Electric Propulsion Systems

Permanent Magnet Motors

MDB1033

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 Contents
– Overview of Direct Current Machines
– Construction
– Principle of Operation
– Types of DC Machine
– Power Flow Diagram
– Speed Control

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 LEARNING OBJECTIVES
• Upon completion of the chapter the student
should be able to:
– State the principle by which machines convert
mechanical energy to electrical energy.
– Discuss the operating differences between different
types of generators
– Understand the principle of DC generator as it
represents a logical behavior of dc motors.

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 Background
• Energy
• Power
• Power loss
• Analysis
• Test

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 Energy
• Work is energy.
• Example: “effort” times “displacement”
– Force is effort
– Distance is displacement

Power
• Power is how fast work gets done.
• Example: “effort” times “speed”
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 Power
• Power is a measure of how fast work gets done.
• POWER = EFFORT x FLOW (speed)

“EFFORT” “FLOW”
– force –travel speed
– torque –rotating speed
– pressure –flow of fluid
– voltage –flow of electrons
– thinking –doing

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 Power Loss in the Mechanism
• Some power from the motor is lost due to
friction in the mechanism
– Gears, belts, cables
– Bearings, guides
– Tires, balls, or other deformable items
– Damage
– Contamination
• Power loss is heat

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 Power required at the motor
• Power at the motor = power required at the
point of use + power lost in the mechanism
• Power loss is heat

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 Power loss in the motor
• Power is lost in the motor due to friction,
damping, and electrical resistance
• Power loss is heat. Overloading will cause
excessive temperature rise. Use appropriate
gear ratio.

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 Basic Theory
• Torque is rotating EFFORT,
speed is rotating FLOW
– Torque = force x radius

• Voltage is electrical
EFFORT, current is FLOW
of electrons
• Power = EFFORT x FLOW
– Mechanical power P(mech) =
torque x speed
– Electrical power P(elec) =
Open voltage x current
 Units, Conversions
International System (SI) of units
Symbol
used Abbrev- Alternate
Item here Comment SI unit iation unit Conversion
Force Mechanical effort newton N lb. 1 lb. = 4.45 N
Distance Mechanical displacement metre m In. 1 in. = 0.0254 m
Speed Travelling speed metre/second m/s mph 1 mph = 0.45 m/s
Torque t Turning effort newton metre Nm lb-in
Angle Angular displacement radian rad degree 360 ° = 2p rad
Speed w Rotating speed radian/second rad/s rpm 1 rpm = 0.105 rad/s
Time Don’t have much second s min., h 1 h = 3600 s
Voltage V Electrical effort volt V
Current i Electrical flow ampere A
Power P Rate of work watt W hp 1 hp = 746 W
Resistance R Cause of power loss as heat ohm W
Energy Work joule (Nm) J ft-lb
Pressure Fluid effort pascal (N/m2) Pa psi 1 psi = 6900 Pa
3
Flow Fluid flow (at stated pressure) cubic metre/s m /s CFM 1 CFM = 0.00047 m3/s

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Prefixes: m = milli- = one thousandth (mm, mNm)
k = kilo- = one thousand (km, kW)
 Basic Motor Theory

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 Electrical Components

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 Basic Motor Theory

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 Basic Motor Theory
Important motor parameters

• Applied voltage ( V )

• Stall torque ( tstall )

• Stall current ( istall )
• Free speed ( wfree )

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 Fisher-Price Motor

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 Fisher-Price Motor (2005)
From data sheet:

Stall torque t stall = 0.65 Nm

Stall current istall = 148 A

Free speed w free = 2513 rad/s
Reference voltage V = 12 V

Calculate:
Resistance R = 12 V /148 A = 0.081 W

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 Fisher-Price Motor - Power loss
Fisher-Price motor

2000

Output power, W 1800 W

Power loss, W
1500 Input power, W
Power (W)

1000

500

407 W

0
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70

Torque (Nm)

Peak power occurs when torque = t stall / 2,

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 Real World: Power loss

14 AWG wire: 3.0 mW/ft.

12 AWG wire: 1.9 mW/ft.
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10 AWG wire: 1.2 mW/ft.
6 AWG wire: 0.5 mW/ft. (Copper at
 Simplified electrical system
model

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 Overview of Direct Current
Machines
• Direct-current (DC) machines are divided into dc generators and dc
motors.
• Most DC machines are similar to AC machines: i.e. they have AC
voltages and current within them.
• DC machines have DC outputs just because they have a
mechanism converting AC voltages to DC voltages at their
terminals.
• This mechanism is called a commutator; therefore, DC machines
are also called commutating machines.
• DC generators are not as common as they used to be, because
direct current, when required, is mainly produced by electronic
rectifiers.
• While dc motors are widely used, such automobile, aircraft, and
portable electronics, in speed control applications…
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 DC Generator
• A dc generator is a machine that converts
mechanical energy into electrical energy
(dc voltage and current) by using the
principle of magnetic induction.

