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IEEE TRANSACTIONS ON ENERGY CONVERSION 1
Design Methodology of a Permanent Magnet
Synchronous Machine for a Screwdriver Application
Nicolas Bernard, Floran Martin, and Mohamed El-Hadi Zam
AbstractIn this paper, a novel methodology is presented in
order to design a permanent magnet synchronous machine associ-
ated with a gearbox for a screwdriver application. The study shows
how, from specication such as maximum volume, maximum heat-
ing, torque, and speed proles, it is possible to formulate the sizing
problem. The modeling is based on a purely analytical formula-
tion. We will show that it is possible to establish rules in order to
make optimal choices of materials (magnets and stator core). The
optimization of the pole pair number and the choice of the gear
ratio will also be discussed. Finally, the nite element method will
be used to validate the designed machine.
Index TermsAnalytical models, design methodology, energy
efciency, frequency conversion, high-speed permanent magnet
synchronous motor, machine tool, magnetic losses, soft magnetic
materials.
NOMENCLATURE
B
f m
Magnitude of the radial magnet ux density [T].
B
r
Remanent magnet ux density [T].
d
iron
Iron mass density [kg/m
3
].
F
s
Stator magnetomotive force [At].
g Gear ratio (g =
M
/
L
).
h Heat transfer coefcient [W/m
2
K].
k
ad
Additional loss coefcient.
k
ec
Eddy current specic loss coefcient [Ws
2
/m
3
T
2
].
k
h
Hysteresis specic loss coefcient [Ws/m
3
T
2
].
k
f
Fill factor.
k
t
Slot opening to the tooth opening ratio.
L Active length [m].
l
g
Air gap length [m].
l
m
Magnet length [m].
N Motor speed [r/min].
n
s
Number of turns/phase/pole/slot.
p Number of pole pairs.
P
av
Average electric losses [W].
P
c
Copper losses [W].
P
em
Electromagnetic power [W].
P
losses
Total losses [W].
Manuscript received September 9, 2011; revised January 24, 2012; accepted
March 19, 2012. Paper no. TEC-00475-2011.
N. Bernard and F. Martin are with IREENA Laboratory, Boulevard de
lUniversit e, Saint-Nazaire 44600, France (e-mail: nicolas.bernard@univ-
nantes.fr; oran.martin@univ-nantes.fr).
M. E.-H. Zamis with IREENALaboratory, Saint-Nazaire 44600, France, and
also with the Department of Electrical Engineering, PolytechNantes, Nantes
University, Nantes 44000, France (e-mail: El-Hadi.Zaim@univ-nantes.fr).
Color versions of one or more of the gures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identier 10.1109/TEC.2012.2199494
P
mg
Core losses [W].
P
wind
Windage losses [W].
R Outer stator radius [m].
R
s
Inner stator radius [m].
r
s
Reduced inner stator radius.
R
w
Outer winding radius [m].
r
w
Reduced outer winding radius.
R
r
Outer rotor radius [m].
R
0
Shaft radius [m].
V
p
Peripheral speed [m/s].
Pole arc [rad].
Torque [Nm].
Temperature elevation [

C].

c1
First critical speed [rad/s].

L
Load mechanical angular velocity [rad/s].

