Design of

Rotating Electrical Machines

Juha Pyrhnen, Tapani Jokinen, Valria Hrabovcov
Three-phase permanent magnet machine with rotor surface magnets, a two-layer
integral slot winding and open-circuit cooling
This calculation sheet is designed for analytical evaluation of a three-phase permanent
magnet machine with rotor surface magnets, a two-layer integral slot winding and
open-circuit cooling.
While every effort has been made to ensure the accuracy of the information and technical
data in this calculation sheet, the authors cannot accept any liability for damage, injury,
breakdown, or poor performance arising from the application of this machine design or
data contained in it. The reader is responsible to check the calculations and the technical
data and conduct such tests as may be necessary to ensure that the machine design
suggested by this publication is suitable for the use to which it is put.
The design process follows the outline presented in Chapter 7. The table and equation
numbers refer to the numbering in the textbook.
The rotor design is according to the next Figure.

Contents
1. Initial data
2. Tangential stress
3. Rotor size
4. Air gap and the core length
5. Stator winding
6. Air-gap flux density and linear current density
7. Number of coil turns in a phase winding
8. Number of conductors in a slot
9. Determination of new air gap flux density
10. Width of the stator tooth
11. Stator slot dimensions
12. Magnetic voltage over the tooth
13. Checking the saturation factor
14. Magnetic circuit
15. Outer stator diameter and inner rotor diameter
16. Total magnetic voltage of the magnetic circuit with rotor magnetization
17. Stator resistance
18. Magnetizing inductance
19. Air-gap leakage inductance and reactance
20. Slot leakage inductance and reactance
21. Tooth tip leakage inductance and reactance
22. End winding leakage inductance and reactance
23. Synchronous inductance and reactance
24. Losses (except stator resistive losses)
25. Rated load, stator current, stator resistive losses and total losses
26. Efficiency and power factor
27. Masses of the active materials
28. Load angle equation graph

1. Initial data
Output power, W

160000

Speed, 1/s (min-1)

41.667

Torque T = P/(2n), Nm

Line-to-line voltage, V star connected

690

Number of phases

Number of pole pairs

Frequency, Hz

f n p

Angular frequency, 1/s

2 f

Desired efficiency

0.95

Power factor

n 60

2 n

cos

611.1501

166.6680

0.91

Coercivity of the permanent magnets, A/m

Hc

800000

Remanence flux density of the permanent magnets, T

Br

1.05

Permeability of vacuum, Vs/(Am)

4 10

Permeability of the permanet magnet

material

rec

Temperature rise in the machine windings, K

Conductivity of copper at 20 degrees C, S/m

Cu20C

Temperature coefficient of resistivity for copper, 1/K

Cu

3.81 10

Space factor of the stator core

k Fe

0.97

Density of iron, kg/m3

Fe

7600

Density of the permanent magnet material, kg/m3

PM

Density of copper, kg/m3

2.5000 10

Br

rec

0 Hc

80

Cu

57 10

7500
8960

1.0445

We introduce the BH curve of the M800-50A lamination material. The specific loss
of this material at 1.5 T and 50 Hz is
P15 6.6 W /kg
0

84.5

107
121

133

145
156

168

180
194

209
H

228
254

304

402

660
1480

3710

7300
15000

30000

100000

BH curve of M800-50

0.0

0.1

0.2
0.3

0.4

0.5
0.6

0.7

0.8
0.9

1.0
B

1.1
1.2

1.3

1.4

1.5
1.6

1.7

1.8
1.9

2.0

2.1

0
0

2 10

410

6 10
H

A/m

810

1 10

We also introduce the graph for the yoke magnetic voltage calculation
0

0.1

0.2
0.3

0.4

0.5

0.6
0.7

0.8

0.9
By
c
1.0

1.1

1.2
1.3

1.4

1.5
1.6

1.7

1.8
1.9

0.72

0.72

0.72
0.72

0.72

0.72

0.71
0.70

0.67

0.63
0.57

0.48

0.40
0.33

0.26

0.20
0.17

0.16

0.15
0.14

Influence of the maximum flux density of the stator or rotor

yoke on the definition of the coefficient c, applied in the
determination of magnetic voltage (see Fig. 3.17)
0.8
0.6
c

