416

IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 21, NO. 2, JUNE 2006

Design of High-Power Density and Relatively

High-Efficiency Flux-Switching Motor
John F. Bangura, Member, IEEE

AbstractA new class of electronically commutated brushless

motor, namely, the flux-switching (FS) motor is gradually emerging in power tools and household appliances. This motor offers
advantages of both high-power density and relatively high efficiency. There are a number of papers introducing this new class of
motor. However, almost all of these papers focused on the analysis, and not the design, of the FS motor. Thus, this paper presents
the design and analysis of the FS motor. Design equations are analytically derived for initial calculations of the main dimensions,
number of turns, and inductances of the FS motor. Furthermore,
a comprehensive time-stepping finite element (TSFE)-behavioral
model is developed and utilized for detailed analysis and design
refinements of a prototype 8/4-pole FS motor. Finally, test results
of the prototype motor are provided to verify the design equations
and efficacy of the design methodology.
Index TermsAnalogue behavioral model, brushless ac,
CSPICE, electronically commutated motors, finite element, fluxswitching (FS) motor, high-power density, power electronic converter, spice, time-stepping.

I. INTRODUCTION
OST power tools and household appliances use universal motors (UMs) that can deliver high torque and/or
variable speed. However, these motors have poor efficiency and
relatively short lifetimes. On the other hand, induction motors
(IMs) are often used in power tool machinery applications and
household appliances requiring silent operation, long life, and
high safety levels. However, these motors have relatively low
power density. Thus, electronically commutated brushless motors are becoming increasingly more attractive and viable due
to the rapidly falling cost of electronic control solutions.
Recently, a new class of motor termed the flux-switching
(FS) motor has been introduced [1][3]. The FS motor can offer the advantages of both high-power density and relative high
efficiency in a smaller and lighter package. The FS motor incorporates the features of a conventional switched reluctance (SR)
machine [4][6] and a conventional dc machine. Thus, the FS
motor has a simple double salient construction and retains the
apparent features of mechanical robustness, high speed, high
torque, high power density, and relatively high efficiency. However, almost all of these papers [1][3] on the FS motor focused
on the analysis, and not on the design and related aspects that
are crucial to designing this type of motor. The analysis reported in these papers cannot help design engineers initiate the
design process. In addition, these papers analyzed specific de-

Manuscript received September 30, 2005; revised September 30, 2005. Paper
no. TEC-00198-2005.
The author is with Pacific Scientific-Electro Kinetics Aerospace Division,
Danaher Corporation, Santa Barbara, CA 93013 USA.
Digital Object Identifier 10.1109/TEC.2006.874243

signs and the machine dimensions, mainly the diameters and

stack lengths, of the designs were known parameters. As a matter of fact, the initial calculation of the motor dimensions and
parameters, such as the core diameter, stack length, number of
turns, and inductance values is considered crucial to the design
process. Furthermore, a model that incorporated a time-stepping
finite element (TSFE) approach was applied in demonstrating
the viability of the FS motor for automotive applications [3].
However, the effects of armature reaction and mutual coupling
were not taken into account in the model. The FS motor has
a highly nonlinear magnetic circuit and the mutual coupling is
required to develop useful electromagnetic power; thus, the assumptions adopted in [3] are considered gross and leaves much
to be desired.
Therefore, the main objective of this paper is to first present
the design details of the FS motor, thus providing the design
engineer a practical way to make initial calculations of the main
dimensions and parameters. Second, to present a robust and
easy to implement in commonly available circuit simulators,
such as PSPICE, CSPICE, Saber, SIMPORER, etc., behavioral
modeling approach that can be readily integrated with a finite
element algorithm, thus providing the design engineer a means
to readily perform detailed design analysis and refinements.
This in turn promises a more comprehensive exploration of design alternatives and a better performing final design. The finite
element behavioral model developed in this paper sufficiently
accounts for magnetic saturation, significant space harmonics
due to the physical design and nature of the motor, as well as
time harmonics due to the converter switching. The model is
extensively utilized to: 1) refine the prototype motor design
and calculate its performance characteristics; 2) size the power
electronics components of the controller; and 3) account for
the interactions between the effects of magnetic saturation and
power electronic switching. Finally, the validity and efficacy of
the design equations are confirmed by comparing parameters
calculated using these equations with those obtained from the
finite element behavioral model, which in turn is adequately
validated by comparing its results with those obtained from tests.
II. THEORY
A. FS Motor Topology
Fig. 1 is shows the prototype FS motor topology with eight
stator poles (teeth) and four rotor poles. It has a double salient
structure similar to SR machine. It comprises a fully pitched field
winding, labeled F, that carries unipolar (dc) current, and a fully
pitched armature winding, labeled A, that carries ac. The field
winding can be connected in series or shunt for dc excitation
with the armature winding that is electronically controlled for ac