M
Machine mechanical angular velocity [rad/s].
I. INTRODUCTION
I
N the last few years, there has been a movement to replace
the pneumatic technology by electric technology of tool ma-
chines in order to improve performance, control, efciency, and
maintenance [1], [2]. For portable applications such as elec-
tric screwdrivers, it is necessary to have a reduced diameter for
easy handling and a holding temperature acceptable. In addi-
tion, a specic duty cycle is dened (see Figs. 2 and 3). To
our knowledge, no reference exists in the literature that solves
this optimization problem by a purely analytical approach and
that combines in one formulation, the coupled equations of the
system (thermal, magnetic, and mechanical) and the duty cycle
proles.
Many design criteria for permanent magnet synchronous mo-
tor (PMSM) already exist to minimize the losses for a given
torque [3][5]. The optimum inner stator radius to outer stator
radius ratio, the optimum number of slots, and the optimum
distribution of losses are then discussed. The analytical models
used are based on the same assumptions as those considered in
this paper; however, the proposed methodologies do not inves-
tigate the optimum number of pole pairs and the mechanical
and thermal constraints are not introduced directly in the for-
mulation of the problem. On the other hand, the optimization
considering operation on duty cycle is not considered in these
papers. At low speed, copper losses are dominant while mag-
netic losses are dominant at high speed. Hence, it is necessary
to calculate the temperature rise considering the real duty cy-
cle. This kind of optimization is generally performed using a
stochastic algorithm [6], [7].
In this paper, we will propose an approach to solve ana-
lytically the problem of the optimization of the machine that
0885-8969/$31.00 2012 IEEE
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2 IEEE TRANSACTIONS ON ENERGY CONVERSION
Fig. 1. Design and geometric data.
Fig. 2. Torque prole on the tool.
Fig. 3. Speed prole on the tool.
includes also its gearbox and the case of intermittent duty cy-
cles. In order to solve this typical problem, we will use a specic
methodology based on an analytical formulation presented in [8]
and [9]. The analytical solution of the problemformulated in [9]
has been completed herein. The complete sizing of the rotor has
been included. In addition, the magnetic and the thermal models
have been validated using a 2-D nite element method (FEM).
Due to its high specic power, the surface-mounted PMSM has
been considered here [10][12] (see Fig. 1). In this paper, we
assume a current angle constant and equal to 0 (i
d
= 0). Indeed,
for the application considered, where the maximum power is
reached at low speed, a ux weakening operation is not interest-
ing and would not lead to a signicant downsizing on the power
converter.
The sizing of the machine is made considering an idealized
duty cycle, dened by the manufacturer and presented in Figs. 2
and 3. These gures represent the torque and speed proles on
the tool. In this paper, the electrical transient responses will be
considered innitely fast.
The duty cycle (with a period T = 1.2 s) is composed of
four phases: an approach sequence (during t
1
= 0.9 s) with
high speed and low torque; a tightening sequence (during t
2

t
1
= 0.14 s) with low speed and a linear rising of the torque;
a braking sequence (we will consider in this paper a braking
without power transfer); and a stop sequence (during 0.1 s). A
repetition of this duty cycle is considered.
Moreover, the maximum volume of the machine is specied:
the external radius is limited to R
max
= 30 mm and the active
length is limited to L
max
= 100 mm. At last, the maximal
contact temperature is limited to 45

C. The heat is extracted by

an external ventilation.
II. 1-D ANALYTICAL MODELING
In the following section, all fringing and leakage effects are
neglected; we assume also that the steel parts are innitely per-
meable. However, it will be checked that levels of ux densities,
although naturally low for high-speed applications [8], will not
exceed the level of saturation. The study is also limited to the
rst harmonic. Let us note, at last, that we will neglect losses
in permanent magnets due to the slot effects (Actually, we will
chose a large airgap, as will be shown in Section III, to minimize
these losses).
A. Electromagnetic Power
Let us note that we consider a concentrated two-pole full
pitched coil with one slot per phase, per pole and 2n
s
conductors
in each slot. If we consider the stator eld in quadrature with
the rotor eld and a sinusoidal distribution, the expression of
the electromagnetic power can be written as follows:
P
em
=
12

2
R
s
LB
f m
F
s
p
M
(1)
where B
f m
is the magnitude of the rst harmonic of the ux
density created by the magnets and F
s
is the magnitude of the
magnetomotive force created by one phase (with 2n
s
conductors
per slot).
B. Copper Losses
Neglecting the proximity effects and the eddy currents in the
conductors, a cross section of the conductors S
c
and an electric
resistivity
c
, the armature winding resistance can be expressed
in the form
R = 4p
c
n
s
k
L
L
S
c
(2)
where k
L
is a coefcient correcting the active length L in order
to take into account the effect of the end windings. We will
consider k
L
= 1.2. We introduce a global ll factor k
f
. It is
calculated as the ratio of the effective copper cross section to
the cross section of the corona dened by the radii R
w
and R
s
(see Fig. 4). Then, it is possible to express the copper losses as
follows:
P
c
=
144

c
_
k
L
L
k
f
_
p
2
R
2
w
R
2
s
F
2
s
. (3)
We will consider here a slot ll factor constant and equal to
0.4. Considering also a slot opening to the tooth opening ratio
k
t
= 0.5, the global ll factor k
f
is equal to 0.2.
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BERNARD et al.: DESIGN METHODOLOGY OF A PERMANENT MAGNET SYNCHRONOUS MACHINE FOR A SCREWDRIVER APPLICATION 3
Fig. 4. Geometry and data associated with a slot opening.
C. Core Losses
The principle of the separation of losses (hysteresis and eddy
current losses) is considered [13], [14]. The additional losses
due to magnetic anomaly, metallurgical and manufacturing pro-
cesses are taken into account using a factor of additional core
losses k
ad
. The magnetic losses in a volume V
ol
, under a si-
nusoidal ux density with a peak value B
m
, will be calculated
using the following classical formula:
P
mg
= k
ad
(k
ec
p
2

