Influence of Manufacturing Tolerances on Cogging Torque in Interior Permanent Magnet Machines with Eccentric and Sinusoidal Rotor Contours

Rotor shaping methods are frequently used to reduce the cogging torque in interior permanent magnet (IPM) machines. This paper investigates the influence of manufacturing tolerances on cogging torque in IPM machines with eccentric and sinusoidal rotor contours. First, two 12-slot/8-pole IPM machine models are established and the fundamental performance under ideal conditions is presented. Then, based on the most sensitive distributions of nonideal PMs and assembly tooth-bulges, additional cogging torque components are calculated, respectively, together with a comparative study to identify the different sensitivities between the two rotor contour designs. For verification, the field spatial harmonics with and without considering the tolerances are further analyzed, followed by tests on the prototypes with and without amplified tolerances.

[1]  Z. Q. Zhu,et al.  Comparison of Cogging Torque Reduction in Permanent Magnet Brushless Machines by Conventional and Herringbone Skewing Techniques , 2013, IEEE Transactions on Energy Conversion.

[2]  R. Fiser,et al.  Additional Cogging Torque Components in Permanent-Magnet Motors Due to Manufacturing Imperfections , 2009, IEEE Transactions on Magnetics.

[3]  宫下利仁.  Permanent magnet-embedded motor and rotor thereof , 2013 .

[4]  S. Ho,et al.  Optimization of Permanent Magnet Surface Shapes of Electric Motors for Minimization of Cogging Torque Using FEM , 2010, IEEE Transactions on Magnetics.

[5]  Z. Q. Zhu,et al.  Influence of manufacturing tolerances on cogging torque in interior permanent magnet machines with eccentric and sinusoidal rotor contours , 2016, 2016 IEEE Energy Conversion Congress and Exposition (ECCE).

[6]  H. Polinder,et al.  Magnet shaping for minimal magnet volume in machines , 2002 .

[7]  M.F. Momen,et al.  Analysis of Flux Leakage in a Segmented Core Brushless Permanent Magnet Motor , 2009, IEEE Transactions on Energy Conversion.

[8]  Ayman M. El-Refaie,et al.  Fractional-Slot Concentrated-Windings Synchronous Permanent Magnet Machines: Opportunities and Challenges , 2010, IEEE Transactions on Industrial Electronics.

[9]  Steven A. Evans,et al.  Salient pole shoe shapes of interior permanent magnet synchronous machines , 2010, The XIX International Conference on Electrical Machines - ICEM 2010.

[10]  G. Ombach,et al.  Influence of Additional Air Gaps Between Stator Segments on Cogging Torque of Permanent-Magnet Machines Having Modular Stators , 2012, IEEE Transactions on Magnetics.

[11]  Jung-Pyo Hong,et al.  Analysis of cogging torque considering tolerance of axial displacement on BLDC motor by using a stochastic simulation coupled with 3-D EMCN , 2004 .

[12]  Kum-Kang Huh,et al.  Comparison of interior and surface PM machines equipped with fractional-slot concentrated windings for hybrid traction applications , 2011, 2011 IEEE Energy Conversion Congress and Exposition.

[13]  Mi-Ching Tsai,et al.  Design and Operation of Interior Permanent-Magnet Motors With Two Axial Segments and High Rotor Saliency , 2010, IEEE Transactions on Magnetics.

[14]  Nobuaki Miyake,et al.  New core structure and manufacturing method for high efficiency of permanent magnet motors , 2003, 38th IAS Annual Meeting on Conference Record of the Industry Applications Conference, 2003..

[15]  Zhiyong Wu,et al.  Analytical Solution for Cogging Torque in Surface-Mounted Permanent-Magnet Motors With Magnet Imperfections and Rotor Eccentricity , 2014, IEEE Transactions on Magnetics.

[16]  D. Howe,et al.  Influence of design parameters on cogging torque in permanent magnet machines , 1997, 1997 IEEE International Electric Machines and Drives Conference Record.

[17]  M. Moallem,et al.  Design improvement of Interior Permanent Magnet synchronous machine for Integrated Starter Alternator application , 2013, 2013 International Electric Machines & Drives Conference.

[18]  Nicola Bianchi,et al.  Design techniques for reducing the cogging torque in surface-mounted PM motors , 2000, Conference Record of the 2000 IEEE Industry Applications Conference. Thirty-Fifth IAS Annual Meeting and World Conference on Industrial Applications of Electrical Energy (Cat. No.00CH37129).

[19]  Mauro Zigliotto,et al.  Torque Estimation in High-Efficency IPM Synchronous Motor Drives , 2015, IEEE Transactions on Energy Conversion.

[20]  Kay Hameyer,et al.  Manufacturing Tolerances: Estimation and Prediction of Cogging Torque Influenced by Magnetization Faults , 2012, IEEE Transactions on Magnetics.

[21]  M. F. Rahman,et al.  Design and Experimental Verification of an 18-Slot/14-pole Fractional-Slot Concentrated Winding Interior Permanent Magnet Machine , 2013, IEEE Transactions on Energy Conversion.

[22]  Yusuke Morita,et al.  Reduction of Cogging Torque Due to Production Tolerances of Rotor by Using Dummy Slots Placed Partially in Axial Direction , 2015, IEEE Transactions on Industry Applications.

[23]  Aimeng Wang,et al.  Comparison of Five Topologies for an Interior Permanent-Magnet Machine for a Hybrid Electric Vehicle , 2011, IEEE Transactions on Magnetics.

[24]  T. Sebastian,et al.  Issues in reducing the cogging torque of mass-produced permanent-magnet brushless DC motor , 2004 .

[25]  Z.Q. Zhu,et al.  A simple method for measuring cogging torque in permanent magnet machines , 2009, 2009 IEEE Power & Energy Society General Meeting.