M a rc h 2 6 -2 9

Design and Analysis of A New Outer-Rotor Permanent-

Magnet Flux-Switching Machine for Electric Vehicle
Propulsion
Jian-Xin Shen, Yu Wang, and Cai-Fei Wang
College of Electrical Engineering, Zhejiang University, Hangzhou, 310027, China
E-mail: [email protected]

Wei-Zhong Fei, and Patrick Chi-Kwang Luk

Power and Drive Systems Group, Department of Engineering Systems and Management
Defence College of Management and Technology, Cranfield University
Shrivenham, Wiltshire, SN6 8LA, United Kingdom
E-mail: [email protected]

Copyright © 2009 MC2D & MITI

Abstract: Permanent-magnet flux-switching (PMFS) machine is a novel doubly-salient machine

which merges the advantages of both switched reluctance and permanent-magnet synchronous
machines. The inherent merits such as simple structure, high torque density and high efficiency
underpin PMFS machine as a potential contender for electric vehicle (EV) propulsion. However, to
date, only the inner-rotor PMFS machines are widely investigated and analyzed, whilst the outer-rotor
PMFS machines have hardly been addressed yet. For the most common configuration of direct drive
motor, an in-wheel outer-rotor PMSF machine is proposed in this paper. The topology and operation
principle of the outer-rotor configuration are introduced, and then the sizing equations are derived for
the preliminary dimensions of the machine. Sequentially, a 3-phase 12/22-pole in-wheel outer-rotor
PMFS machine for direct vehicle drive is designed and verified by finite element analysis (FEA).
Furthermore, some techniques are employed to improve and optimize the machine performance, and
the validity of the proposed techniques is demonstrated by comprehensive FEA results. Finally, based
on the transient two-dimensional (2-D) FEA, the machine losses are computed and deduced, and the
machine performance has been revealed.

Keywords: Outer-rotor permanent-magnet flux-switching machines, electric vehicle propulsion, in-

wheel direct drive, finite element analysis.