2
M
+k
h
p
M
)V
ol
B
2
m
(4)
where k
ec
and k
h
are the specic loss coefcients, respectively,
for eddy currents and hysteresis. The losses in the yoke P
mg y
and in the teeth P
mg t
are both considered. The orthoradial com-
ponent of the ux density in the yoke B
ym
and the radial com-
ponent in the teeth B
tm
are calculated using the Gauss law
B
ym
=
R
s
R R
w
1
p
B
f m
(5)
B
tm
=
1
k
t
.B
f m
. (6)
The volume of the yoke (V
ol y
) and the volume of the teeth
(V
ol t
) are
V
ol y
= (R
2
R
2
w
) L (7)
V
ol t
= k
t
L(R
2
w
R
2
s
). (8)
For the machines with Si.Fe stator core, the specic loss
coefcients (noted k
ec Si.Fe
and k
h Si.Fe
) and the additional co-
efcient (noted k
ad Si.Fe
) will be equal to
k
ec Si.Fe
= 6.5 10
3
Ws
2
/m
3
T
2
k
h Si.Fe
= 15 Ws
2
/m
3
T
2
k
ad Si.Fe
= 5.
These specic coefcients are calculated using theoretic ex-
pressions [15] (considering laminations of thickness 0.3 mm)
corrected by measurements [8], [16], [17]. For the soft magnetic
composite (SMC) machines, the coefcients (with the subscript
SMC), neglecting eddy current losses, will be equal to
k
ec SMC
= 0
k
h SMC
= 200 Ws
2
/m
3
T
2
k
ad SMC
= 1.
These coefcients are obtained by experimental data given
in [18].
D. Windage Losses
The power losses due to the friction of the gas in the airgap
will be estimated using the following expression:
P
wind
= c
f

air
R
4
r
L
3
M
(9)
where
air
and R
r
are, respectively, the density of air (1.3 kg/m
3
at 20

C and 1 atm) and the rotor radius. The skin friction co-
efcient c
f
depends on rotor radius, airgap thickness e, and
Reynolds number value
e
(
e
= eR
r
/v, with the kinematic
viscosity equal to 17 10
6
m
2
/s for air at 20

C and 1 atm).
For turbulent ow (
e
> 1000), the following formula serves
to perform the calculation [19]:
4.11

c
f
+ 3.54

c
f
ln
_

c
f
_
= 1. (10)
For laminar ow (
e
< 1000), we will take c
f
= 2/
e
.
E. Thermal Constraint
The case studied here constitutes a specic thermal problem
where the limitation of the surface temperature (
max
=25

C
with
ambient
= 20

C) and the small dimensions involve a

reduced elevation of the temperature in the winding. Thus, the
thermal analysis can be reduced and limited to the calculation
of the temperature rise on the external surface. We consider in
this paper that the machine operates with a repetition of the
duty cycle dened in Figs. 2 and 3. If we consider an uniform
distribution of temperature in the stator, the thermal constant
can be estimated by

th
=
1
hS
th
(d
iron
V
ol
C
p
) (11)
where d
iron
is the mass density (7800 kg/m
3
for iron), V
ol
is
the volume of the stator, h is the heat transfer coefcient, and
C
p
is the heat capacity (C
p
= 440 J/kgK). The surface area of
convective heat transfer is given by
S
th
= 2 R(R +L). (12)
With an external fan, an equivalent heat transfer coefcient
h = 100 W/m
2
K can be considered [20]. Considering R =
R
max
=30 mm and L =L
max
=100 mm, it gives
th
6 min.
Then, it is possible to consider the variation of the temperature
lowalong T (T = 1.2 s
th
). Thus, the temperature elevation
can be estimated using
=
P
losses
hS
th
. (13)
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4 IEEE TRANSACTIONS ON ENERGY CONVERSION
Fig. 5. Simplied geometry and thermal model associated.
Fig. 6. Rotor geometry.
Considering the maximal surface area calculated with R
max
and L
max
, it gives a level of losses equal to 6.12 W. If we
consider the simplied thermal model represented in Fig. 5 and if
we consider the case where all the losses are located at the inner
radius of the winding, it gives an elevation of the temperature in
the machine equal to 8

