ISSN 2319-8885

Vol.03,Issue.16
July-2014,
Pages:3289-3293
www.semargroup.org,
www.ijsetr.com

Design of Conventional Permanent Magnet Synchronous Motor used in

Electric Vehicle
EI KYAW AUNG NAY TUN1, THET TIN2
1
Dept of Electrical Power Engineering, Mandalay Technological University, Mandalay, Myanmar, E-mail: [email protected].
2
Dept of Electrical Power Engineering, Mandalay Technological University, Mandalay, Myanmar.

Abstract: Conventional permanent magnet synchronous motors are popularly used in electric vehicle application. This study
addresses the theoretical design of a conventional permanent magnet synchronous motor (PMSM) for electric vehicles. The
study applies to both surface mounted and inset magnet rotor configurations. Various losses estimations are embedded into the
design procedures to ensure that the desired overall drive performance is achieved. Influences of parameters such as air gap size
and magnet material on the performances are studied. Application of neodymium-iron-boron (Nd2Fe14B) and samarium cobalt
(Sm2Co17) rare earth magnets results in high torque and power density, efficiency, and controllability, reliability, and
ruggedness. Design of 47 kW PMSM with various magnets for electric car is presented.

Keywords: Electric car, Design theory, Nd2Fe14B, PMSM, Surface PM rotor.

I. INTRODUCTION electricity from the battery. However, beyond a defined level

An electric car is an alternative-design automobile that of battery consumption the vehicle reverts back to using the
uses an electric motor to power the car, with the electricity internal combustion engine alongside the electric motor like a
being provided by a battery. . In an electric vehicle the standard hybrid. Table I shows the description of components
traditional gasoline or diesel engine and fuel tank is replaced in Fig 1. By replacing the fuel tank with a high energy
with an electric motor, a battery pack and controller. The density battery and the internal combustion engine with an
vehicle also has a controller that powers the electric motor efficient electric motor, EVs are capable of achieving
uses rechargeable batteries as its energy source. The motor significant efficiency improvements and emission reductions.
itself can be either AC or DC. The main advantage to electric Their range, efficiency, cost and torque-speed characteristics
vehicles is that the motor and battery configuration allows the are predominantly determined by their battery pack and
vehicle to run more fuel-efficiently [1]. The permanent electric motor(s).
magnet synchronous motor (PMSM) is considered to be a
better fit for electric cars because the PMSM offers some
advantages as low rotor inertia, high efficiency, efficient heat
dissipation structure, and reduced motor size. The elimination
of brushes reduces noise and suppresses the need for brush
maintenance is another big advantage.

II. PRINCIPLE OF ELECTRIC CARS

Electric vehicles can be divided into three main types:
hybrid electric vehicles (HEVs), pluggable hybrid electric
vehicles (PHEVs) and full electric vehicles
(FEVs/BEVs/EVs). Hybrid electric vehicles retain the
internal combustion engine and drive, while also
incorporating a small battery and electric drive motor. While
the higher efficiency of the electric drive and the capacity for
regenerative breaking results in decreased fuel consumption,
the vehicle cannot be powered by electricity alone and still
relies on petrol or diesel. Full EVs are generally
mechanically less complex than both internal combustion and
hybrid vehicles, as shown in Fig.1. Consequently, the vehicle
can be driven over short ranges where it only consumes Fig 1. Key Functional Components Typical to an EV [1].

Copyright @ 2014 SEMAR GROUPS TECHNICAL SOCIETY. All rights reserved.

 EI KYAW AUNG NAY TUN, THET TIN
TABLE I: Description of Components in Figure-1

Fig.2. Stator Case with Winding.