1. Introduction direct drive EVs which are propelled by in-

wheel or wheel electric machines without
Due to drastic issues on the protection of the differential gears have drawn significant
environment and the shortage of fossil fuels, attention in both industry and academic
political and public pressures helped a lot to researches. Direct drive propulsion systems can
develop practical and efficient electric vehicles enjoy their implicit benefits such as high
(EVs) during this decade. It is fully convinced efficiencies, free maintenances and low noise
that the zero-emission electric vehicles will be productions in virtue of the absence of
rapidly exposed on and dominate the future mechanical gears. Prominent features such as
automotive market. The propulsion system has high torque density, excellent efficiency and
been one of the most essential parts in EV, terrific overload capability make permanent-
magnet (PM) brushless machine become the a 12/22-pole 3-phase in-wheel outer-rotor
cogent candidate for direct drive propulsion. PMFS machine is designed, and furthermore,
The permanent-magnet flux-switching (PMFS) validated and optimized by FEA. The predicted
machine is a novel doubly-salient PM brushless outstanding performance implies that the
machine, having both windings and magnets in proposed machine is a leading contender for
the stator. The rotor is only a salient passive direct EV drives.
rotor and can be robust and fabricated at an easy
rate exactly same as a switched reluctance (SR) 2. Topology and Operation Principle
machine. Consequently, the machine inherits
the advantages of both SR machine and PM A Topology
synchronous machine. Single phase PMFS Figure 1 (a) shows the cross-section of a typical
machines are studied and developed as 12/22-pole, 3-phase outer-rotor PMFS machine.
alternators in airborne application [1], motors As shown in the figure, the machine is
for low energy axial fans [2] and high speed composed of an inner stator that includes stator
applications [3], whilst the most familiar 3- steel laminations, permanent magnets and
phase 12/10-pole PMFS machine was first armature coils, and an outer salient passive rotor
described in [4]-[6], and further detailed which is exactly the same as conventional SR
investigations on this machine structure were machine, simply constructed by stacked soft
carried out in [7]-[15]. All the aforementioned magnet steel sheets. Additionally, the
literatures have revealed that the machine has concentrated windings, same as SR machine as
some distinct attributes of high torque density, well, are employed, which result in less copper
high efficiency, excellent flux-weakening consumption, high winding fill factor and lower
capability [16] and convenience of cooling, copper Joule loss because of the short end
which are the exact stringent requirements of windings. Compared to the conventional outer-
EV drive. When compared to conventional PM rotor PM brushless machines having the
machine, due to the peculiar locations of the magnets on the rotor, the magnets are inset in
permanent magnets, the PMFS machine exhibits the middle of the stator poles, which separate
the following advantages [9]: easier to dissipate the machine stator yoke. Since the magnets and
heat from the stator and therefore, to limit the coils are all placed in the stator, the major heat
temperature rise of the magnets; the influence of from the machine operation can be easily
the armature reaction field on the working point removed from the stator by various cooling
of the magnets is almost negligible since the methods, which is desirable for the EV
windings and the magnets are effectively applications where the ambient temperature of
magnetically in parallel. Consequently, the the machine may be high. Moreover, the
magnets demagnetization hazards owing to over number of pole-pairs in the PMFS machine is
load drive or over temperature are essentially the same as the number of rotor teeth, hence, it
prevented. Additionally, an innovative hybrid is easy to achieve a high number of pole-pairs
excitation flux-switching machine based on 3- by employing sufficient rotor teeth. This is
phase 12/10-pole structure was presented in important for EV propulsion motors which
[17]. Moreover, 3-phase 6/4 and 6/5-pole PMFS usually require high torque and low speed.
machines for high speed operation were In order to reach sufficient winding area in the
investigated in [18], [19]. outer-rotor PMFS machine, the machine main
Compared with the conventional inner-rotor dimension configuration is proposed as
machine, outer-rotor machine is intrinsically
βr=βs=hpm=hslot/5, as shown in Figure 1 (b),
suitable for direct drive of EV as a result of its
instead of βr=βs=hpm=hslot in conventional inner-
low-speed, high-torque features. So far, only the
rotor PMFS machines [4]. Consequently, an
inner-rotor PMFS machines are focused in both
adjustment of the main parameter relations to
academic researches and industry applications.
define a polyphased structure must be
The purpose of this paper is to propose and
undertaken and can be demonstrated as follows:
⎛ n ⎞
analyze a new outer-rotor PMFS machine
Nr = Ns ⎜ 2 ± ⎟
⎝ q⎠
structure especially for EVs. Firstly, the (1)
topology and operation principle of the outer- 2
rotor PMFS machine are introduced, and the where Nr and Ns are machine rotor and stator
stator and rotor pole number relations defining pole numbers, respectively, q is the number of
machine phase configuration are delivered. machine phases, and n is a natural number. The
Secondly, the sizing equations are achieved to relation between the machine mechanical
provide simple and sufficient mean for rotation frequency F and the electrical
machine’s initial dimensions derivation. Finally, frequency f can be expressed as
 Figure 2: Operation principle of outer-rotor PMFS
machine, (a) Position-a, (b) Position-b.

Figure 1: Topology of a 12/22-pole three-phase

outer-rotor PMFS machine, (a) Cross-section. (b)
Main dimension.