C only. This value is obtained with

a thickness of 0.1 mm for the insulation and a winding replaced
by an equivalent homogeneous material (copper, enamel, and
resin) of thermal conductivity assumed here equal to 2 W/mK
with a slot ll factor equal to 0.4 [21], [22]. With geometrical
data r
s
= 0.44 and r
w
= 0.73 (see Section III), it gives a total
thermal resistance equal to 1.4 W/m
2
K. Let us note that this
simple model gives an upper estimation of the temperature rise.
F. Mechanical Constraints
We consider at rst the limitations introduced by the mechan-
ical stresses in the rotor due to centrifugal forces and the rst
critical frequency. If we neglect the airgap thickness compared
with the external radius of the rotor R
r
, it comes that
V
p
= R
s

M
R
r

M
V
p max
. (14)
We consider a rigid and homogeneous rotor (length L and
radius R
r
) supposed to be simply supported at both ends with
two exible shafts (length l and radius R
0
) and two bearings
assumed to be innitely rigid (see Fig. 6). If we consider that
the rst critical speed is equal to the rst natural frequency, we
can write [23], [24]

c1
=

4
E
Y
64 d
iron

R
2
0
l
4
+Ll
3
(R
r
/R
0
)
2
(15)
where E
Y
is Youngs modulus and d
iron
is the mass density,
which are 210 10
9
N/m
2
and 7800 kg/m
3
, respectively, for
iron. Considering the typical limit V
p
= V
p max
= 150 m/s, and
considering that the machine does not operate above the rst
critical speed, the equality of
M
and
c 1
conducts to the
Fig. 7. Limitations of the rotor radius considering mechanical constraints
versus speed (with R
r
/R
0
= 3).
following limitation (see Fig. 7):
L
R
r

L
R
s
5. (16)
Now, if we consider the shear stress in the shaft due to the
load torque, the radius of the shaft has to satisfy the following
equation [25]:
R
0

_
2

max

max
g
_
1/3
. (17)
If we consider a maximumgear ratio g =100 and a maximum
stress equal to 400 MPa, it gives R
0
1 mm.
III. SIZING OPTIMIZATION
The sizing of the machine must be developed, considering
the duty cycle (not one operating point only). A sizing from
the maximum torque and the maximum speed would lead to
an oversizing (let us note that the peak power value is 630 W
when the average power is only 177 W). If we consider that
the variation of the machines temperature remains within a
small range, then the temperature rise can be expressed from
the average level of losses. From the speed and torque proles,
we can consider that copper losses can be neglected during the
approach sequence (low torque) and that the core losses can be
neglected during the tightening sequence (low speed). Let us
consider, at rst, that windage losses are negligible (their effect
will be studied later). Then, the average level of electric losses
is calculated since
P
av

1
T
_
t
1
0
P
mg
(t) dt +
1
T
_
t
2
t
1
P
c
(t) dt. (18)
Let us write
=
12

2
p R
s
L (19)
= 144
c
_
k
L
L
k
f
_
p
2
R
2
w
R
2
s
(20)
=
R
2
s
L(R
2
R
2
w
)
p
2
(R R
w
)
2
+
L(R
2
w
R
2
s
)
k
t
. (21)
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BERNARD et al.: DESIGN METHODOLOGY OF A PERMANENT MAGNET SYNCHRONOUS MACHINE FOR A SCREWDRIVER APPLICATION 5
Then, from (1), (3), and (4)(8)

em
= B
f m
F
s
(22)
P
c
= F
2
s
(23)
P
mg
= k
ad
(k
ec
p
2

2
M
+k
h
p
M
)B
2
f m
. (24)
During the tightening sequence (t
1
< t < t
2
), the magneto-
motive force can be expressed from (22) as follows:
F
s
(t) =
(t)
g B
f m
(25)
where (t) is the torque on the tool. If we neglect the con-
tribution of
min
, the evolution of the load torque during the
tightening sequence can be written as
(t) =

max
t
2
t
1
(t t
1
). (26)
From (23)(26), it is possible to write
P
av
=
t
1
k
ad
T
(k
ec
p
2