B. Stator Coil Arrangement

The windings are connected in wye. The two windings in
each phase are wound in the same direction. At any instant in
time, the magnetic field generated by one particular phase
will depend on the current through that phase. Since the
currents in the three windings are 120° out of phase, the
magnetic fields produced will also be 120° out of phase. The
three magnetic fields will combine to produce one field,
which will act upon the rotor. In an AC induction motor, a
magnetic field is induced in the rotor opposite in polarity of
the magnetic field in the stator. Therefore, as the magnetic
field rotates in the stator, the rotor also rotates to maintain its
alignment with the stator's magnetic field. This motor used
six winding for electrical configuration of stator winding, two
for each of the three phases. The coils are wound around the
soft iron core material of the stator. When current applied
III. PERMANENT MAGNET SYNCHRONOUS each winding become electromagnet with one winding is a
MOTOR north pole and the other is south pole, the polarities of the
The PM Synchronous motor is a rotating electric machine winding also reverse.
where the stator is a classic three phase stator like that of an
induction motor and the rotor has surface-mounted C. Winding Insulation
permanent magnets. In this respect, the PMSM is equivalent Insulation of the winding is one of the most critical parts
to an induction motor where the air gap magnetic field is in this design. When the insulation breaks down, the machine
produced by a permanent magnet. The use of a permanent shorts out. The cost of repair machine with shorted insulation
magnet to generate a substantial air gap magnetic flux makes is expensive and sometimes impossible. The temperature of
it possible to design highly efficient PM motors. A PMSM is the winding should be limited to prevent the insulation from
driven by sine wave voltage coupled with the given rotor breaking down because of the overheating. This can be
position. The generated stator flux together with the rotor preventing by providing circulation of cool air over the
flux, which is generated by a rotor magnet, defines the windings. The continuous power supplied to the machine
torque, and thus speeds, of the motor. usually limited by the maximum temperature of winding. The
increased in temperature usually degrades the insulation. Life
A. Stator Construction of the machine is halved for a temperature rise of 10 percent
The stator is the stationary part of the motor. The core of above the rate temperature winding. In this motor prefer used
the stator is made up of several hundred thin laminations. type F insulation class. This type of insulator is the most
Stator laminations are stacked together forming a hollow commonly used for motor. The allowable temperature 105°C
cylinder and coils of insulated wire are inserted into slot of rise from ambient temperature 40°C.
the stator core. The basic concept of the motor operation is
electromagnetism which is, each group of coils together with D. Rotor Construction
the steel it surrounds form an electromagnets. The stator The type of rotor used is permanent magnet type. With a
winding are connected directly to the power circuit. Fig 2 permanent magnet mounted on a shaft can be substituted for
below shows the stator case with the winding insulator. brush-type shaft with slip ring of rotor. When stator winding
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.16, July-2014, Pages: 3289-3293
 Design of Conventional Permanent Magnet Synchronous Motor used in Electric Vehicle
are energized, a rotating magnet is established. The magnet IV. DESIGN THEORY OF PMSM
has its own magnetic field that interacts with rotating Synchronous machines are designed to achieve the following
magnetic field of the stator. The north pole of the rotating information regarding its various parts supply.
field attracts the south pole of the magnet, and the south pole  Main dimensions of stator frame,
of rotating magnetic field attracts the north pole of the  Complete details of the stator winding,
magnet. As the magnetic field rotates, it pulls the magnet  Details Design of the PM rotor and
along. NdFeb rare earth magnet is the type of permanent  Performance of the designed parts, in order to justify
magnet suitable used to produce strong magnetic field. Fig 3 the design of the above parts.
shows the mounted magnet on the rotor shaft.
Design of electrical machines mainly consists of obtaining
the dimensions of the various parts of the machine to suit
given specifications, using available material economically
and then to furnish these data to the manufacture of the
machine.

A. Main Dimensions of Stator Frame

Internal diameter and gross length of the stator frame are
its main dimensions. It is essential to develop an equation
connecting the output of synchronous motor with its main
dimensions in order to estimate the latter.
For the synchronous motor,
Pout  ε