0.4
0.2
0

0.5

1.5

By

2. Tangential stress
The determination of the main dimensions starts with choosing the appropriate
tangential stress for open-circuit cooling according to the machine type (Table 6.3).
Ftan

33500 cos

Ftan

3. Rotor size
The rotor volume Vr can be solved from Eq. (6.2)

Dr2
T F tan
l ' 2 F tanVr ,
2

3.0485 10

Pa

where Dr is the outer rotor diameter and l' the equivalent length of the rotor.
The volume Vr is
Vr

Vr

2 Ftan

m3

0.0100

The ratio of equivalent core length and air-gap diameter is according to Table 6.5:

l'

4p
Dr

4 p

0.3927

From the equations above we can solve the rotor diameter (including surface magnets)
and the equivalent iron core length:
3
Dr

4 Vr

Dr

0.3191 m

We select a rounded number

Dr 0.32 m
l Dr

Use Dr = 1152 [mm]

l

Use l` = 558 [mm]

0.1257

4. Air gap and core length

Air-gap length (from the surface of the permanent magnet to the stator inner surface) is
calculated from Eq. (6.42):
0.18 0.006 P0.4

1000

9.0410 10

Surface magnets need a supporting band, the thickness of which is about 1 mm,
and thus the physical air-gap length is increased to

0.0016

10

1.6000

mm Use = 4 [mm]

The inner diameter of the stator is

Ds Dr 2

Ds

0.3232

Ds 10

323.2000

mm

As it is known, process of energy transformation is accompanied by various losses which ar

allocated in the form of heat in separate parts of the electrical machine.
For the purpose of heat removal in synchronous machines the radial cooling system in whic
the stator core is divided into a number of substacks is applied. Such system is called double
radial cooling (with smooth rotor). If it is necessary, the rotor core is also divided into a
number of substacks (single radial cooling). With the help of the distance bars between
substacks the radial ventilating ducts of certain width for pass of cooling air are formed.
In case of single radial cooling in a PMSM the cooling channels in the rotor are in the same
places as the stator channels.
In our case the PMSM has
ns

is the number of stator substacks

b s

0.12

is the width of the stator substack [m]

nvs

is the number of stator ventilating ducts

b vs

is the width of the stator ventilating duct [m]

nr

is the number of rotor substacks

b r

is the width of the rotor substack [m]

nvr

is the number of the rotor ventilating ducts

b vr

is the width of the rotor ventilating duct [m]

bv
ventilating duct
stator

No cooling channels!

bve
B

bv
l
rotor

Fig. 3.1 Influence of radial ventilating ducts on the equivalent length of the machine and the
behaviour of the flux density in the vicinity of the ventilating duct.

By applying Eqs. (3.7a) and (3.7b) and by substituting the width of the slot opening b with
the width of the ventilating duct bv we obtain
bve k bv
The coefficient k can be determined as
bvs bvr

b vs b vr

0.0000

The equivalent width of the ventilating duct is

b ve k b vs

b ve

0.0000

The real length of the machine is

l ns b s nvs b vs

0.1200

According to (3.38) the equivalent length of the machine is

l l nvs b ve 2

0.1232

5. Stator winding

The number of slots per pole and phase q is chosen

q

Use q = 1

and the winding pitch .