0885-8969/$20.00 2006 IEEE

BANGURA: DESIGN OF HIGH-POWER DENSITY AND RELATIVELY HIGH-EFFICIENCY FS MOTOR

Fig. 1.

An 8/4 FS motor topology.

Fig. 2.

FS motor and power electronic controller schematic.

417

excitation. Thus, the FS motor operates on the interaction of dc

and ac magnetic fields. Unlike the series connection, the shunt
connection facilitates independent control of the field-winding
current. However, in this paper, the focus is on the design of a
series-connected FS motor. Meanwhile, Fig. 2 shows the motor
and its power electronics controller for a series-connected FS
motor drive system [6]. The field and armature windings are
connected to the power electronics controller such that dc and ac
excitations are provided to the field and armature, respectively.
B. Principle of Operation
The FS motor operates on the resultant flux vectors due to the
interaction between the ac and dc magnetic fields produced by
the currents in the armature and field windings. The resultant
flux vectors are directed along the axes centered through the
stator poles. Fig. 3(a) shows the rotor at a location r = 22.5 ,
with respect to the reference rotor position, r = 0 , as indicated
in Fig. 1. The field winding is excited with a unipolar current
that creates flux vectors that are directed along the centers of the
armature slots. Meanwhile, the armature winding is excited with
a positive current that creates flux vectors that are directed along
the centers of the field slots. Therefore, the resultant flux vectors
are directed along the centers of the stator poles, and this will
subsequently cause the rotor poles to align with the stator poles
as shown in Fig. 3(b). This is because, like all motors with double

Fig. 3.

Flux patterns for armature- and field-winding excitations.

salient construction, the torque is developed by the tendency of

the rotor poles to align with the stator poles at positions of
minimum reluctance when the magnetic circuit is energized. As
the rotor continues to rotate, the field and armature windings are
excited in the same direction as shown in Fig. 3(c) and (d). Thus,
the resultant flux vectors are directed along the same stator poles.
However, as the rotor approaches the next alignment position
shown in Fig. 3(e), the armature-winding excitation is reversed
while the field-winding excitation is maintained in the same
direction. As a result, the directions of the field flux vectors
are unchanged and those of the armature flux vectors are now
shifted by 180 electrical degrees. The resultant flux vectors have
now switched between the sets of adjacent stator poles linked

418

IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 21, NO. 2, JUNE 2006

Fig. 5.

Fig. 4. Idealized winding inductance (self and mutual) and current waveforms.

