PMSM Design and Loss Analysis
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PMSM Design and Loss Analysis
Liping Zheng
07/23/2003
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PMSM Configuration
Litz-wire:
1.78 mm x 2.27 mm
50 strands @ AWG 30
Gap : 0.5 mm
Stator Di: 25.5 mm
Do: 38 mm
Length: 25.4 mm
Shaft diameter: 16 mm
No major shaft stress problem if we select high stress shaft material.
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Progress
Got the Litz-wire with rectangular profile.
Total 22 lb.
Found the permanent magnets (PM) manufacturer to fabricate the special shape PM with 0.001 in (0.025 mm) tolerance.
According to new PM profile, adjust the winding configuration and perform all simulations.
Filter inductor preliminary design.
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5
5
2.5
2.5
Ø 16
All Dimensions are in mm
Shaft Cross-section
Shaft Cross Section
Courtesy of Dipjyoti Acharya
(mm)
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Airgap Flux Density
Low harmonics of the normal flux density.
Tangent flux density is a little large due to large airgap.
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0.0000 0.0001 0.0002 0.0003 0.0004-0.12
-0.10
-0.08
-0.06
-0.04
-0.02
0.00T
orq
ue (
N.m
)
Time (s)
Simulated Torque
Winding pitch is modified from 12/15 to 10/15.
Simulated back EMF=12 V
Use Generator mode to simulate Torque.
Load current = 60.8 A
1.5% ripple
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Inductor Design
W
T
WAu
ggc
g
c
g
g
A
nlR
nAWK
lBRABnI
l
nA
R
nL
Rni
0maxmaxmax
20
2
Constraints:
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DC Filter Inductor
Negligible core loss, proximity loss.
Copper loss dominated.
Flux density chosen simply to avoid saturation.
Airgap is employed.
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AC Filter Inductor
Core loss, copper loss, proximity loss are all significant.
Flux density is chosen to reduce core loss.
A high-frequency core must be employed.
An air gap is employed.
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P Core Structure-p66/56
d1=66.29 mm
d2=54.51 mm
d3=28.19 mm
h1=57.3
h2=43.28
Ferrite type: MnZn (manganese and zinc)
Material :3C81,3C91
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Use P66/56 core
Copper loss
1.2W
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Loss of FiltersCopper Loss (3 turns):
1.2W
Core loss (3C91):
50mW/cm3 @ 10KHz (from manufacturer’s data).
Estimated 10mW /cm3 @ 3.3KHz.
Estimated 20mW /cm3 considering harmonics.
The volume is 124 cm3 2.48W
Total loss of the filters (3 inductors):
3x (1.2+2.48)=11W.
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PMSM LossCopper loss 16.9 W
Shaft eddy loss 0 ?
Iron loss 10.4 W
Bearing loss 10 W
Filters loss 11 W
Windage loss 12.8 W
Total loss 61.1W
%97)1.612000(2000 m
%95c%1.92 mc
Motor Efficiency:
Control Efficiency:
Total Efficiency:
Future work