2
M max
+k
h
p
M max
)B
2
f m
+

2
max
(t
2
t
1
)
3g
2

2
T
1
B
2
f m
. (27)
A. Optimization of the Flux Density in the Airgap
If we dene the following expressions:

0
=
t
1
T
k
ad
(k
ec
p
2

2
M max
+k
h
p
M max
) (28)

0
=

2
max
.(t
2
t
1
)
3 g
2

2
T
(29)
then (27) becomes
P
av
=
0
.B
2
f m
+

0
B
2
f m
. (30)
Therefore, the minimization of the losses gives
B
f m opt
=
_

0
_
1/4
. (31)
It is achieved when the average level of copper losses is equal
to the average level of magnetic losses.
B. Optimization of the Geometry and Choice of the Gear Ratio
From (30) and (31), the expression of P
av
that minimizes
losses per cycle can be written as follows:
P
av
= 2
_

0

0
. (32)
If we consider P
losses
= P
av
in (13) and if we use successively
(32), (28), (29), and (19)(21), it is possible to express the
volume of the machine by (36).
Then, for a constant L/R ratio, the volume minimization is
achieved by the minimization of the following function:
F =
_
1 +
k
h
k
ec
p g
L max
__
1 +r
w
(1 r
w
)(r
2
w
r
2
s
)
+
p
2
k
t
r
2
s
_
.
(33)
Fig. 8. Optimum pole pair number for Si.Fe machines versus machine speed.
Fig. 9. Optimum geometry versus speed for Si.Fe machines.
TABLE I
OPTIMAL GEOMETRIC AND POLE PAIR NUMBER PARAMETERS
From (36), it comes that no optimum gear ratio exists (the
minimization is achieved with g = ). From (33), r
w opt
de-
pends on r
s
only. By using a numerical calculation, the optimum
value of r
w
can be expressed as
r
w opt
0.52 + 0.47 r
s
. (34)
Then, optimum values of r
s
and p can be calculated solving
the system

2
k
ec
g
L max
k
h
p
3
+p
2

k
t
r
2
s
(1 +r
w
)
(r
2
w
r
2
s
)(1 r
w
)
= 0
_
p
2
k
t
+
1 +r
w
1 r
w
_
r
4
s
2 r
2
w
r
2
s
+r
4
w
= 0.
(35)
Figs. 8 and 9 showthe optimumvalues of p, r
s
, and r
w
versus
speed in the case of laminated steel machines. The solutions of
(35) give real numbers that are represented in dotted lines. The
optimum possible values (i.e., considering only integer values
for p) are plotted in continuous lines. According to (35), the opti-
mumnumber of pole pairs depends on the product k
ec
g
L max
.
For Si.Fe machines, this optimum value decreases quickly with
the speed and above 3000 r/min, it is equal to 1. Then, the re-
duced geometric variables remain constant. In the case of SMC
machines (k
ec
= 0), the optimum values are independent of the
speed (see Table I).
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6 IEEE TRANSACTIONS ON ENERGY CONVERSION
Fig. 10. Optimum volume versus electrical frequency with L/R = 3.
Fig. 11. Optimum airgap ux density frequency with L/R = 3.
C. Optimal Choice of Magnetic Material
From (36) as shown at the bottom of the page, we can see that
it would be interesting to choose a gear ratio as high as possible,
i.e., as much important as the stress in the rotor is acceptable.
Such a choice conducts to high electrical frequencies. Thus, the
choice of the magnetic material (for the magnets and the stator)
has to be considered. In addition, high electrical frequencies
increase the constraints on the power electronic converter (dis-
tortions on the electrical waveforms, important commutation
losses, etc.).
Fig. 10 shows, for a given L/R ratio, the variation of the op-
timum volume versus the electrical frequency. As represented,
it is interesting to choose iron powders instead of steel sheets
above a limit frequency. From (36), it is possible to express this
frequency by
f
lim it
=
1
2
_
k
h SMC
k
ad Si.Fe
k
ec Si.Fe
F
2
geo SMC
F
2
geo Si.Fe