• In this example, the ends of the wire loop

have been connected to two slip rings
mounted on the shaft, while brushes are
used to carry the current from the loop to
the outside of the circuit.

Principle of magnetic induction in DC machine

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 DC Motor
• DC motors are everywhere! In a house, almost every mechanical
movement that you see around you is caused by an DC (direct
current) motor.

• An dc motor is a machine that converts electrical energy into

mechanical energy by supplying a dc power (voltage and current).

• An advantage of DC motors is that it is easy to control their speed in

a wide diapason.

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 Construction of DC machine

Cutaway view of a dc motor Stator with poles visible.

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 Construction of DC machine
segments

Rotor of a dc motor.

brushes
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 Construction of DC machine
Rotor is the rotating part - armature
Stator is the stationary part - field

Armature coil

Brushes

Stator: non-moving coil

Rotor: rotating part

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 ARMATURE
• More loops of wire = higher rectified voltage
• In practical, loops are generally placed in slots of an iron core
• The iron acts as a magnetic conductor by providing a low-reluctance path for
magnetic lines of flux to increase the inductance of the loops and provide a
higher induced voltage.
• The commutator is connected to the slotted iron core.
• The entire assembly of iron core, commutator, and windings is called the
armature.
• The windings of armatures are connected in different ways depending on the
requirements of the machine.

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Loops of wire are wound around slot in a metal core DC machine armature
 ARMATURE WINDINGS
• Lap Wound Armatures
– are used in machines designed for low voltage and high current
– armatures are constructed with large wire because of high current
– Eg: - are used is in the starter motor of almost all automobiles
– The windings of a lap wound armature are connected in parallel.
This permits the current capacity of each winding to be added and
provides a higher operating current
– No of current path, M=p ; p=no of poles

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 ARMATURE WINDINGS (Cont)
• Wave Wound Armatures
– are used in machines designed for high voltage and low current
– their windings connected in series
– When the windings are connected in series, the voltage of each
winding adds, but the current capacity remains the same
– are used is in the small generator in hand-cranked megohmmeters
– No of current path, M=2

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 ARMATURE WINDINGS (Cont)
• Frogleg Wound Armatures
– the most used in practical nowadays
– designed for use with moderate current and moderate
armatures voltage
– the windings are connected in series parallel.
– Most large DC machines use frogleg wound armatures.

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 FIELD WINDINGS
• Most DC machines use wound electromagnets to
provide the magnetic field.

• Two types of field windings are used :

– series field
– shunt field

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 FIELD WINDINGS (Cont)
• Series field windings
– are so named because they are connected in series with the
armature
– are made with relatively few windings turns of very large wire and
have a very low resistance
– usually found in large horsepower machines wound with square or
rectangular wire.
– The use of square wire permits the windings to be laid closer
together, which increases the number of turns that can be wound in
a particular space

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 FIELD WINDINGS (Cont)
– Square and rectangular wire can also be made physically smaller than
round wire and still contain the same surface area

Square wire contains more surface than round wire

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Square wire permits more turns than round wire in the same area
 FIELD WINDINGS (Cont)
• Shunt field windings
– is constructed with relatively many turns of small wire, thus, it
has a much higher resistance than the series field.
– is intended to be connected in parallel with, or shunt, the
armature.
– high resistance is used to limit current flow through the field.

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 FIELD WINDINGS (Cont)
• When a DC machine uses both series and shunt fields, each pole
piece will contain both windings.

• The windings are wound on the pole pieces in such a manner that
when current flows through the winding it will produce alternate
magnetic polarities.