by the field winding. Consequently, the rotor poles will align

with these stator poles to maximize the flux. This process of
sequential commutation of the armature current repeats once the
rotor rotates past the position shown in Fig. 3(f). Therefore, the
reversal of current direction in the armature winding causes
the resultant stator flux vectors to switch between the adjacent
stator poles linked by the field winding; hence, the name FS
machine. These resultant stator flux vectors do not rotate but
rather oscillate between the adjacent stator poles linked by the
field winding. However, with the proper sequential commutation
of the armature current with respect to the rotor angular position,
the rotation of the rotor can be maintained.
C. Idealized Winding Self- and Mutual Inductances
In the following discussion, it is assumed that the ideal inductances shown in Fig. 4 vary linearly with rotor position. As
the rotor rotates from the aligned position to the position shown
in Fig. 3(c), the self-inductances of the armature and field windings decrease linearly to a minimum value due to the increase in
the reluctance. This value corresponds to the point at which the
leading edges of the rotor poles just begin to overlap with the
stator poles. However, as the rotor continues to rotate, the selfinductances remain fairly constant until the trailing edges of the
rotor poles just begin to leave the stator poles. This is because
the total overlapped area between the stator and rotor poles is unchanged. With further rotation of the rotor, the self-inductances
increase linearly since the rotor poles are approaching alignment
with the stator poles.
Meanwhile, the mutual inductance between the armature and
field windings decreases linearly from its maximum positive
value as the rotor rotates from the aligned position in Fig. 3(b)
to the position where the rotor poles are between adjacent stator
poles as shown in Fig. 3(d). The value of the mutual inductance
at this location is zero. This is because the total flux linking
the armature winding when the field winding is excited or the
total flux linking the field winding when armature winding is
excited is zero, see Fig. 3(g) and (h). As the rotor continues to

Simplified geometry of the prototype 8/4-pole FS motor.

rotate toward the next alignment position, Fig. 3(e), the resultant
flux will switch between the poles linked by the field winding,
and thus the mutual inductance becomes negative. The mutual
inductance value will decrease to its minimum negative at the
end of the half cycle. Similarly, for the remaining half cycle, the
mutual inductance increases linearly to its maximum positive
value at the end of the cycle.
From the idealized inductance waveforms, the average value
is the predominant component of the self-inductances while the
fundamental is the predominant component of the mutual inductance. Hence, the mutual inductance is the major contributor
to the developed power and torque production. This means that
torque production is obtained where the polarities of the winding
currents are arranged for mutual inductance to provide positive
contribution to the torque production. For positive torque production, the corresponding idealized winding currents are to be
controlled as shown in Fig. 4. Note that the zero-current interval, 20 , between the positive and negative armature currents is
purposely provided to ensure successful current reversal. Meanwhile, during the zero-current interval of the armature current,
the idealized field-winding current will consequently decay to
zero. The torque developed is given as
Tdev =

dLAF
1 2 dLA
1 dLF
i
+ i2F
+ iA iF
2 A dr
2 dr
dr

(1)

where, iA and iF are the armature- and field-winding currents;

LA , LF , and LAF are the self- and mutual inductances of and
between armature and field windings, respectively. Clearly, for
positive developed torque, it implies that the following must be
satisfied:

i i >0

A F
(2a)
dL

AF > 0
dr

i i <0

A F
.
(2b)
dL

AF < 0
dr
III. DESIGN EQUATIONS
In this section the design equations for initial calculations
of the machine inductances, dimensions, and the number of
turns are derived. In the following development, the simplified
geometry of the magnetic circuit of the prototype 8/4-pole FS

BANGURA: DESIGN OF HIGH-POWER DENSITY AND RELATIVELY HIGH-EFFICIENCY FS MOTOR

Fig. 7.

Fig. 6. MMF waveforms of the developed half-geometry configuration for:

A(+) and F(0), A(0) and F(+), and A(+) and F(+) excitations, respectively.

motor with identical armature and field slots, as shown in Fig. 5,

is used. The iron core is assumed to be of infinite permeability
and flux leakage effects are neglected.
A. Magnetomotive Force (MMF) and Magnetic Loading
Consider Fig. 6 that shows the idealized air-gap MMF distributions of the developed layout of the simplified geometry
given in Fig. 5. These distributions correspond to the cases
for: 1) only positive armature excitation; 2) only positive field
excitation; and 3) both positive armature and field excitations,
respectively. Each of these MMF distributions can be expressed
using Fourier series in terms of the stator reference position angle (see Fig. 5), , and the rotor angular position r with respect
to a fixed point on the stator as




h( 0 )
Fs (, r ) =
fsh cos
h
(3)
2ps

419

Rotor and stator air-gap functions at r = /4.