W p

W Wp p

5
6

The number of stator slots:

Q

2 p m q

48.0000

The stator slot pitch:

u

Ds
Q

The stator pole pitch:

0.0212

Ds

2 p

0.1269

6. Air-gap flux density and linear current density

As the magnets are rectangular, also the waveform of the flux density is approximately
rectangular. About 5-8 % of the flux that the rotor surface permanent magnets create is lost
as leakage flux, so the real magnets have to be 5-8 % wider than they are in our calculations
Let us choose for the effective relative magnet width
PM

0.80

The air gap flux density distribution produced only by permanent magnets is
hPM_i
i

10.066 10

is the iterated value for the PM height

0 100

x i i

1
200

1 2 k

8Br

x
p

sin 1 2 k e
cos 1 2 k
300
p
1 2 k PM
2

BPM ( x )

2 12 k 2 12 k hPM_i
k 0 2 1 2 k

p
p

1.05e
1 e
1
p

1
e

2 12 k hPM_i

p
1
e

A peak vaue of the rectangular flux density is

BPMmax max BPM ( x )

BPMmax

0.8998

The fundamental flux density distribution according to Fourier series is

p
2
n x
n

B1( x )
BPM ( x ) dx
p BPM ( x ) cos p dx cos p x
p

n 1
0

A peak value for the fundamental flux density is

B1peak max B1( x )

B1peak

1.0855

According to Table 6.2, the linear current density RMS value for an air-cooled
nonsalient pole PMSM is 35-80kA/m
Tangential loading assuming sinusoidal flux density waveform to estimate the
mechanical torque is

F tan

A B cos AB cos

2
2

We may solve for the RMS linear current density

A

Ftan

0.5 B1peak cos 2

4.3647 10

A/m

This value corresponds well to the values given in Table 6.3.

7. Number of coil turns in a phase winding

The number of coil turns in series in a phase winding can be calculated according
to Eq. (7.7)

2 E PM
k
w1

where EPM is the permanent-magnet-induced voltage. The value of EPM has a significant
influence on the machine performance. Depending on the desired machine performance,
EPM may vary from slightly under the supply voltage to slightly over the supply voltage. If
the motor performance after the design is not desired the designer may consider changing
EPM. Now EPM is assumed to be
EPM

1.0U

EPM

398.3717

According to Eq. (4.71), the skewing factor is calculated as

ksq

s
sin sq
2
p

ssq

p 2

The skewing is carried out in the rotor so that it corresponds to one stator slot
pitch (Fig. 4.16)

ssq

ssq

p 2
ssq

p 2

sin

Ds

k sq( )

k sq

1 0.9886

The winding factor is a product of the skew, pitch and skew factors

ssq
2 sin Wp sin
sin
2
m 2 p 2
k w( )
Q
p

ssq
sin

m p
Q

p 2

2 EPM

N
kw

kw

1 922.3912 10 3

53.9789

B1peak p l

8. Number of conductors in a slot

The number of parallel branches is selected as

a

The number of conductors in a slot is

zQ

2 a m

N
Q

zQ

6.7474

zQ has to be an even number in a two-layer winding. (In a one-layer winding, zQ

has to be an even or odd number, i.e. an integer number.) The rounding to an even
number may make a large difference to zQ calculated above. Changing the number
of parallel paths may help.
a
zQ

Use a = 1

2
2 a m

N
Q

zQ

13.4947

zQold zQ

we select zQ 14

zQnew zQ

and the number of coil turns in the phase winding becomes

N

Q zQ

2 a m

56.0000

9. New Bmax

The rounding of zQ influences the peak value of the flux-density-induced voltage EPM and
the power factor. To keep the induced voltage EPM unchanged, we will use a new air-gap
flux density in the following calculations
BPMold ( x ) BPM ( x )

(Appropriate values are used in the following equation to get new Bmax)
BPM ( x )

zQold
z
BPMold ( x )
Qnew

p
n x
2
n x
BPM ( x ) cos
B1( x )
BPM ( x ) dx

d
x

cos

p
p
p

p
0

n1
0

Peak vaues are

B1peak max B1( x )

Bmax max BPM ( x )

B1peak

Bmax

1.0463

0.8673

T
T

10. Width of the stator tooth

According to Table 6.1, the flux density of a stator tooth for nonsalient-pole synchronous
machines varies normally from 1.5 T to 2.0 T. Let us choose for the apparent density
Bdapp