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 MACHINE WINDINGS
OVERVIEW

Winding

armature field

Self excited Separately

Excited
Wave Lap Frogleg
M=2 M=p

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series shunt compound
 Principle operation of Generator
• Whenever a conductor is moved within a
magnetic field in such a way that the conductor
cuts across magnetic lines of flux, voltage is
generated in the conductor.
• The AMOUNT of voltage generated depends on:
i. the strength of the magnetic field,
ii. the angle at which the conductor cuts the magnetic
field,
iii. the speed at which the conductor is moved, and
iv. the length of the conductor within the magnetic field

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 Principle of operation (Cont)

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 Fleming’s Right hand rule
(Generator Rule)
• Use: To determine the direction of the induced emf/current of a
conductor moving in a magnetic field.
• The POLARITY of the voltage depends on the direction of the
magnetic lines of flux and the direction of movement of the
conductor.

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 THE ELEMENTARY
GENERATOR
• The simplest elementary generator that can be
built is an ac generator.
• Basic generating principles are most easily
explained through the use of the elementary ac
generator.
• For this reason, the ac generator will be
discussed first. The dc generator will be
discussed later.
• An elementary generator consists of a wire loop
mounted on the shaft, so that it can be rotated in
a stationary magnetic field.
• This will produce an induced emf in the loop.
• Sliding contacts (brushes) connect the loop to an Elementary Generator
external circuit load in order to pick up or use the
induced emf.
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 Elementary Generator (Conclusion)
• Observes
– The meter direction
– The conductors of the armature loop
– Direction of the current flow

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 THE ELEMENTARY DC
GENERATOR

• The loop is parallel to the magnetic

lines of flux, and no voltage is
induced in the loop
• Note that the brushes make
contact with both of the
commutator segments at this time.
The position is called neutral
plane.

00 Position (DC Neutral Plane)

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 THE ELEMENTARY DC
GENERATOR
• Observes
– The meter direction
– The conductors of the armature loop
– Direction of the current flow

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 Effects of additional turns
• To increase the amount of output voltage, it is
common practice to increase the number of
turns of wire for each loop.
• If a loop contains 20 turns of wire, the induced
voltage will be 20 times greater than that for a
single-loop conductor.
• The reason for this is that each loop is
connected in series with the other loops. Since
the loops form a series path, the voltage
induced in the loops will add.
• In this example, if each loop has an induced
voltage of 2V, the total voltage for this winding
would be 40V
(2V x 20 loops = 40 V).

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Effects of additional turns
 Effects of additional coils
• When more than one loop is used, the average
output voltage is higher and there is less
pulsation of the rectified voltage.
• Since there are four segments in the
commutator, a new segment passes each
brush every 900 instead of every 1800.
• Since there are now four commutator
segments in the commutator and only two
brushes, the voltage cannot fall any lower
than at point A.
• Therefore, the ripple is limited to the rise and
fall between points A and B on the graph. By
adding more armature coils, the ripple effect
can be further reduced. Decreasing ripple in
this way increases the effective voltage of
the output.
Effects of additional coils
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 The Practical DC Generator
• The actual construction and operation of a practical
dc generator differs somewhat from our elementary
generators
• Nearly all practical generators use electromagnetic
poles instead of the permanent magnets used in our
elementary generator
• The main advantages of using electromagnetic
poles are:
(1) increased field strength and
(2) possible to control the strength of the
fields. By varying the input voltage, the
field strength is varied. By varying the field
strength, the output voltage of the generator
can be controlled.

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 DC Motor Operation

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 Motor:

An eclectic current interacts with a magnetic field to

cause an electromagnetic torque, which drives some
load. The load provides a mechanical torque, which
opposes the electromagnetic torque.

Generator:

A mechanical torque is applied to turn

conductors through a magnetic field
and generate electric current.
The mechanical torque is opposed by an
electromagnetic torque that results from
the interaction of the current with the
magnetic field.