k
h Si.Fe
k
ec Si.Fe
_
(37)
where F
geo SMC
and F
geo Si.Fe
are the values of the last term
of (36) considering values given in Table I. According to the
coefcients and the optimal values given in Section II, (37)
gives the following theoretical frequency: f
limit
=1390 Hz. This
result is conrmed in [26], where a frequency limit of 1500 Hz
is obtained from a nite element analysis (FEA). Consequently,
Fig. 11 shows that the use of ferrite magnets associated with iron
powders may be sufcient for high speeds. In the case of Si.Fe
machines, the speed can be increased to reduce the volume with
a limitation of the thickness of the steel sheets. For example,
Fig. 12. Variation of the optimum MMF with the optimum volume for Si.Fe
machines.
above 1 kHz, it is necessary to use steel sheets with thickness
below 0.3 mm. This solution, more efcient, will be in the mean
time more expensive.
D. Magnetomotive Force and Active Length to Radius Ratio
It can be shown from(36) that the minimization of the volume
is achieved for a minimum L/R ratio. Let us note that such a
result greatly depends on the thermal modeling. For instance,
if we consider only the radial external surface (with a thermal
surface S
th
= 2RL), then no optimal ratio (L/R) exists. Thus,
considering the thermal constraint dened by (13) and the oper-
ating point corresponding to the maximum torque, we can write
from (1)
F
s max
=

2
max
12 p g r
s
1
B
f m
RL
. (38)
From (23), (24), and (26), we can write
F
s max
=
k
_
L/R
(39)
where the constant k depends on optimum geometrical data.
As represented in Fig. 12, a choice has to be made between
the minimization of the volume and the minimization of the
constraints on the electronic converter.
E. Optimization Considering Windage Losses
Let us consider now an optimization taking into account the
effect of the windage losses. In the case of an external venti-
lation, it is possible to assume that the heat generated by the
windage losses is directly brought out from the airgap. Then,
the variation of the temperature between the inner parts and the
ambient given by (13) remains valid. As a consequence, the
optimum volume is still given by (36). Therefore, the windage
losses affect the energy efciency per cycle only. Fig. 13 shows
the variation of the windage losses considering the optimum
geometry dened in the previous section. Three airgap lengths
have been considered: 0.5, 1, and 2 mm. Compared with the
electrical losses, windage losses become signicant for high
V
ol
=

max

L max
h
max
L/R
1 +L/R
_
2 t
1
(t
2
t
1
)
3 T
2

c
k
L
k
f

k
ad
(k
ec
p g
L max
+k
h
)
p g
L max

1 +r
w
(1 r
w
)(r
2
w
r
2
s
)
+
p
2
k
t
r
2
s
(36)
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BERNARD et al.: DESIGN METHODOLOGY OF A PERMANENT MAGNET SYNCHRONOUS MACHINE FOR A SCREWDRIVER APPLICATION 7
Fig. 13. Electric and windage losses considering optimum machine design.
Fig. 14. Energy efciency with l
g
= 2 mm.
Fig. 15. Magnetic equivalent circuit.
speed. Such a result introduces an optimum gear ratio. As rep-
resented in Fig. 14, the gear ratio can be chosen equal to 40.
This value represents a good compromise between the optimum
volume and the optimum efciency. Let us note, at last, that for
g = 40, the electrical frequency is f = 667 Hz (with p = 1).
At this frequency, low-cost steel sheets with a thickness th
t
=
0.3 mm can be chosen. At 40 000 r/min, the rotor peripheral
speed remains low (V
p
=40 m/s) if we consider L/R=3. Then,
no retaining sleeve is necessary in that case.
F. Rotor Design
Fig. 15 shows the equivalent magnetic circuit that takes into
account the main ux paths [27]. R
g
is the airgap reluctance,
P
m
is the magnet internal leakage permeance, and p
m%
is the
normalized rotor leakage permeance. The magnet is represented
by a ux generator
r
. The rst harmonic magnetic eld created
by the magnet in the airgap is given by
B
f m
=
4

B
g
sin
_
p
2
_
(40)
where B
g
and are, respectively, the ux density created by the
magnets in the airgap and the magnet pole arc. From Fig. 15, it
is possible to write
B
g
=
C

1 +P
m
R
g
B
r
(41)
where B
r
is the remanent ux density of the magnet and C

is
the ux concentration factor (ratio of magnet pole area A
m
to
airgap area A
g
) as
C