1.6

According to the textbook, the apparent flux density is

The minimum tooth width is solved as

Bd'

l ' u
B
kFe l nvbv bd

b dmin

l u

Bmax

b dmin

k Fe l nvs b vs Bdapp

0.0121

11. Stator slot dimensions

To determine the stator slot dimensions, we have first to estimate the stator current.
According to Eq.(7.9a) the stator current of the motor is

Is

P
mU s,ph cos

According to Eq.(7.9b) the stator current of the generator is

P
Is
mU s,ph cos
The stator phase voltage Usph
Usph

The initial guess for the stator current is

Is1

Is2

for the motor

m Usph cos
P

for the generator

m Usph cos

Depending on the machine type (motor or generator) the user have to choose
the corresponding subcript:
1 - for the motor
2 - for the generator
Is Is2

Is

147.1190

The area of one conductor in a stator slot is

Scs

Is
aJ s

Selecting the stator current density from Table 6.2, we obtain

J s
Scs

The designer can choose another

value. See the textbook.

4.5 10 A /m2
Is

Scs

a Js

1.6347 10

m2

Scs 1000000

16.3466 mm2

The wound area SCus of the stator slot is obtained by

z Q S cs

S Cus

k Cus

where kCu,s is the space factor of the slot. The space factor inside the slot
insulation is about
k Cus

Use kCus = 0.5

0.63

With this value of the space factor, the wound area of the slot
SCus

zQ Scs

SCus

k Cus

3.6326 10

m2

SCus 1000000

363.2569 mm2

The slot form and the slot dimensions are

presented in the figure below.

bw
aCus
hw
bCus

h'

mm

5 10

b is

5 10

mm

bw bs 4...6

mm

hs

bis
bs
The width of the rectangular slot
b s u b dmin

bs

9.0164 10

b s 10

a Cus 10

9.0164

mm

The width of the copper in the slot

a Cus b s 2b is

a Cus

8.0164 10

The height of the copper in one layer

8.0164

mm

b Cus

SCus

b Cus

2a Cus

b Cus 10

hs 10

2.7049 10

hw 10

0.0130

b w 10

hd 10

0.0227

22.6570

mm

The height of the rectangular slot

hs 2b Cus h 2 b is

hs

0.0468

46.8141

mm

2.7049

mm

13.0164

mm

49.5190

mm

The height of the wedge

hw

0.3 b s

hw

The width of the wedge

3

b w b s 4 10

bw

The height of the stator tooth

hd hw hs

hd

0.0495

The total area of the slot is needed later in the calculations

Sslot b s hs

Sslot

4.2210 10

m2

Sslot 10

422.0956

mm2

12. Magnetic voltage over the tooth

The flux density in the tooth is obtained by solving the intersection of the BH curve of the
electric sheet in question and the line given by Eq. (3.46)
S
Bd Bd' u 0 H d
Sd

where

B
B d'

Su
l ' u

1
S d k Fe l n v bv bd
B d

S
B d B d' u 0 H d
Sd

see Eq. (3.44)

The apparent flux density in the stator tooth is

H d

The tooth width along the height is nonuniform.To simplify the problem we will calculate th
magnetic voltage in 4 different parts of the tooth and then we will sum up them.

hd
4

hr hd

2
3hd

Different widths along the tooth height

b d

Ds 2hr
Q

0.0121

0.0138
bd

0.0154
0.0170

bs

The apparent flux densities in the stator tooth are

Bdapp

l u B1peak

k Fe l nvs b vs b d

1.9301

1.7027
Bdapp

1.5233
1.3781

Using the BH curve of M800-50A, we get for the field strengths in the teeth
vs lspline( H B)

Initial guess
Bed Bdapp

Hed interp vs B H Bed

A/m

Given
Bdapp

l u

k l n b b 1 0 interp vs B H Bed = Bed

vs vs d
Fe

Bd Find Bed

1.9095

1.6821
Bd

1.5027
1.3575

Hd interp vs B H Bd

1.6424 104

Hd 3.3119 10

682.2864
360.3483

A/m

The solution for the magnetic voltage of the tooth is

hd

U m,d H d dl

ld

Umds ld Hd

Umds

hd hd hd hd

4 4 4 4
A

257.2337

13. Checking the saturation factor

In the case of a surface permanent magnet machine, the saturation of the teeth does not
influence the waveform of the air-gap flux density, in other words, PM remains constant.
14. Magnetic circuit.