f = NrF (2)
By virtue of peculiar structure and zero resultant
radial stress of the machine, both Nr and Ns
should be even numbers. For instance, Figure 1
(a) presents a 3-phase machine with q=3, Ns=12,
Nr=22, and n=1. Figure 3: Four typical rotor positions of 12/22-pole
three-phase outer-rotor PMFS machine with open-
B Operation principle circuit field distributions, (a) θr=0o, (b) θr=4.09o, (c)
θr=8.18o, (d) θr=12.27o.
The concept of PMFS machine was firstly
introduced and investigated in [1]. The
operation principle of the outer-rotor PMFS to the respective stator teeth belonging to Phase-
machine is illustrated as Figure 2. The PM- A. In accordance with the polarity of the magnet
excited flux always exists and has a constant inset, the fluxes go into the corresponding stator
direction in the magnets. In Figure 2 (a), the teeth. Thus, the PM flux-linkage of Phase-A
rotor pole aligns with one of two stator teeth reaches the positive maximum when the flux
which are embraced by a concentrated winding going into the stator teeth is defined as positive.
coil and the PM flux which is linked in the coil When the machine keeps rotating to θr=4.09o
goes out of the coil and into the rotor pole. anti-clockwise, Figure 3 (b), two of the rotor
When the rotor moves to the left, the rotor pole poles leave the corresponding stator poles
leaves the current stator pole and aligns with the belonging to Phase-A, and other two of them
next stator tooth which belongs to the same coil, align with the magnets in the rest of Phase-A
as shown in Figure 2 (b), thus, the PM flux stator poles. Therefore, the PM flux-linkage of
linked goes out of the rotor pole and into the Phase-A reduces to zero. Likewise, as depicted
stator coil. As a result, both magnitudes and in Figure 3 (c), the PM flux-linkage of Phase-A
polarities of the flux-linkage in the windings increases to the maximum again when rotor
will vary periodically along with the rotor reaches θr=8.18o. However, the polarity changes
moves. to negative since the fluxes go out of the stator
Figure 3 shows four typical rotor position of the teeth. Similar to Figure 3 (b), in the case of
12/22-pole outer-rotor PMFS machine (shown θr=12.27o shown as Figure 3 (d), the PM flux-
as Figure 1 (a)) with open-circuit flux linkage of Phase-A reduces to zero again. If the
distribution. θr=0o is defined at the position in machine keeps rotating 4.09o forward, the rotor
Figure 3 (a) where rotor poles are fully opposite will return to the initial position as illustrated in
Figure 3 (a) to accomplish one electric cycle, or, Machines with 5kW output at 1000rpm rated
1/22 mechanical cycle. It can be noticed from speed, which are especially suitable for urban
the foregoing analysis that the phase PM flux- vehicle propulsion, have been attracting
linkage in the outer-rotor PMFS machine is tremendous attentions from both academics and
bipolar, which brings the machine outstanding industry. Since the machine is designed with
performance. three phases, the most common stator pole
number 12 can be used. Higher stator pole
numbers, which are not considered in this paper,
3. Machine Modelling and Design
are usually accompanied by higher rotor pole
A Analytical Sizing Equations number that can cause higher eddy current
losses and increase the assembly complexity. In
Analytical sizing equations are usually helpful this paper, a 3-phase 12/22-pole structure
and necessary during the preliminary stage of machine is designed and optimized for certain
machine design, which can significantly application. The basic machine dimensions,
improve the machine design efficiency so as to which is demonstrated in Table 1, can be
gain the valuable competition time which is conveniently derived from equations (3) to (6)
exceptionally important in industry. For outer- by substituting Tem=50N.m, Nr=22, Ns=10,
rotor PMFS machine, the sizing equations can Kd=0.75, Kp=50%, Bg=2.0T, Jpeak=7.5A/mm2,
be derived as follows. When the stator outer l=50mm, and g=0.6mm into the equations.
radius Rso is given, the stator tooth width βs,
stator magnet thickness hpm, backiron thickness
hb and slot opening width hslot can be given as Table 1: machine parameters.
follows: Symbol Machine Parameter Value Unit
h π R so (3) Number of Stator
β s = h pm = hb = slot = Ns 12
5 4Ns Poles
Then, the area of one stator slot would be Nr Number of Rotor
22
5π π Poles