where gsr0 is the average value of the air-gap function and p is

the pole pitch. The parameters, gsr0 , g1h , and g2h are functions
of the geometric parameters indicated in Fig. 5, and are given
as
2gmin 1 + gmax 2
(5)
p

 

 
gmax gmin
h2
h(21 + 2 )
g1h =2
sin
cos
h
p
p

gsr0 =

(6)

 

 
gmax gmin
h2
h(21 + 2 )
g2h =2
sin
.
sin
h
p
p
(7)
The air-gap function due to a slotted rotor and a smooth stator, denoted as gr (, r ), can be deduced by substituting in (4)
through (7) as follows:
1 = 3 = 0.5pr

h=1,3,5

where h is the harmonic order, ps is the stator pole pitch,

h is the phase shift of the h th harmonic, 0 is the phase shift
with respect to the reference rotor position, r = 0, and fsh is
the magnitude of the h th harmonic.
The air-gap flux density, which is an important parameter related to the magnetic loading, flux linkage, and electromagnetic
power of the machine, can be calculated by multiplying the
resulting MMF distribution function by the inverse of the effective air-gap function. The effective air-gap function essentially
represents the air-gap length at a given point, and is a function of both stator and rotor geometries as well as rotor angular
position. That is, the effective air-gap function can be viewed
as comprising two rotor-position-dependent components 1) an
air-gap function due to a slotted rotor and a smooth stator and
2) an air-gap function due to a slotted stator and a smooth rotor.
These rotor and stator air-gap functions corresponding to Fig. 5
are depicted in Fig. 7. In general, each of these air-gap functions
can be expressed using Fourier series as




2h( r )
g1h cos
gsr (, r ) = gsr0 +
p
h=1


2h( r )
+ g2h sin
(4)
p

gmax = gl + gmin

2 = pr pr
p = pr .

(8)

Similarly, for the air-gap function due to a slotted stator and a

smooth rotor, denoted as gs (), can be deduced by substituting
as follows
1 = 3 = 0.5ps
gmax = gs + gmin

2 = ps ps

r = 0

p = ps .

(9)

Here, gmin is related to the minimum air-gap height g0 at the

aligned rotor position as gmin = 0.5g0 . Once the air-gap functions due to a slotted rotor and a smooth stator as well as a
slotted stator and a smooth rotor are derived, the effective airgap function ge (, r ) due to a slotted rotor and a slotted stator
can be easily deduced. Therefore, the air-gap flux density can
now be expressed in terms of the inverse of the effective air-gap
function as

Bs (, r ) = 0


h=1,3,5

h( 0 )
Fsh cos
h
2ps

ge1 (, r ).
(10)

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IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 21, NO. 2, JUNE 2006

Fig. 8.

Idealized back EMF in the armature and field windings.

Upon obtaining the flux density in the air-gap, the flux linkages of the armature and field windings are deduced by integrating the air-gap flux density in the region covered by the coils of
these windings. That is
 2
N (, r )Fs (, r )ge1 (, r ) d (11)
w (r ) = 0 LRs