The magnetic voltage of the air gap is calculated in the following.

According to Eqs. (3.7b) and (3.8)
The permeability of a semi magnetic wedge is about

A good approximation of the slot opening is found by selecting

b 1

bs
r

b1

2.2541 10

b 1 10

2
2 b 1 2
b1
atan
ln 1

2( ) b1
2

2.2541

The Carter factor is

k C1

k C1

u b 1

1.0227

The equivalent air gap

e k C1

1.6364 10

0.2086

mm

The magnetic voltage of the air gap is according to Eq. (3.35)

Ume

Bmax
0

Ume

1.1294 10

The height of the stator yoke hys and the height of the rotor yoke hyr are solved
from Eqs. (3.48) and (3.49):

m
B ys m
2 S ys 2k Fe l nv b v hys

m
B yr m
2 S yr 2k Fe l nv bv hyr
where the air-gap flux is
m PM Bmax p l

0.0108 Vs

The maximum flux densities of the stator and rotor yokes are selected according to Table 6.1
Bys
hys

hyr

1.3

Byr

2kFe l nvs bvs Bys

m

2kFe l nvs bvs Byr

1.3

The designer can choose another

value. See the textbook.

hys

0.0359

hyr

0.0359

In our example, the rotor carries thin laminations of height hyr. Permanent magnets are also
often placed on solid steel. Such an arrangement may, however, create extra losses under the
permanent magnets.
The magnetic voltages are according to Eqs. (3.51) and (3.52)
U m,ys cs H ys ys
U m,yr cr H yr yr
The coefficient c can be taken from Fig. (3.17) below

0.8

0.6
0.4
0.2
0
0.5

1.0

1.5

Byr, Bys /T

2.0

From the BH curve of M800-50A, we get for the maximum field strengths in the stator
and rotor yokes
vs lspline( B H )

Hymaxs

304.0000

A /m

Hymaxr

304.0000

A /m

Bys

1.3000

Hymaxs interp vs B H Bys

Byr

1.3000

Hymaxr interp vs B H Byr

Using Fig. 3.17, we get the correction factor c:

vs lspline( By c)
cs interp vs By c Bys

cs

0.3300

cr

0.3300

cr interp vs By c Byr

The average stator yoke diameter (see Figs. 3.1 and 3.2) is
Dys Ds
ys

2 hs hw hys

Dys

2p

ys

0.1799

Dys

0.4581

The magnetic voltage of the stator yoke is

Umys cs Hymaxs ys

Umys

18.0467

The height of the permanent magnets is calculated in the following.

The peak value of the total magnetic voltage has to be equal to the current linkage HchPM

U
U
U mtot U m U mds U mPM mys myr H c hPM
2
2

The magnetic voltage over the permanent magnet is

H
U mPM c BPM hPM
Br

The permanent magnet flux density BPM is equal to the air-gap flux density
BPM Bmax

The magnetic voltage over the rotor yoke is according to the textbook
U myr cr H yr yr

yr
U myr

Dyr

Dr 2hPM hyr
2p
2p

cr H yr Dr hyr cr H yr hPM
2p
p

The total magnetic voltage

U mtot H c hPM

H
U mys

U me U mds c BPM hPM

cr H yr Dr hyr
cr H yr hPM
Br
2
4p
2p

from which we can solve the height of the permanent magnets

Ume Umds
hPM
Hc

hPM

0.0101

Umys

Hc
Br

4p

BPM

cr Hymaxr Dr hyr
cr Hymaxr

2p
1000 hPM 10.0665 mm

For more accuracy of the flux density calculation the PM height is substituted as a new valu
of iteration in Item 6.
The magnetic voltage of the permanent magnet
UmPM