Generator Animation
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 Negative Battery
Positive Battery Terminal
Terminal

Magnetic Field Lines

When current moves through a conductor a circular

magnetic field is induced around the conductor

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 The Right Hand Rule
The direction of the magnetic field
surrounding the conductor can
be found using your
right hand

Position the thumb of your right hand

pointing in the direction of
conventional current (Positive to
Negative) and your fingers will wrap
around the conductor in the direction
of the induced magnetic field.
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 Motor (armature) rotation is caused by the simultaneous
attraction and repulsion between the electromagnetic
field in the armature and a fixed magnetic field

Armature

Fixed Magnets
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 A Conductor in a Fixed A Current Carrying Conductor
Magnetic Field in a Fixed Magnetic Field

Force

Fixed Magnetic Field

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Induced Magnetic Field
(Due to current)
 A Motor Armature in a Fixed
Magnetic Field

S
N
Direction of Force (Torque) acting
to turn the Armature (Conductor)

The magnetic field surrounding a current

carrying conductor interacts with an
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existing magnetic field.
 Fleming's Left Hand (Motor) Rule
Thumb = Direction of
Conductor Motion Fore Finger = Direction of
Fixed Magnetic Field (N to S)

Middle Finger =
Conventional
Current Direction

Determines the direction of DC current

carrying conductor in a fixed magnetic field
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 Fleming's Left Hand (Motor) Rule
Direction of Rotation

Fixed Magnetic Field Direction

Conventional
Current Direction S
N

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 A S Use the Left Hand Rule to
Determine the Rotation
Direction of the Armatures
in A and B

N Hint: You will have to turn

your left hand upside down
for example A

B
Notice that when the
current through the
armature is reversed,
S
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it moves (Rotates) in
the opposite direction
N
 DC Machine Equivalent Circuit

https://youtu.be/LAtPHANEfQo
https://youtu.be/-xebh8wU8gY

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 DC Machine Equivalent Circuit

• The magnetic field produced by the stator poles induces a

voltage in the rotor (or armature) coils when the generator
is rotated.
• This induced voltage is represented by a voltage source.
• The stator coil has resistance, which is connected in
series.
• The pole flux is produced by the DC excitation/field
current, which is magnetically coupled to the rotor
• The field circuit has resistance and a source
• The voltage drop on the brushes represented by a battery

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 DC Machine Equivalent Circuit

1. Permanent magnet

2. Separately excited

3. Self-excited

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 DC Machine Equivalent Circuit

1. Permanent magnet
• The poles are made of permanent magnets.
• No field winding required.
• Small size.
• Disadvantage is low flux density, so low torque.

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 DC Machine Equivalent Circuit

2. Separately excited
The field flux is derived from a separate power source
independent of the generator itself.

B
Armature
Field winding
winding

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 DC Machine Equivalent Circuit
3. Self-excited
• Shunt machine
The field flux is derived by
connecting the field directly
across the terminals of the
generator.

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 DC Machine Equivalent Circuit
3. Self-excited
Series machine
• field are connected in
series with armature

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 DC Machine Equivalent Circuit
3. Self-excited
Compounded dc generator
• both a shunt and a series field are
present

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 DC Machine Equivalent Circuit
3. Self-excited
Compounded dc motor
• both a shunt and a series
field are present

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 Equivalent circuit of a DC
motor
The armature circuit (the entire
rotor structure) is represented by
an ideal voltage source EA and a
resistor RA. A battery Vbrush in the
opposite to a current flow in the
machine direction indicates brush
voltage drop.
The field coils producing the
magnetic flux are represented by
inductor LF and resistor RF. The
resistor Radj represents an
external variable resistor
(sometimes lumped together with
the field coil resistance) used to
control the amount of current in
the field circuit.

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 DC Motor Equivalent Circuit.
 The armature is represented by an ideal voltage source EA and a
resistor RA.
 The brush voltage drop is represented by a small battery Vbrush
opposing the direction of the current flow in the machine.
 The field coils, which produce the magnetic flux, are represented
by inductor LF and RF.
 The separate resistor Radj represents an external variable resistor
used to control the amount of current in the field circuit.

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Equivalent Circuit of a DC Motor.
  The brush drop voltage is often only a very tiny fraction of the
generated voltage in the motor.
 Therefore, in cases where it is not critical, the brush drop voltage
may be left out or approximately included in the value of RA.
 Also, the internal resistance of the filed coils is sometimes lumped
together with the variable resistor, and the total is called RF , Figure
below.

A Simplified Equivalent Circuit eliminating the Brush Voltage

Drop and Combining Radj with the Field Resistance .

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 Motor types: The permanent-magnet
DC motor
A permanent magnet DC (PMDC) motor is a motor whose poles are
made out of permanent magnets.
Advantages:
1. Since no external field circuit is needed, there are no field circuit copper
losses;
2. Since no field windings are needed, these motors can be considerable
smaller.
Disadvantages:
1. Since permanent magnets produces
weaker flux densities then externally
supported shunt fields, such motors
have lower induced torque.
2. There is always a risk of
demagnetization from extensive
heating or from armature reaction
effects (via armature mmf).
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 Motor types: Separately Excited DC motors.

