].
about designing Interior Permanent Magnet (IPM) motors for
hybrid electric car application with fractional slot pole Conventional PM machine consist of three phase winding in
combination in order to achieve maximum efficiency with lowest the stator and magnets mounted on the rotor or buried inside of
possible costing. It additionally incorporates imperative it. Regarding the magnetic flux path, PM machines can be
assumptions and estimations of machine parameters that can be separated into Radial Flux PM (RFPM) machines, Axial Flux
utilized for genuine machine outline. Two IPM machines have PM (AFPM) machines and Transverse Flux PM (TFPM)
been designed, simulated and analyzed by 2D Finite Element machines [4]. Again, Surface mounted, inset magnet and buried
analysis (FEA) for lowest possible torque ripple, iron loss, cogging magnet PM machines are three major kinds of radial flux
torque and harmonic distortion. Optimized back EMF, cogging machine [5].
torque, rated torque, machine volume, pricing and other
simulation results are compared for both the machine. Finally the In IPM or buried magnet machines, magnets are buried
study ends up with the selection of the better machine with respect inside the rotor with different orientation. For high speed
to the efficiency, size, torque ripple and cost effectiveness. automotive applications, IPM machine stay ahead of surface
mounted PM machine due to its higher air gap flux density,
Keywords— Interior Permanent Magnet Synchronous Machine magnet security from armature reaction, higher mechanical
(IPMSM), Hybrid Electric Vehicle (HEV), Rare Earth Magnet, stability due to buried magnets, armature reaction dominant
Finite Element Analysis (FEA), Torque Ripple, Cost Effectiveness extensive constant-power (field weakening) region and
additional salient torque due to the saliency (Xqs>Xds). Field
I. INTRODUCTION weakening range depends on the direct axis inductance (Ld)
Permanent magnet synchronous machine (PMSM) are proportionally. Ld is high in buried magnet machine as the
getting substantial interest in Hybrid Electric Vehicle and magnets are connected in parallel with respect to the air gap flux,
traction applications due to their simple machine construction whereas they are connected in series in surface mounted
with three phase winding configuration, lower machine volume machine [6]. Another reason behind high d-axis inductance is
and higher efficiency over other types of machines in various the high rate of leakage flux embedded magnet machine.
fields [1], [2]. Another important feature is almost no rotor loss Buried magnet machine have higher D-axis inductance and
(joule loss) that makes it even easier to cool the machine, sinusoidal flux distribution around the air-gap that helps reduce
increase heat transfer capability and ultimately upsurge the the cogging. It is very useful in speed control application due to
lifetime of the machine. its poor overloading (1~2 p.u.) characteristics [7].
The aim of this paper is to design, simulate and optimize two From load angle equation,
variable speed IPM motors for automotive application such as
electric car. An existing IPM machine for electric car (Toyota =3 ( ) (1)
Prius) has been used as a benchmark for the study. Focuses have
been made upon maximizing rated torque, minimizing torque
Assuming, Ld = Lq= 0.7 p.u. and Ea=1 p.u., it is possible to
ripple, harmonic contents, iron loss, magnet materials and
boast the maximum torque by making Lq>Ld. It can be achieved
costing to achieve highest performance.
by putting larger air-gap and hence reducing Ld, but causing
In order to understand the operating principle and predict the more magnetic material to be included with the machine.
performance of an electrical machine, it is necessary to know the
It is a prerequisite of multiphase machine that the slots are
fundamental relationships between the machine parameters such
divisible by the number of phase. Torque density, air-gap flux
as back EMF, MMF, current density, flux linkage, air-gap flux

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 2017 IEEE Region 10 Humanitarian Technology Conference (R10-HTC)
21 - 23 Dec 2017, Dhaka, Bangladesh

distribution, back EMF, machine losses, cogging torque,

harmonic contents are the most important features of PMSM
machine and slot/pole combination has substantial effect upon
them [8], [9].
Slot/pole combination largely depends on different winding
configurations. Choice of pole/slot combination for a 3-phase
no overlapping winding configuration is given by the following
equation,
Nslot /NPole =3/2 K; k=1,2,3,4…..n (2)
Nslot and Npole are the number of slots and poles in a machine
respectively. But, the main drawback of this non-overlapping 9 Slots / 8 Poles (Design 2) 12 Slots / 10 Poles (Design 1)
combination is the lower utilization of winding and it gives a
maximum winding factor of only 0.867 [9]. Fig. 1. 2D sketch of the two proposed IPM machines.

Following chapters explain useful insight of two IPM

their amelioration in design technique and simplicity, short end-
machine topologies and important machine parameters that have
windings, lower copper loss, lower torque ripple, sinusoidal
direct impact on machine performance. It also considers the
MMF and back EMF and higher torque and power density [9].
calculation of initial machine parameters and 2D Finite element
analysis (FEA) results from the FEA software. Final chapter For a typical PM machine the shear stress value is close to
discusses the comparison between two optimised machines that 40KPa.
have been designed and simulated. Finally the better machine
will be selected based on machine performance, cost T=2Vr σ (7)
effectiveness, volume of the machine and efficiency. Here, T is the mechanical torque, σ is the shear stress and Vr
Design and analysis of the PM motor is limited by the is the rotor volume. Again,
specified parameters provided bellow, D=√ ((4Vr)/πl) (8)
TABLE I. SUPPLIED MACHINE SPECIFICATION FOR THE PROPOSED D is the rotor outer diameter, Vr is the rotor volume and l is
DESIGNS the axial length. (Assume, l= 150mm)
Parameters Values ty = (Bg,max/Bm) πD/4P (9)
Machine output Power (P) 100 kW (1x Direct Drive)
lm=(B lg μr)/(B0-B) (10)
Terminal Voltage 600 V(Peak)
Where, ty is rotor core back, lm is the magnet width, B= Bg
Maximum electrical frequency 1kHz is air gap flux density, B0 is residual flux density of magnet
Corner speed (nrated) 6000rpm material, μr is relative permeability of steel, lg is length of air gap.