2
D1in L i
 pns (1)
Fig.3. Mounted magnet on the rotor shaft.
 p  0.5 π k  1 A m B mg η cos φ
2

E. Rotor Configuration Where,

Permanent magnet synchronous motors are usually built
D1in ― Internal diameter of stator, (cm)
with one of the following rotor configurations.
Li― Gross length of stator, (cm)
 Classical (Merrill’s rotor), with salient poles,
Pout― Designing power, (W)
laminated pole shoes and a cage winding,
 Interior-magnet rotor,  p ― Output coefficient
 Surface-magnet rotor, ε ― Relative eccentricity
 Inset-magnet rotor and, Ns― Synchronous speed, (rev/s)
 Rotor with buried magnets symmetrically distributed. k1 ― Winding coefficient
F. Surface PM Rotor Am― Specific electric loading, (A/m)
The surface magnet motor can have magnets magnetized Bmg― Air-gap magnetic flux density, (T)
radially or sometimes circumferentially. An external high η ― Efficiency
conductivity non-ferromagnetic cylinder is sometimes used. cos φ ― power factor
It protects the PMs against the demagnetizing action of
armature reaction and centrifugal forces, provides an The size and cost of synchronous machine is decreased by
asynchronous starting torque, and acts as a damper as shown choosing comparatively a higher value of air gap flux
in Fig.4. If rare-earth PMs are used, the synchronous density. However, operating flux density in stator teeth and
reactances in the d-and q-axis are practically the same. core increases, which results into higher iron losses. Thus
reducing the efficiency and raising the temperature rise of the
machine. With improvement in magnetic materials, it is
possible to choose comparatively higher value of flux density
in modern synchronous machines. Output equation clearly
indicates that the size of the machine for the same output can
be reduced by choosing higher value of specific electric
loading, which amounts to decreased cost of the machine.
Moreover, the leakage reactance and the armature reactance
of synchronous machine are higher with large value of
specific electric loading.

Internal diameter and gross length of the stator can be

calculated from the product D2L. And a suitable relation is
Fig.4. Surface-magnet rotor. assumed between D and L. For round pole- The ratio of pole
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.16, July-2014, Pages: 3289-3293
 EI KYAW AUNG NAY TUN, THET TIN
arc to pole pitch may be assumed from 0.6 to 0.7 and pole arc
may be taken equal to the axial length of the stator core. The (9)
length of air gap in synchronous machines is an important Mean length of stator turn,
design parameter because its value greatly influences the l1e  2.5 p
(10)
performance of the machine. However, longer length of air
gap will require increased values of field mmf making the lmt  (2L  2.5 p  0.05kV  0.15)
(11)
machine costly. Resistance of stator winding,
I mt N1
Rs 
B. Stator Winding as (12)
Slot pitch, which depends upon the number of slots, should
Where,  ― resistivity
have approximately the following values for different cases.
For low voltages machine: Less than or equal to 3.5 cm. as― sectional area of stator conductor, [mm2]
Normally, the number of poles is quite large in non-salient
pole synchronous machine and the number of slots per pole C. Rotor Magnet Dimension
per phase may be assumed from 1to 3.Number of turns per The volume of all PMs used in a motor
phase can be calculated, using the emf equation of VM  2ph M w M l M depends on the quality of PM material
synchronous machines. (maximum energy). In above equation 2p is the number of
poles, and hM,,wM, and lM are the height, width and length of
Total number of stator slots, S = mpq the PM, respectively. The output power of a PM synchronous
Where, m = number of stator slots per pole per phase motor is proportional to VM. The maximum electromagnetic
Conductors per slot, power developed by PM synchronous motor can be
N1 expressed as follows:
N cs 
no : of conductor/ phase π 2ξfB r H c VM
(2) Pmax 
Turns per phase, 2k f k ad (1  ε)
(13)
A m pτ p Where,
N1  kf ― form factor of the rotor
3 2Ia (3) kad ― d-axis armature reaction factor
The pole pitch, ξ ― coefficient of utilization of the PM
πD1in f― input frequency
τp 
2p Br― remanent magnetic flux density
(4)
Hc― coercive force
Where, ― pole pitch, m; y― number of slots per pole
Air gap flux per pole,
D. Efficiency of PMSM
2
φf  τ p Li Bmg1 Copper Losses of Stator Winding,
π (5)
Stator winding factor k 1 may be assumed as per the (13)
Eddy current losses in the stator conductors,
winding details. For full pitch coils with infinitely distributed Average loss factor,
winding, stator winding factor, is k 1 equal to 0.955. The
number of turns should be an integer. Sectional area of the (14)
conductor for the stator winding can be calculated, based on Eddy current Loss,
the stator current per phase and operating current density for
the stator winding. (15)
Sectional area of conductor, Efficiency of the motor,
I
as  a
Js
(6)
Current density, Js should be assumed as per the cooling (16)
system used. Usual values for the current density in the stator
winding can be assumed varying from 3 to 5 A per mm2. V. DESIGN CALCULATION OF 47 KW PMSM
Width of the teeth, In this paper, 47kW three-phase surface mounted PMSM
 is designed for EV. At the speed of PMSM range from 0 to
bt  2000 rpm, the maximum torque is 180 Nm, but the EV
Bt  Li  N t (7) PMSM is controlled by the number of poles of PMSM used
Where, Nt ― the number of teeth per pole arc in EV is calculated as follow,
Flux core section, 120  f 120  50
c 
1
f pole   2
2 (8) ns 3000
(17)
The outer diameter of the stator is calculated from: The input line to neutral voltage;