Separately excited DC motor:

a field circuit is supplied from a
separate constant voltage power
source.

The Equivalent Circuit of Separately Excited dc Motor.

From the above figure,

VF
IF  VT  E A  I A RA
RF
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IL  IA
 Motor types: Shunt DC motors.

Shunt DC motor:
a field circuit gets its power from the
armature terminals of the motor.

The Equivalent Circuit of a Shunt dc Motor.

 From the above figure,

VF
IF 
RF
VT  E A  I A RA

IL  IA  IF
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 Motor types: The series DC
motor
A series DC motor is a DC motor whose field windings consists of a
relatively few turns connected in series with armature circuit. Therefore:

VT  E A  I A RA  RS 

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 Motor types: Compounded DC
motor
A compounded DC motor is a motor with both a shunt and a series field.

Current flowing into a dotted

end of a coil (shunt or
series) produces a positive
mmf. Long-shunt
connection
If current flows into the
dotted ends of both coils, the
resulting mmfs add to
produce a larger total mmf –
cumulative compounding.

If current flows into the dotted end of

one coil and out of the dotted end of Short-shunt
another coil, the resulting mmfs connection
subtract – differential compounding.

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 Motor types: Compounded DC
motor
The Kirchhoff’s voltage law equation for a compounded DC motor is
VT  E A  I A RA  RS 
The currents in a compounded DC motor are
VT
I A  IL  IF IF 
RF

Cumulatively compounded
The mmf of a compounded DC motor:

Fnet  FF  FSE  FAR

Differentially compounded
The effective shunt field current in a compounded DC motor:

N SE FAR
I  IF 
*
F IA 
NF NF Number of turns
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 MACHINE WINDINGS
OVERVIEW

Winding

armature field

Self excited Separately

Excited
Wave Lap Frogleg
M=2 M=p

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series shunt compound
 MACHINE WINDINGS
OVERVIEW
armature

Wave Lap Frogleg

M=2 M=p

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 MACHINE WINDINGS
OVERVIEW
field
PMDC

Self excited Separately

Excited

series shunt compound

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 Torque Equation

T  k AI A

T = torque of armature (N-m)

kA = geometry constant
= flux/pole (Wb)
IA = armature current (A)

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 Geometry Constant

pN
kA  ( rad / s ),
2pM
pN
kA 
'
( rpm )
60 M

p = number of field poles

N = number of active conductors on armature
M = number of parallel paths in armature winding
(M=p for lap winding & M=2 for wave winding)
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 Power Equation

P  EI A  Tw
P=power (W) – not counting losses
E = EMF induced in armature (back EMF)
(Electromotive force)
IA = armature current (A)
T = torque of armature (N-m)
w = speed of rotation (rad/s)
Note that Pin = VTIT which will be higher than P
because of loss in the field and armature windings as
well as rotational (friction) losses.
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 EMF Equation (Electromotive force)

E  k Aw  k n '
n
60w
A 2p

E = EMF induced in armature (V)

kA = geometry constant
= flux/pole (Wb)
w = speed of rotation (rad/s)
n = speed of rotation of armature (rpm)

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 EX. For Shunt DC motors the terminal
Voltage Equation

VT  E  I A RA

VT = voltage at motor terminals

E = EMF induced in armature (V)
IA = armature current (A)
RA = armature resistance

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 Speed Equation

VT  I A R A
n
k A' 
(applies to shunt connected motor only)
Note that  can also be written as kfIf where kf is
/If (normally a constant ratio)

Ratio Equation n2 E 2

n1 E1
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 Speed-Torque
Speed

Differential Compound

Shunt
Cumulative Compound

Series
Torque

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 Power flow and losses in DC
machines
Unfortunately, not all electrical power is converted to mechanical power by a motor
and not all mechanical power is converted to electrical power by a generator…

The efficiency of a DC machine is:

Pout
 x100%
Pin
or
Pin  Ploss
 x100%
Pin

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 The losses in DC machines
There are five categories of losses occurring in DC machines.