Here:
Number of armature series turns.
NA
r
Motor speed in mechanical radians/s.
Stroke angle in radians.
(/4 20 )
Factor for MMF consumed in the iron.
km
kl
Factor for incomplete mutual coupling.
Stacking factor of the lamination.
ks
Stator pole arc factor.
kp
L
Stack length.
Air-gap flux density.
Bg
ps = Ds /Ps Stator pole pitch.
Inner diameter of stator.
Ds
Stator number of poles.
Ps
Rotor number of poles.
Pr
Substituting (15) and the stator pole pitch, ps , into (14) yields
EA max = 2NA

where N (, r ) is equal to the coil turns in the region covered

by these coils and zero otherwise, 0 is the permeability of free
space, and Rs is the inner stator radius. Also, the self- and mutual
inductances of and between the armature and field windings can
now be calculated, and are reported in Section IV.
B. Rotational Voltage and Output Equation

km kl ks kp LDs Bg

r .
Ps 4 20

From the idealized waveforms in Figs. 4 and 8, the input power

into the motor can be expressed as

1 T
E(r )I(r )dr
Pm =
T 0


/4 20
= 2(EAmax IAmax + EFmax IFmax )
.
pr

The rotational voltage induced in the armature and field windings expressed in terms of the winding inductances are
EA =

d
d
(LA iA + LAF iF )
(LAF iF )
= r
dt
dr

(12)

EF =

d
d
(LF iF + LAF iA )
(LAF iA ).
= r
dt
dr

(13)

The rotational voltage expressions have been simplified further

in terms of the mutual inductance whose predominant fundamental component contributes significantly to the torque production. The predominant dc (average) components of the selfinductances do not contribute to the torque production. This
phenomenon, which is clearly observable in the ideal inductance profiles given in Fig. 4, is at variance with a conventional
short-pitched SR machine in which the torque production is derived mainly from the variations of the self-inductances. Based
on Fig. 4, (12), and (13), the resulting idealized rotational voltage waveforms of the armature and field windings are shown in
Fig. 8. Note that the frequency of the rotational voltage induced
in the field winding is twice that of the armature winding.
The rotational voltage induced in the armature winding due
to the flux produced by a constant field-winding excitation can
be expressed as
EA = NA

d(r )
d(r )
2max

.
= NA r
= NA r
dt
dr
4 20
(14)

Meanwhile, the maximum value of the mutual flux max is

given by
max = km kl ks kp Lps Bg .

(15)

(16)

(17)
Under balanced MMF conditions for optimum performance and
using (12) and (13), it can be deduced that the average power
supplied to the armature and field windings are equal, and can
be expressed as
 
1
(18)
(NA IAmax )km kl ks kp LDs Bg r .
Pm = 8
Ps
The electric loading expressed in terms of the rms values of the
winding currents is

Irms
2(NA IArms + NF IFrms )
4NA IArms
Al =
=
=
.
Ds
Ds
Ds
(19)
From Fig. 4, the magnitude of the armature current is related to
its root mean square (rms) value as
i =

IAmax
IAmax
1
=
= 

IArms
1 T 2
0
2 /42
T 0 ia (r ) dr
pr

(20)

where i is the current factor. By substituting (19), (20), pr =

2/Pr , and r = 2nr /60 into (18), where nr is the operating
speed of the machine, the power supplied to the machine is
deduced as
 
2 Pr
(21)
i km kl ks kp Al LDs2 Bg nr .
Pm =
30 Ps
Upon accounting for the motors resistive and core losses, friction and windage, and neglecting converter-switching losses,
the output power of the drive system can be expressed in terms

BANGURA: DESIGN OF HIGH-POWER DENSITY AND RELATIVELY HIGH-EFFICIENCY FS MOTOR

of the overall efficiency, denoted as , as

 
2 Pr
Pout =
i km kl ks kp Al LDs2 Bg nr .
30 Ps

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TABLE I
DESIGN DATA FOR THE PROPOSED 8/4-POLE FS MOTOR

(22)

Meanwhile, the output power expressed in terms of the input

power into the drive is given as
Pout = VIN IIN cos(PF )

(23)

where VIN , IIN , and cos(PF ) are the input rms voltage, input
rms current, and load-dependent input power factor of the drive
system. For a series-connected FS motor drive system, Fig. 2,
the field- and armature-winding currents are related to the input
current by the relationships
IF = i IIN

(24)

