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Brushless DC machines, particularly those of the interior permanent magnet (IPM) type are gaining favour for hybrid and electric vehicle applications. MotorSolve is able
to produce accurate results for these types of designs while maintaining the simplicity of use of a template-based, results-driven environment
Brushless DC machines,particularly those of the interior permanent magnet (IPM) type are gaining favour for hybrid and electric vehicle applications.
These machines are characterized by high power density, high output torque over a wide range of operational speed due to a highly salient rotor and a strong reluctance torque component. Field weakening and operation in the constant-power speed range
(CPSR) is key to operating at a wide range of vehicle speeds without the need for excessive gearing.
Field weakening is accomplished by increasing the advance angle as speed increases to reduce the back EMF so it does not exceed the available supply voltage.
MotorSolve is able to provide useful results to investigate these complex characteristics. The FEA engine that powers MotorSolve can consider non-linear materials, PWM drive circuitry and set up complicated geometries with only a few simple instructions.
Results
The 8-pole, 48 slot three phase IPM machine, while complicated in appearance, is specified in minutes using the MotorSolve geometry editor. The stator poles take advantage of strong neodymium iron boron (NdFeB) magnets as
well as a highly salient rotor design that gives a reluctance torque component for extended speed range operation.
The interior permanent magnet machine relies on rotor core saturation to operate, requiring consideration of non-linear material characteristics. The flux plot (100 A current) shows the saturation in the rotor bridge and allows the designer to optimize the geometric parameters.
Determining the torque-speed curve for a machine like this is not a trivial task, requiring an optimization of advance angle for each speed.MotorSolve allows a quick setup of multiple runs for several speeds and advance angles to show the torque avai lable. The envelope of these curve provides the torque speed curve and the optimal advance angle can also be obtained. The wide CPSR (constant power speed range) of the IPM is shown
This plot extracts the peak torque at each speed at the optimal advance angle. The advantage of field weakening becomes apparent as the machine exceeds the constant-torque region around 875 rpm.
The IPM's wide speed range results from its high saliency ratio (d-axis inductance to q-axis inductance). The non-linear behaviour of this inductance due to magnetic saturation can be accurately depicted by MotorSolve. This graph shows Ld and Lq as a function of current.
Core losses can be a significant fraction of total losses in motors and MotorSolve's advanced loss calculation capabilities allow the user to estimate hysteresis and eddy current losses at the component level. The figure on the right show the rotor hysteresis and eddy current losses as a function of rotor speed (or equivalently, the frequency). The eddy current trend shows a parabolic behavior while the hysteresis loss follows a power law behavior as expected |
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