Hc
Br

BPM hPM

UmPM

6.6523 10 A

The average diameter of the rotor yoke

Dyr Dr 2hPM hyr

Dyr

0.2640

 yr

Dyr

yr

2p

0.1037

The magnetic voltage of the rotor yoke

Umyr cr Hymaxr yr

Umyr

10.4011

15. Outer stator diameter and inner rotor diameter

The outer stator diameter is

Dse Dys hys
Dse

0.4939

The inner rotor diameter is

Dri Dyr hyr

Dri

0.2282

16. Total magnetic voltage of the magnetic circuit

The total magnetic voltage is

Umtot Ume Umds UmPM
Umtot

8.0532 10

Umys

Umyr

All the dimensions of the motor have now been defined. Next, the resistances, inductances,
losses and other characteristics of the permanet magnet machine are calculated.
17. Stator resistance

The average length lav of a coil turn (Eq. (5.2))

lav

2l 2.4Wp p 0.1

lav

0.5938 m

where l is the length of the stator stack ( the real length) - p.256
The conductivity of copper wire in 100 degrees C (the temperature rise = 80 K) is
Cu

Cu20C

1 Cu

Cu

4.3685 10

The DC resistance of a phase winding

S/m

N lav

Cu a Scs

0.0233

18. Magnetizing inductance

The effective air gap

Ume Umds UmPM
ef

Umys

Umyr

Ume

ef

0.0117

The calculation of magnetizing inductance in d-direction of the two-axis model, Eq. (3.110)
Lmd

m 2
1 4 p
2
0 l

k w 1 N
2
2 p ef

Lmd

6.8291 10

Lmq

6.8291 10

As the machine is symmetrical in this case,

Lmq Lmd

otherwise the q-axis effective air gap should first be evaluated.

19. Air-gap leakage inductance and reactance

Leakage factor, Eq. (4.18)

k
w
k w1
1

Pitch factor, Eq. (2.32)

Distribution factor, Eq. (2.24)

kp sin
2
p

p 2
Q

k d

0.5236

sinq u / 2
qsin u / 2

Eq. (2.2)

The air-gap leakage is calculated in two parts for 600 harmonics

sin 1 2 k m q

sin 1 2 k m Wp 2

q sin 1 2 k m u

300
2

k 1

1 2 k m kw1

k 1

sin 1 2 k m q

sin 1 2 k m Wp 2

q sin 1 2 k m u

300
2

k 12

1 2 k m kw1

k 1

k 1

0.0105

k 12

0.0135

Thus, the air-gap leakage factor is

s k 1 k 12

0.0240

The air-gap leakage inductance

L s Lmd

1.6384 10

and the air-gap leakage reactance

X L 2 f

0.0172

20. Slot leakage inductance and reactance

1 Wp

16
3
k 2 1
4
k 1

u k 1

Lu

4m

Xu

0.1667

Eq. (4.51)

k1

0.9063

Eq. (4.53)

k2

0.8750

2b is h

3 bs
2

0 l N u

2 f Lu

bis

k 2

bs

hw
bw b1

bw h

b 1 4 bs

ln

Lu

2.3865 10

Xu

0.2499

Eq. (4.30)

1.9662

Eq. (4.49)

21. Tooth tip leakage inductance and reactance

5
d k 2

b1

5 4
Ld
Xd

4m
Q

Eq. (4.62)

0.3961

b1

0 l d N

2 f Ld

Ld

4.8082 10

Xd

0.0504

23. End winding leakage inductance and reactance

The average length lw of the end winding (See Fig. 4.15)

zQ

zQ

q2

leW

WeW

lew

0.025 m

W ew lw 2lew

lw
W ew

lav

0.1269

lw

0.1769

l is the length of the machine stack which includes the cooling ducts.