1. Electrical or copper losses – the resistive losses in the armature and field
windings of the machine.

Armature loss: PA  I A2 R A
Field loss: PF  I RF2
F

Where IA and IF are armature and field currents and RA and RF are armature and
field (winding) resistances usually measured at normal operating temperature.

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 The losses in DC machines
2. Brush (drop) losses – the power lost across the contact potential at the
brushes of the machine.
PBD  VBD I A

Where IA is the armature current and VBD is the brush voltage drop. The voltage
drop across the set of brushes is approximately constant over a large range of
armature currents and it is usually assumed to be about 2 V.

Other losses are exactly the same as in AC machines…

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 The losses in DC machines

3. Core losses – hysteresis losses and eddy current losses. They vary as B2
(square of flux density) and as n1.5 (speed of rotation of the magnetic field).

4. Mechanical losses – losses associated with mechanical effects: friction

(friction of the bearings) and windage (friction between the moving parts of the
machine and the air inside the casing). These losses vary as the cube of rotation
speed n3.

5. Stray (Miscellaneous) losses – losses that cannot be classified in any of the

previous categories. They are usually due to inaccuracies in modeling. For many
machines, stray losses are assumed as 1% of full load.

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 The power-flow diagram
On of the most convenient technique to account for power losses in a
machine is the power-flow diagram.

For a DC
motor:

Electrical power is input to the machine, and the electrical and brush losses must be
subtracted. The remaining power is ideally converted from electrical to mechanical
form at the point labeled as Pconv.

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 The power-flow diagram
The electrical power that is converted is

Pconv  E A I A
And the resulting mechanical power is

Pconv  t indwm
After the power is converted to mechanical form, the stray losses, mechanical
losses, and core losses are subtracted, and the remaining mechanical power is
output to the load.

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 Example 1
A 6 pole, 2.4 KW, 120V DC lap-wound shunt motor has 960
conductors in the armature. It takes 25.0 A from the supply at full
load. Armature resistance is 0.75W, flux/pole=10.0 mWb, field
winding current is 1.20A. Find the speed and torque.

E  K Aw
 746W 
P  3hp 
E 102V
  2.24kW w   66.9rad / s
 hp  
K A 153 10 x10 3 
I A  I L  I F  25 A 1.2 A  23.8 A  60 
n  w   638rpm
 2p 
E  VT  I A RA  120V  23.8 A0.75W  102V
P 2.24kW
KA 
pN

6960  153 T   33.5 N  m
w 66.9rad / s
2pM 2p 6
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 Example 2
A 10hp, 115V Dc series motor takes 40A at its full load speed of
1800rpm. What is the torque at 30A?

2pn 2p 1800  T  K AI A  K A K F I F I A

w   188rad / s
60 60
IF  I A
 746W 
P  10hp    7.46kW T  K AKF I A
2

 hp 
T 39.6 N  m
K AKF    0.025
P  Tw IA
2
40 A2
P 7.46kW
T   39.6 N  m Tnew  K A K F I Anew  0.02530 A  22.2 N  m
2 2
w 188rad / s

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 Example 3 (a)
A 220V DC shunt motor draws 10A at 1800rpm. The armature
resistance is 0.2W and field winding resistance is 440W.
(a) What is the torque?

VT 220V
IF    0.5 A
RF 440W 2pn 2p 1800 
w   188rad / s
60 60
I A  I L  I F  10 A  0.5 A  9.5 A P 2.07 kW
T   11.0 N  m
w 188rad / s
E  VT  I A RA  220V  9.5 A0.2W  218V

P  EI A  218V 9.5 A  2.07kW

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 Example 3 (b)
A 220V DC shunt motor draws 10A at 1800rpm. The armature
resistance is 0.2W and field winding resistance is 440W.
(b) What will be the speed and line current at a torque of 20 N-m (if
field current is constant)?