Terminal voltage limit (Vt) 600 V Slot pitch= 2πr / (no. of slots) (11)
Maximum Speed (nmax) 12000 rpm Wt = (Bm×Slot pitch)/Bt (12)
Here, Wt is Stator tooth width, Bt= maximum flux density of
II. INITIL DESIGN AND CALCULATION stator tooth, ∅peak is peak magnetic flux
Comprehensive machine design incorporates some basic ∅peak= (2Bg la r) / P (13)
parameter calculation based on supplied information and few
important assumptions on sizing of PM machines. For a PM A. Design 1
machine with a rated angular speed of ωrated, rated mechanical
speed of nrated, rated torque of Trated, peak phase back EMF of First machine includes a V-shaped IPM model with 10 pole /
Ephase, Maximum speed at max frequency of Nmax and a peak 12 slots configuration. Three phases are distributed around the
power of Pmax, following equations can be used .
ωrated = (2πnrated)/60 (3)

Trated=P/ωrated (4)

Ephase = Vt/√3 (5)

Nmax=60f/Pmax (6)

It is convenient to use concentrated winding and fractional

pole/slot combinations for the permanent magnet motors due to Fig. 2. Phasor diagram of the winding distribution of design 1

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 2017 IEEE Region 10 Humanitarian Technology Conference (R10-HTC)
21 - 23 Dec 2017, Dhaka, Bangladesh

12 slots. Following figure shows the phasor diagram and

winding distribution for design 1.

Mechanical angle between slots = (360°)/12 = 30°

Electrical angle between slots = Coil span = 30°× 5 = 150°
Short pitching angle, α=180°-150°=30°

Pitch factor, Kp= cos = 0.966

Design 1 Design 2
Here, for a 12 slots 10 poles single tooth winding Fig. 4. Three phase winding distribution in the stator
configuration,
Red (A) Phase : 1, -2, -9
Slot pitch, β=30° and n = 2
Blue (B) Phase: -3, 4, -5

Distribution factor, Kd = = 0.966 Yellow (C) Phase: -6, 7, -8

.
Number of coils in each phase= = =3
.
Red, Blue and Yellow phases are made of the following slots
combination,
TABLE II. CALCULATED MACHINE PARAMETERS FOR BOTH MODEL FROM
Red (A) Phase : 1, -2, -9 THE SPECIFICATION PROVIDED

Blue (B) Phase : -3, 4, -5 Parameters Design 1 Design 2

Yellow (C) Phase : -6, 7, -8 Rated Torque (Trated) 160 Nm 160 Nm

. No. of poles (Nmax) 10 8

Coils in each phase= =4
. No of slots 12 9
No. of coils per phase 4 3
B. Design 2
° Axial Length (mm) 150 200
Mechanical angle between slots = = 40°
Rotor outer diameter (D) 150mm 168mm
Electrical angle between slots (Coil span) = Mechanical angle Peak magnetic flux
6.5 mWb 7.5 mWb
between slots × Pole pairs= 40°×4 = 160° (∅peak)

Short pitching angle, α = 180° 160° = 20° Winding Factor 0.93 0.83
°
Pitch factor, Kp= cos = cos = 0.985 III. FEA RESULTS ANALYSIS & COMPARISON
Here, for a 9 slots 8 poles single tooth winding configuration, This chapter discusses the FEA results for both machine models
developed. Initial FEA models have been built by following the
Slot pitch, = 40° and n = 3 theoretical calculation of machine parameters. But the
° parameters were further modified to meet demanded
Distribution factor, Kd = = ° = 0.844 performance in simulation results. As both machines are buried
magnet machine, there exist saliency in the machine. That
means, maximum torque will be developed when there is a
Red, Blue and Yellow phases are made of the following slots phase shift between the back EMF and applied phase current.

combination,

Fig. 5. Angular displacement between back EMF and applied current for
Fig. 3. Phasor diagram of the winding distribution of design 2 maximum rated torque.

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 2017 IEEE Region 10 Humanitarian Technology Conference (R10-HTC)
21 - 23 Dec 2017, Dhaka, Bangladesh

Fig. 6. Improved cogging and rated torque for the Design 1 Fig. 7. Improved cogging and rated torque for the Design 2.
This phase shift provides the extra reluctance torque in the
machine that increase the rated torque. were improved by optimizing slot opening, magnet dimensions,
air barrier insertion, geometric shape and skewing. After
Fig. 6 and Fig. 7 shows the cogging and the rated detailed comparison based on the major machine criteria and
torque for design 1 and design 2 respectively. Both machines soundness of geometry, design-2 has been selected as the better
have been optimised to provide maximum rated torque with the design for hybrid electric car application due to its higher
minimum cogging. Mechanical optimisations have been made efficiency, lower torque ripple, smaller machine volume and
for both models by skewing, curving stator tooth edge and tooth reduced cost.
tips, minimising slot opening etc. for optimum performance. REFERENCES
Iron loss and winding loss have also been calculated for the
efficiency calculation. Final results from both the models are
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Two different interior permanent magnet machine has been

designed, analysed and compared in terms of maximum torque,
torque ripple, harmonic contents, back EMF, losses, field
weakening characteristics and flux density by using 2D finite
element analysis. Furthermore performance of initial designs

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