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| Cogging Torque Suppression of Interior Permanent Magnet Synchronous Motor Based on Air-Gap Magnetic Field Reconstruction |
| Ma Jiyuan1, Zeng Yu1, Zhao Wenxiang2, Ji Jinghua1, Yuan Dongyang1 |
1. School of Electrical and Information Engineering Jiangsu University Zhenjiang 212013 China;
2. School of Electric Power Engineering Nanjing Institute of Technology Nanjing 211167 China |
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Abstract The cogging torque of an interior permanent magnet synchronous motor (IPMSM) is related to its structural parameters. Cogging torque induces torque ripple, vibration, and noise under load conditions. The structural design of low cogging torque in IPMSMs has become a focus of research. Precise prediction of the air-gap magnetic field is crucial for evaluating the rationalization of motor design. However, due to the complex rotor structure and uneven core magnetic saturation, accurately predicting the air-gap magnetic field in IPMSMs is a challenging task. This paper presents an enhanced analytical method that integrates magnetic field modulation with the magnetic equivalent circuit method. The speed and accuracy of magnetic field calculation are improved. Then, the rotor surface is notched to reduce specific harmonics in the air-gap magnetic field. The air-gap topology is created through notching on the rotor surface, which results in the reconstruction of the air-gap magnetic field and the suppression of cogging torque.
Firstly, according to the modulation theory, the modulation structure of the air-gap magnetic field is analyzed. A refined magnetic circuit model is developed for the motor's structure. Modulation consists of two aspects: the magnetic motive potential of the permanent magnets is modulated by the rotor bridge; the air-gap magnetic field is modulated through the stator slots. Secondly, the target 44th harmonic is separated from the original air-gap magnetic field to construct the target magnetic field. The modulation function transforms the modulation of the original magnetic field into the target magnetic field. The notch function is analyzed by the proposed magnetic equivalent circuit method. After the proposed notching, the model analyzes that the air-gap harmonics are the ideal harmonics. Finally, the modulation function feeds back on the notch function, which notches the rotor surface. The reconstructed air-gap magnetic field is achieved by optimizing the magnetic field harmonics on the rotor surface topology.
In terms of calculating results, the analysis and simulation waveforms are highly overlapping. The waveforms consist of the air-gap flux density distribution of the slotless stator, the slotted stator, and the air-gap reconstruction. For the torque performance, the original motor and the air-gap reconstruction motor are compared. The cogging torque of the air-gap reconstructed motor is reduced from 2.45 N∙m to 0.76 N∙m, which is a reduction of about 68.88%, and a slight increase in output torque from 10.79 N∙m to 11.07 N∙m. The torque ripple is considerably reduced, from 37.09% to 8.58%, under load conditions, specifically at 7.5 A and 700 r/min.
The following conclusions can be drawn. (1) With the refined magnetic circuit model and improved modulation analysis method, the modulation can be accurately characterized. Simultaneously, the air-gap magnetic field harmonics are calculated. (2) The harmonics of the air-gap magnetic field are effectively optimized by the method of notching on the rotor surface. The air-gap is reconstructed, and the target harmonic of the air-gap magnetic field is reduced. This method significantly reduces the cogging torque while maintaining the motor's output characteristics. Feasible solutions are offered in the field of industrial servo drives, aerospace, and other high-precision controls.
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Received: 14 October 2024
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2025, Vol. 40 