E  K Aw I L  I A  I F  17.3 A  0.5 A  17.8 A

K A 
E

218V
 1.16 E  VT  I A RA  220V  17.30.2W  217V
w 188rad / s
E 217V
w   187 rad / s
T  K AI A K A 1.16
T 20 N  m 60w
IA    17.3 A n  1.79 x10 3 rpm
K A 1.16 2p

(shunt is constant speed)

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 Design estimation of radial FLUX
motor
• Back EMF equation:
(emf / ωm) = NmkdkpksBgLRroNsppNphns (V/(rad/s)
• Torque per phase equation:
Tper phase = (NmkdkpksBgLRroNsppns)I (N.m/phase)

There are many design parameters, most important are:

-Rotor outside radius, Rro
-Motor length, L
- No of magnet poles, Nm
- Maximum flux density, Bg
- no of turns per coil, ns
- no of phase, Nph
- current I
- pitch factor (kp), distribution factor (kd), skew factor (ks) and no of slots per
pole per phase (Nspp) are typical design geometric and motor winding type
factors.
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 Design estimation of radial FLUX
motor
• Estimate back emf constant and torque constant of a radial flux electric
motor with no of magnets, Nm = 6, rotor radius, Rro = 0.12 m, motor
length, L = 0.03 m, air gap flux density, Bg = 1.86 T, no of phases, Nph
= 3, no of turns per winding, ns = 30. Given: distribution factor, kd = 1,
pitch factor, kp = 0.333, skew factor, ks = 0.833 and no of slots per pole
phase, Nspp = 1.
• If the supply voltage, Vt = 72 V, maximum current, Is is 60 Amp and the
phase-to-phase internal resistance, Rs is 0.35 ohm; determine the
motor theoretical peak torque, current limited peak torque and
maximum speed.

Ke=(emf / ωm) = NmkdkpksBgLRroNsppNphns (V/(rad/s)

Tper phase = NmkdkpksBgLRroNsppnsI (N.m/phase)

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 Solution
• Obviously to solve for kp, kd, ks would require detail design refinements of the
motor geometry. Thus, for this analysis we are only using values derived from
similar design as given. You can refer to the excel file for detail motor properties.
• From the equation for back emf constant:

Ke = (emf / ωm) = NmkdkpksBgLRroNsppNphns (V/(rad/s)

• Thus, Ke = 6 x 1 x 0.333 x 0.833 x 1.86 x 0.03 x 0.12 x 1 x 3 x 30 = 1.002 V/(rad/s)
• Or Ke = 1.002 x (2π/60) V/rpm = 0.105 V/rpm
• If the supply voltage, VT = 72 V, the estimated motor top speed is:
ωmax = 72 / 0.105 = 686 rpm
• The motor peak torque per single phase is given by:
Tper phase = NmkdkpksBgLRroNsppnsI (N.m/phase)

• For 3 phases and Imax = 60 A;

Tmax = 3 x 6 x 1 x 0.333 x 0.833 x 1.86 x 0.03 x 0.12 x 1 x 30 x 60 = 59.1 N.m
and Kt = 0.985 N.m/A
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 Solution
• Given Rs = 0.35 Ω. We can estimate the theoretical peak torque (no limit on current) of
the motor utilizing the following equation:

• Thus, at 0 rpm, Te = (72 – 0.105 x 0) x 0.985 ÷ 0.345 = 205.6 N.m

• The motor torque characteristic is plotted below:

• At the knee region (rated speed);

– ω = (1/Ke)(Vt –TexRs/Kt)
– = (1/0.105)(72 – (59.1 x 0.345 / 0.985))
– = 489 rpm (51.2 rad/s)

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 Solution
• Estimated plot for Power (P = Tω) using only 3 points:
•

• Note: Actual plot would required more points as the peak power would occur
around the knee region.

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 Group Activity 1
• Using the following magnet properties
and dimensions, propose a design of a
radial flux permanent magnet motor
capable to deliver 20 N.m peak torque at
16 A (72 V) from 0 rpm until 350 rpm
rated speed. Estimate the peak power
output and using a CAD package, show
your design.

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http://www.kjmagnetics.com/proddetail.asp?prod=AX2C45-N&cat=168
 Group Activity 2
• Your company has been given a task to design a compact 3-
phase permanent magnet generator system capable of
generating 48 VDC (5 kW output) from a river turbine rotating
at 30 rpm. Propose a suitable design for the generator and the
power electronics required to convert from 3 phase input of the
generator to 48 VDC output used to recharge a battery bank.
Your design should be based on magnets you can find from
K&J Magnetics, Inc. You may include gearing if necessary and
you can choose either radial or axial flux configuration. Show
your design using a CAD software and plot the proposed circuit
schematics.
Radial flux PM motor (emf / ωm) = NmkdkpksBgLRroNsppNphns

Axial flux PM motor (emf / ωm) = Nm kd kp ks Bg Nspp ns Nph (Ro2-Ri2)

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