The permeance factors are selected according to Table 4.2. (When we select the end windin
permeance factor, a permanent magnet machine may be regarded as a salient-pole machine.)
lew
W

0.518
0.138

2 lew lew Wew W

lw

0.2454

The end winding leakage inductance, Eq. (4.64)

4m

Lw

Xw

q N 0 lw w

2 f Lw

Lw

8.5545 10

Xw

0.0896

23. Synchronous inductance and reactance

The stator leakage inductance, Eq. (4.7)

Ls L Lu Ld Lw

Ls

3.8866 10

Xs

0.4070

and the leakage reactance

Xs

2 f Ls

The direct-axis synchronous inductance, (See Item 18)

Ld Lmd Ls

Ld

1.0716 10

Xd

1.1222

and the reactance

Xd

2 f Ld

Because there is no saliency in the rotor, the quadrature-axis synchronous

inductance is equal to the direct-axis synchronous inductance
3

Lq Ld

Lq

1.0716 10

Xq Xd

Xq

1.1222

24. Losses (except stator resistive losses)

To calculate the core losses, we need the masses of different iron parts.
Bys
f

1.3000

166.6680

Vs/m2
Hz

The total volume of the stator is

Vs

Dse Ds

l nvs bvs

Vs

0.0131

m3

The volume of the stator yoke

Dse 2

Vys

2

Dse

hys

l nvs b vs

Vys

6.1913 10

m3

mys

45.6419

kg

The mass of the stator yoke

mys Vys k Fe Fe

The total volume of the stator slots

Vslots Q Sslot l nvs b vs

Vslots

2.4313 10

m3

The total volume of the wedges in the stator slots

Vwedges Q

bs bw hw
2

l nvs b vs

Vwedges

1.7164 10

m3

The volume of the teeth

Vds Vs Vys Vslots Vwedges

Vds

4.3551 10

m3

mds

32.1057

kg

The total mass of the teeth

mds Vds k Fe Fe

Masses of different parts along the tooth height

Ds 2hd

b s min b d ld
Q

l n b
md k Fe Fe Q
vs vs
2
Correction coefficients for the core loss calculations, Table 3.2
k Fed

k Fey

1.5

The core loss in the stator yoke is according to Eqs. (3.69 and 3.77)
3
2

2
Bys
f
mys
1.5
50

PFeys k Fey P15

PFeys

2.0655 10 W

The core loss of the tooth area is calculated using the mass md defined above

 Bd

1.5

PFeds k Fed P15 md

50

3
2

PFeds

3.0527 10 W

The total iron losses are

PFe PFeys PFeds

PFe

5.1182 10

Mechanical losses consisting of windage and ventilator losses are calculated from
an experimental equation (Eq. (9.19) and Table 9.2)

P k Dr (l 0.6 p ) r2
vr n Dr
k

m/s

41.8882

vr

Ws2/m4

10

P k Dr l

0.6 p vr2

1.1014 10

The stator slot openings cause permeance harmonic losses in the rotor surface permanent
magnets.
The slot openings b1 cause a frequency fPM on the rotor surface
fPM n Q
fPM

2.0000 10

Hz

The fictitious air gap for the loss calculation is

PMEC

hPM

2rec

b e b 1

be

4.7022 10

6.4190 10
m

See Item 14

k CPM

PMEC

u be

k CPM

1.0227

b1
b1

2 PMEC
2 PMEC
1 u2 2u

2 1 u2

Eq. (3.10)

1.1909

7.5334 10

B0 Bmax

B0

6.5340 10

fPM 2 rec 0

fPM 2

1
a R

S /m

74.3325

300.0000
4

4
k k

2
a R

2
u B0 k
aR
PPMEC
1 Dr PM l
2l 0 rec PM
2
PPMEC

670000

PM

Dr n

PM

4.0435

2 k

71.6798

The calculation assumed bulky magnets of one piece each. The losses are large and
therefore the magnets should maybe be made of pieces to minimize the losses.
There are also some additional losses in the machine.
Let us assume that they are 0.5 % of the output power
Pex