International Journal of Scientific Engineering and Technology Research

Volume.03, IssueNo.16, July-2014, Pages: 3289-3293
 Design of Conventional Permanent Magnet Synchronous Motor used in Electric Vehicle
380 The Fig.5 shows the efficiency of the permanent magnet
Vph   219.39V synchronous motor. The different type of permanent magnet
3 (18) materials such as Sm2Co3, Sm2Co17 and NdFeB are mounted
The armature rated current; on the rotor of PM. By changing the magnets, the efficiency
Pout of the PMSM is also changed.
Ia 
3V1 ηcosφ
(19) VI. CONCLUSIONS
The design considered in this paper is 47 kW, 3000 rpm
surface mounted magnet PMSM. By changing the magnet
material, not only the internal diameter of the stator and gross
Table II shows the detail designed data sheet for 47kW
length of the stator but also the efficiency of the motor is also
surface mounted magnet PMSM.
changed. As the magnetic flux density of the different
magnet materials are not the same, the output coefficient is
TABLE II: Detail Designed Data Sheet for PMSM with
changed and other parameters concerned with the output
Magnet NDFEB
coefficient are also changed. In this design, the NdFeB is
chosen magnet to mount on the surface of the rotor because it
has high efficiency compared with other magnet. The
efficiency of the PMSM used NdFeB magnet is 98 per cent.
The design of PMSM is suitable for EV. PMSM offers some
advantages as low rotor inertia, high efficiency, efficient heat
dissipation structure, and reduced motor size.

VII. ACKNOWLEDGEMENT
First of all, the author would like to acknowledge the
support and the encouragement of Prof. Dr. Myint Thein,
Pro-rector, Mandalay Technological University. The author
is deeply indebted to Dr. Khin Thuzar Soe, Associate
Professor and Head of Department of Electrical Power
Engineering, Mandalay Technological University, for her
invaluable help and indispensable guidance. The author
wishes to extend grateful thanks to her supervisor, U
ThetTin,, Lecturer, Department of Electrical Power
Engineering, Mandalay Technological University, for his
supervision, critical reading of manuscript and tolerance
helped in all the time of this research work. The author is also
special thanks to all her teachers and friends who help in
preparation of this paper. The author specially thanks to her
family, especially her beloved parents, for their supports and
encouragements to attain her destination without any trouble.

VIII. REFERENCES
[1] Anonymous, "Electric Vehicles: Charged with
Potential", Royal academy of engineering, 2010.
[2] Bhim Singh, B.P.Singh, S Dwivedi, “A State of Art on
Different Configurations of Permanent Magnet Brushless
Machine”, 2002.
[3] Jacek F. Gieras Mitchell Wing, “Permanent Magnet
Motor Technology design and application”, 2nd, Ed 2002.
[4] TayfunGundugdu, “Design of Permanent Magnet
Machines with Different Rotor Type”, 2000.
[5] Miss SisudaChaithongsuk, “Design and Construction of a
Permanent Magnet Synchronous Motor”, ISBN 974-190-
887-3, 1989.

Fig.5. Efficiency of designed PMSM for Various Magnet.

International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.16, July-2014, Pages: 3289-3293