=
A
m
A
g
. (42)
The magnet internal permeance, including the normalized
rotor leakage permeance p
m%
, is given by
P
m
= P
m0
(1 +p
m%
) (43)
with
P
m0
=

0

m
A
m
l
m
. (44)
The airgap reluctance is
R
g
=
k
c
l
g

0
A
g
(45)
with k
c
, the Carters coefcient. From (40)(45), innity of so-
lutions exists to obtain the optimal ux density B
f m
depending
on the three parameters l
g
, l
m
, and . We privilege the mini-
mization of the losses in the magnets by choosing a large airgap
length l
g
= 1.5 mm [12]. For example, if we consider the typi-
cal values of C

and p
m%
equal to 0.8 and 10%, respectively,
an airgap ux density B
f m
= 0.3 T can be achieved with the
following choices: l
g
= 1.5 mm, l
m
= 3 mm, = 120

, and
B
r
=0.5 T. For example, MQI grades produced Magne Quenche
International Inc. could be chosen.
The permeance coefcient PC (slope of the airgap line in the
second quadrant of the BH curve of the magnet) is given by
PC =
m
1 + P
m0
p
m%
R
g
P
m0
R
g
. (46)
This coefcient gives an indication on the capacity to with-
stand demagnetization. It must not be too low, in order to avoid
risks of demagnetization, and not too high to limit the cost.
In [28], it is shown that, when losses in the supply converter
are taken into account, a permeance coefcient from 1.5 to 3
allows a global minimization of losses. Considering this result,
we choose PC = 3.
IV. 2-D FEM CALCULATIONS
The 1-D modeling of the nonsalient PMSM has already
proved its efciency. As a consequence, the FEA proposed in
this section has just been developed to check the validity of
assumptions presented in Section I: no saturation constraint, no
armature reaction, and no prohibitive temperature in the arma-
ture winding. According to the results obtained in the previous
section, we choose a laminated steel machine (0.3 mm S
i
.F
e
)
associated with a gear ratio g = 40. The optimal ux density
B
f m
is 0.3 T and the rotor design is dened in the previous
section. The ratio L/R is chosen equal to 3. Then, it is possible
to calculate Rand L from (36) where all other terms are known.
This article has been accepted for inclusion in a future issue of this journal. Content is final as presented, with the exception of pagination.
8 IEEE TRANSACTIONS ON ENERGY CONVERSION
Fig. 16. BH curve for electrical steel grade M235-35A
Fig. 17. Flux lines and magnitude of ux density at
max
We will consider a number of slots/pole/phase equal to 2. The
simulated data are presented in Table II.
The FEA has been done with the software program FEMM
(approximately 25 700 elements and 13 000 nodes in the whole
mesh). A magnetostatic simulation has been used in which the
current density is imposed. The ux densities and the torque
have been computed at
max
. The torque has been calculated
using the virtual energy principle around a torque angle (i.e.,
angle between stator and rotor elds) = 90