As = R so2 sin 2 tan (4) Number of Phases
8Ns Ns q 3
Number of Winding
The electromagnetic torque Tem can be obtained as Ncoil 7
Turns per Coil
follows:
NdFe
π 5π PM PM Material
N r K d K p B g J peak R so3 l sin 2 B35
16 8N s (5) Kp Winding Packing 50%
Tem =
π Factor
tan
Ns Rsi Stator Inner Radius 22.9 mm
where Kd and Kp are the leakage and winding Rso Stator Outer Radius 75 mm
packing factors respectively, Bg is the peak Ro Rotor Outer Radius 94.8 mm
airgap flux density at no load condition, Jpeak is g Air Gag 0.6 mm
the peak current density of the coils, and l is the hpr Rotor Pole Height 9.4 mm
active length of the machine. The leakage factor βs Stator Tooth Width 3.8 deg
in outer-rotor machine is far bigger compared hpm PM Width 3.8 deg
with the one in conventional inner-rotor βr Rotor tooth Width 4.9 deg
hps Stator Tooth Width 47.2 mm
machine due to its large slot opening. Inspecting
Machine Active
equation (5), the machine torque output is l
Axial Length
50 mm
proportional to Rso3. Rso and l can be analytically Rated Peak Current A/
gained from equation (5) during the preliminary Jpeak 7.5
Density mm2
design stage. In addition, the rotor pole height Udc DC-Link Voltage 42 V
hpr is chosen as 1/8 stator outer radius Rso and n Rated Speed 1000 rpm
rotor yoke thickness hyr is designed as twice the Pem Rated Output Power 5.2 kW
stator back iron thickness hb for the sake of Tem Rated Output Torque 50 Nm
vibration alleviation. Hence, the machine radial Rated Peak Phase
Ipeak 152 A
dimension can be expressed as Current
9 R so π R so (6) Phase PM Flux
Ro = +g+ Ψpm Linkage
10.2 mWb
8 2Ns
Ld d-axis Inductance 62.7 µH
where Ro is the rotor outer radius, and g is the
machine airgap. Lq q-axis Inductance 72.0 µH
Phase Resistance
Rph 11.1 mΩ
B Machine Optimization (100 oC)
Comprehensive FEA are employed to validate From the FEA results as shown in Figure 4, the
the analytical sizing equations, determine the discrepancy between dq- axes permeance
rest machine parameters, and optimize the declines while the rotor pole width increases, as
machine performance. It can be facilely noticed a result of machine saliency attenuation. And,
from the FEA results that the back-EMFs of the the phase PM flux reaches its maximum when
proposed machine are essentially sinusoidal, the rotor pole width approaches 1.4. The
which implies that the presented machine is maximum electromagnetic torque and
congenitally suitable for BLAC operation. corresponding reluctance component at certain
Consequently, the machine performance can be current density can be deduced from equations
analyzed based on dq-coordinates, and the (7) and (8). Figure 5 shows the variations of
machine electromagnetic torque can be electromagnetic and reluctance torque with
expressed as rotor pole width at rated current density, which
qN r K p2 As2 are calculated based on the FEA results in
Tem =
8
(φ pm )
+ (Λ d − Λ q ) J d J q (7)
Figure 4. Compared to the total electromagnetic
where φpm is the phase PM flux per turn, Λd and torque, the reluctance component is exiguous
Λq are the dq- axes permeance per turn, and Jd even negligible, and meanwhile it diminishes
and Jq are the dq-axes current density, along with the machine rotor pole width
respectively, which are restricted by escalation and saliency lessening. Furthermore,
(8) the electromagnetic torque which the machine
J d2 + J q2 = J peak
2
could generate at rated current density,
Machines with various rotor pole width βr are resembling the phase PM flux, achieves the
studied to optimize the machine back-EMF maximum with the rotor pole width 1.4.
waveform [11]. In this paper, the rotor pole Sequentially, the induced voltage (phase back-
width is also employed to optimize the machine EMF) obtained for each particular rotor pole
performance. It should be perceived that the width is analyzed and the belt (nontriplen)
rotor pole width after-mentioned is the harmonic distortion (BHD%) in the phase back-
normalized value βr/βs. Based on FEA, the EMF is determined. There are only belt
phase PM flux per turn can be directly derived harmonics existing in the line-line back-EMF
from open circuit field analysis and the dq-axes since the triplen harmonics are eradicated
permeance per turn can be calculated by the internally in the 3-phase machine, and the belt
simplified two position method [13]. harmonics bring the machine torque ripple that