0.005 P

Pex

800.0000

25. Rated load, stator current, stator resistive losses and total losses

The stator current should be known in the loss calculation. The final value of the current
must be iterated.
The old stator current
Is

147.1190

The stator current iteration:

We give a new iteration value for the stator current
Is

144

The stator resistive losses (Item 17)

PCu

3 Is2 R

PCu

1.4485 10

The sum of losses in the machine

Ploss PFe PCu P PPMEC Pex

Ploss

8.5397 10 W

Input power
Pin P Ploss

Pin

1.6854 10

According to Eq. (7.214)

U E
2 Ld Lq
Pin 3 sph PM sin U sph
sin 2

L
2s Ld Lq
s d

Initial guess for the new load angle is the previous load angle
loadin

Given

Usph EPM

Pin = 3

Xd

2 Xd Xq

sin loadin Usph

2 Xd Xq

sin

loadin

Thus, the load angle is

loadinN Find loadin

loadinN

The machine runs at a load angle of

0.4085rad

deltaN

23.4060

deltaN loadinN

180

degrees

The direct-axis component of the stator current

U
Id

Xq cos loadinN R sin loadinN

Xd Xq R

EPM Xq
Id 32.1248

The quadrature-axis component of the stator current

U
Iq

R cos loadinN Xd sin loadinN

Xd Xq R

EPM R
Iq

140.3573 A

The old stator current

Is

144.0000

The new stator current

2

Is

Id Iq

Is

143.9867

If Is differs more than 1 % from the estimated value, give the stator current a new
value and repeat the calculations of Item 25.
26. Efficiency and power factor

The efficiency of the machine is

P
Pin

100

94.9331

The power factor of the machine may be calculated as

cos

Pin

cos

3 U Is

0.9794

27. Masses of the active materials

The masses of the stator yoke mys and the teeth mds have been calculated above.
The rotor core outer diameter
Dryi Dr 2 hPM

Dryi

0.2999 m

The mass of the permanent magnets

mPM

Dryi Dr

PM l nvr b vr hPM PM

mPM

7.0571

kg

mCu

46.6376

kg

The mass of the copper

mCu Cu l 2 lw Q zQ Scs

The mass of the rotor yoke

myr k Fe

Dryi Dri

2
l Fe

myr

26.3054

kg

mtot

157.7478

kg

The total mass of the active parts is

mtot myr mys mds mCu mPM

28. Load angle equation graph

Depending on the machine type (motor or generator) the user have to choose
the corresponding load angle equation graph:

T = f (load) - for the motor

P = f (load) - for the generator
The output power at the rated point is
Pout P

Pout

1.6000 10

Neglecting losses, the load angle equation is

i

0 100

load i

100
2
EPM Usph

Usph 1
1

P load m
sin load

sin
2

load
2 Xq Xd
Xd

4.2427 10

max P load

max P load
Pout

2.6517

Maximum power

Peak power per rated power

Load characteristic

Power (W)

P load

4.510
5
4.12510
5
3.7510
5
3.37510
5
310
5
2.62510
5
2.2510
5
1.87510
5
1.510
5
1.12510
4
7.510
4
3.7510
0

0.314 0.628 0.942 1.257 1.571 1.885 2.199 2.513 2.827 3.142
load
Load angle (rad)

28. Load angle equation graph

The output torque at the rated point is

Tsh

Pout

Tsh

2 n

611.1501

Nm

Neglecting losses, the load angle equation is

i

0 100

load i
i

100

3 p
T load
2 f

2
EPM Usph

Usph 1
1

sin load

sin
2

load
2 Xq Xd
Xd

1.6206 10

max T load

max T load
Tsh

2.6517

Nm

Maximum torque

Peak torque per rated torque

Load characteristic

Torque (Nm)

T load

1.810
3
1.6510
3
1.510
3
1.3510
3
1.210
3
1.0510
900
750
600
450
300
150
0

0.314 0.628 0.942 1.257 1.571 1.885 2.199 2.513 2.827 3.142
load
Load angle (rad)