. The nongrain-
oriented electrical steel grade M235-35A [29] (fully processed
standard grade, available at low cost) can be used here. Its BH
curve (see Fig. 16) has been considered.
No signicant magnetic saturation is observed in the iron
core (see Fig. 17). The value of the ux density was checked
in the teeth and the stator yoke of the machine. As shown in
Table III, the computed torque is closed to the torque obtained
analytically (see Fig. 18). The difference is more signicant on
the ux densities observed in the teeth B
tm
and in the yoke
B
ym
at
max
. That is mainly due to the fact that the armature
reaction is no more negligible at
max
. Such a variation would
lead in practice to increase the magnetic losses. Nevertheless,
it is possible to consider the effect of this variation negligible
because the phenomenon happens during a short sequence and
at low speed. Let us note that B
tm
and B
ym
given for the 2-D
FEM are the average values measured in the cross section of a
tooth and the yoke.
As shown in Fig. 19, the mean value of the ux density in the
air gap is close to the ux density calculated. The slot effects
TABLE II
SIMULATED MACHINE DATA
TABLE III
SIMULATED AND CALCULATED MOTOR DATA
Fig. 18. Torque variation at
max
.
Fig. 19. Flux density in the airgap at no load.
produce a low variation of ux density, approximately 0.03 T.
Such a value will lead to a reduced value of losses in the magnet.
Fig. 20 shows the variation of the cogging torque. Due to the
large airgap chosen, its value is reduced and negligible.
The power converter has not been studied in this paper; nev-
ertheless, the number of turns n
s
has to be considered in order to
satisfy the constraint on the dc-link voltage U
d
which is limited
for portable applications. If we take U
d
= 36 V, for N
max
=
40 000 r/min and a current angle equal to 0, the number of turns
is n
s
= 10. From (2), the armature winding resistance R =
90 m. An analytical calculation of the ux linkage gives a
This article has been accepted for inclusion in a future issue of this journal. Content is final as presented, with the exception of pagination.
BERNARD et al.: DESIGN METHODOLOGY OF A PERMANENT MAGNET SYNCHRONOUS MACHINE FOR A SCREWDRIVER APPLICATION 9
Fig. 20. Cogging torque.
Fig. 21. Temperature distribution and isothermal lines at
max
.
synchronous inductance L=205 H. Note, at last, that the wire
diameter is 1 mm, which is less than the skin depth at 667 Hz.
Fig. 21 shows the thermal 2-D FEA results using FEMM.
This calculation has been performed considering the average
level of specic losses per cycle in the winding, teeth, and core
with the machine dened in Table II and thermal data given
in Fig. 5. In order to highlight the temperature rise within the
machine, the temperature at the external surface has been set
to 25

C and the heat ux density at the inner radius has been

set to 0. As shown in Fig. 5, the maximum temperature rise in
the winding is about 7

C. This result conrms the choice of the

simplied model presented in Section II.
V. CONCLUSION
As shown in this paper, it is possible to solve analytically the
problem of the optimization (the minimization of the volume
here) of a permanent magnet synchronous machine associated
with a gear box and considering a deterministic duty prole.
The result of the optimization shows how the increase in the
speed contributes to the reduction of the volume of the machine
and allows us to choose cheaper materials, e.g., such as ferrite
magnets. If the constraint on the volume is strong, the solution
is to make use of SMC material. We have shown that it is
possible to formulate analytically the problem of the choice
of the magnetic material. Above 1500 Hz, SMC becomes more
efcient. At last, if we consider the effect of windage losses, and
if we assume that these losses are extracted directly from the
airgap by using an external fan, an optimum value of the gear
ratio exists that maximize the energy efciency. Considering
both the minimization of the volume and the maximization of
the energy efciency, a choice of the gear ratio between 30
and 50 represents a good compromise. Let us note, at last, that
the methodology developed herein may be extended to other
applications as long as the duty cycle is known. For example,
the methodology can be easily used to optimize the specic
power of a machine at a given speed. Then, it can be shown
that the maximum specic power can be expressed analytically
where the function F given in (32) appears in the formulation. It
means that the optimal values of pole pair number and reduced
radius are not changed.
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Nicolas Bernard was born in France in 1971. He re-
ceived the M.S. degree in electrical engineering from
the University of Poitiers, Poitiers, France in 1995,
the Agr egation instructors credential in 1997, and
the Ph.D. degree from the Ecole Normale Sup erieure
de Cachan, Cachan, France, in 2001.
His research activities mainly concerned ywheel
energy storage, and the design, modeling, and opti-
mization of new topologies for electromagnetic actu-
ators. Since 2004, he has been an Assistant Professor
in the IREENA Laboratory, Saint-Nazaire, France.
His major research interest is in the eld of high-speed electrical machines
design.
Floran Martin was born in 1985. He received the
Masters degree in electrical engineering fromNantes
University, France, in 2009. Actually, he is pursuing
a Ph.D. degree on the optimization of high speed
synchronous generators in the IREENA Laboratory,
Saint-Nazaire, France.
Mohamed El-Hadi Zam received the Ph.D. degree
fromthe Institut National Polytechnique de Lorraine,
France, in 1979, the Doctorat ` es-Sciences from the
Ecole Nationale Polytechnique, Algiers, Algeria, in
1989 and the Habilitation ` a Diriger des Recherches
from Nantes University, France, in 2000.
He is currently a Professor in the Department
of Electrical Engineering, PolytechNantes, Nantes
University, France. He is involved in the research and
development of electrical machines design, particu-
larly in the eld of permanent magnets and solid-
rotor high-speed synchronous machines and reluctance machines for low speed
applications.