0.0015 1.5 3.5 4.5%

Fundamental
BHD
Permeance (mWbA )
-1

1.4 3.3 3.0%

Flux (mWb)

EMF(V)

BHD%
0.0013

d-axis permeance 1.3 3.1 1.5%

q-axis permeance
PM flux
Rotor Pole Width Rotor Pole Width
0.0011 1.2 2.9 0.0%
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Figure 4: Variations of dq axes permeance per turn Figure 6: Variations of fundamental amplitude of
and phase PM flux per turn with rotor pole width. phase back-EMF and belt harmonics with rotor
pole width.
12
52 1.2
Reluctance Torque (N.m)
Electromagnetic Torque

Cogging Torque (N.m)

8
49 0.8
(N.m)

Electromagnetic Torque
4
46 Reluctance Torque 0.4

R otor Pole Width

Rotor Pole Width
0
43 0
1 1.2 1.4 1.6 1.8 2
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2
Figure 5: Variations of electromagnetic/reluctance Figure 7: Variation of peak-to-peak cogging torque
torque with rotor pole width at rated current density. with rotor pole width.
would cause mechanical vibration. The 4. Machine Losses Analysis
fundamental amplitude of the phase back-EMF
and BHD% for different rotor pole width are Machine losses are a complex function of speed
illustrated in Figure 6. Similar to the phase PM and load. Electromagnetic losses dominate the
flux and electromagnetic torque, the total losses in low speed machines,
fundamental amplitude of the phase back-EMF consequently, this paper is only concentrated on
accomplishes its maximum when the rotor pole the analysis of electromagnetic losses.
width is 1.4. However, BHD% accesses Electromagnetic losses can be broken down into
minimum with rotor pole width 1.3. Moreover, three distinct parts, copper loss in the machine
cogging torque, arising from the magnet’s coils, core losses in the stator and rotor
tendency to align itself with the minimum laminations, and eddy current losses in the
reluctance path given by the relative position permanent magnets. The motor coil copper loss
between rotor and stator, is a parasitic source of can be computed from the estimated phase
mechanical vibration and noise which degrade resistance and the torque-current profile of the
machine performance, especially at low speed. machine from the FEA static analysis. The
It also causes startup hesitation for the motor, estimated resistance of one phase of the
which is particularly undesirable for traction machine at 100 oC is 11.1 mΩ. Using the
applications. The peak-to-peak cogging torque predicted current densities required to achieve
variation with different rotor pole width is different torque values, the copper losses for
investigated, as shown in Figure 7. The lowest different load conditions are given in Table 2.
cogging torque is located at where the rotor pole Transient FEA can be used to calculate the core
width is 1.2. losses in electrical steel laminations considering
the harmonics. At a given frequency, the core
C Machine Parameters losses for electrical steel is
2 1.5
According to the previous analysis, a rotor pole 2
Pc = K h Bmax f + K c ( Bmax f ) + K e ( Bmax f ) (11)
width 1.3 is chosen to achieve the optimal where Kh, Kc, and Ke are hysteresis loss, classic
machine performance. So far only the winding eddy current loss, and excess or anomalous
turns per coil Ncoil is still unknown, which can eddy current loss coefficients, respectively,
be calculated by the equations in [12]. The PM which are all information of the material from
flux-linkage ψpm and dq-axes inductances Ld/Lq manufacturer. Bmax is the maximum amplitude
can be derived by of flux density. Figure 9 shows the sensitivity of
2
ψ pm = N coilφ pm , Ld = N coil 2
Λ d , Lq = N coil Λ q (9) the overall lamination core losses to the
Furthermore, the phase resistance can be machine speed and load. Increasing the load of
evaluated by the machine, the armature current increases the
⎡⎛ ⎞ ⎤
⎢⎜ ⎟ R so + l ⎥
5π 2
sin
5π peak flux density in the lamination which leads
⎢⎜ ⎟ ⎥
2 8Ns 8 Ns
4NsN + 3π to higher core losses. The peak load condition
⎣⎝ ⎠ ⎦ (10)
coil π 4 Ns
sin
Ns will approximately double the core losses
R ph = ρ cu
qk p As compared to the no load condition. However,
The key parameters of the proposed machine the core losses will not be significant compared
are all included in Table 1, and the waveforms with copper loss or eddy current losses in PM.
of phase back-EMF and cogging torque versus The magnetic field in PM will vary when the
rotor mechanical position are both depicted in rotor rotates, since the sintered NdFeB35 has
Figure 8. conductivity of roughly 10% that of mild steel,
which can generate considerable eddy current
25 3 losses. Figure 10 shows that the eddy current
back-EMF Cogging Torque
losses in the PM of the proposed machine are
15 significant, which are nearly two times the
Cogging Torque (N.m)

1.5
copper loss under the rated load condition.
Reducing eddy current losses in PM is
Back-EMF (V)

5
0 important, not only because the magnets have
-5 0 4.09 8.18 12.27 16.36 a low maximum working temperature, but also

-1.5 Table 2: copper loss.

-15

Torque Phase Peak Current Loss

-25 Rotor Position (Degree) -3 25 N.m 76 A 96 W
50 N.m 152 A 383 W
Figure 8: Phase back-EMF and cogging torque
waveforms. 75 N.m 228 A 862 W
 80 principle are introduced comprehensively, and
75N.m
50N.m the machine sizing equations are developed for
60 preliminary design, which is validated by FEA.
Core Losses (W)
25N.m
0N.m A 5kW machine is designed based on the
40 analytical model and moreover, FEA is
employed to optimize the machine
20 performance and predict the electromagnetic
losses. It is concluded that the machine
0 possesses several distinct advantages that
0 250 500 750 1000 underpin the machine as a leading candidate
Rotor Speed (rpm)
Figure 9: Core losses in stator and rotor laminations. for EV application, even though the machine
efficiency is not as good as desired.
1000
On the other hand, minimization techniques of
PM Eddy Current Losses (W)

75N.m
50N.m the eddy current losses in permanent magnets
750 25N.m
0N.m as well as the copper loss in winding coils will
be investigated in future works.
500

250
Acknowledgement
0
This work was supported by National Natural
0 250 500 750 1000 Science Foundation of China (NSFC, 50677061) and
Rotor Speed (rpm) Qianjiang Professionals Program of Zhejiang
Figure 10: Eddy current losses in permanent Province (2006R10014). The work was also carried
magnets. out under the collaboration MOU between Zhejiang
University and Cranfield University.
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notably condensed as their temperature
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