IA = i t IIN

(25)

where i is the ratio of field-winding current to input current,

and is strongly dependent on the load, and t is the ratio of the
field and armature number of turns.
Thus, the output power equation derived in (22) describes
the relationship between the output power and the principal
dimensions of the machine and the quantities that define the
specific utilization of the materials of its magnetic and electric
circuits. Moreover, this equation shows that the output power
is directly proportional to the ratio of rotor to stator number
of poles and the stroke angle. Therefore, for given electric and
magnetic loading conditions, a larger rotor to stator pole ratio
could result in higher power density. Similarly, a larger stroke
angle could result in higher power density. Meanwhile, (23)
provides a relationship between the output power, input voltage,
input current, input power factor, and overall efficiency of the
motor drive system.
IV. DESIGN PROCEDURE
A. Initial Motor Sizing and Calculations of Winding Turns
The sizing equation can be derived from (22) as
Ds2 L =

0.8 2
30

Pr
Ps

Pout

(26)

i km kl ks kp Al Bg nr

It is worth pointing out that (22) was derived based on idealized rectangular current and back EMF waveforms, while the
actual current and back EMFs are rather more trapezoidal. In
addition, the design experience of this author in designing other
prototypes indicates that 80% of the value given by (22) is close
to the actual value of the output power. Therefore, a correction
factor of 0.8 has been taken into account, as applied in (26). The
ranges and values of the parameters, km , kl , ks , kp , t , i , and
Al have all been determined through extensive use of the finite
element-behavioral model discussed in Section V.
The first step in the design process is to determine the corresponding magnitude of the armature-winding MMF, MMFA ,
that is required to produce a specified flux density, Bg , in the
air gap. Once the magnitude of the armature MMF, and hence
the ampere loading, Al , is determined the corresponding inner
diameter Ds of the stator is readily computed. From (26) and

using the calculated value for the inner diameter of the stator,
the corresponding stack length of the motor laminations is obtained. Furthermore, knowing the main dimensions of the motor,
the other structural dimensions such as the stator outer diameter,
pole heights, air-gap height, and pole arcs can be specified.
From (23)(25), the number of turns of the armature and field
windings can then be readily computed in terms of the supply
voltage, magnitude of the armature-winding MMF, input power
factor, ratio of field current to input current, and turns ratio as
NA =

MMFA VIN cos(PF )

i t Pout

NF = t NA .

(27)
(28)

Based on the above design equations and procedure, the corresponding initial dimensions, parameters (inductances, poles
widths, etc.), number of turns, and turns ratio of the prototype
8/4-pole FS motor were calculated. The initial and final design
data in per unit for the prototype 8/4-pole FS motor are given in
Table I.
V. MODEL DEVELOPMENT AND ANALYSIS
Upon completing the preliminary motor design, as detailed above, a robust and integrated-system-level computational
model was developed for evaluation and refinements of the preliminary design. This is deemed necessary because the magnetic
circuit of the FS motor is highly nonlinear and the winding design can have substantial effects on the behavior of the associated
power electronic converter, output power, and efficiency of the
overall drive. The model comprises a TSFE algorithm [7], [8],
and an analog behavioral modeling (ABM) algorithm. The ABM
algorithm was implemented in CSPICE.
A. TSFE Model and Analysis
The FS machine can be treated as a quasi-static magnetic system that is modeled using two-dimensional (2-D) finite element
method. Based on Maxwells equations, the partial differential
equation governing the physical behavior of the magnetic field
distribution in the x y plane cross section of the machine

422

Fig. 9.

IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 21, NO. 2, JUNE 2006

Fig. 10. Computed flux density distributions at r = 30 .

Computed flux density distributions at r = 0 .

solution domain can be expressed as [7][9], [10]






AZ

AZ

= JZ
x
x
y
y

(29)

where is the magnetic reluctivity of the medium; JZ and AZ

are the axial (z) components of the total current density and
magnetic vector potential. Meanwhile, the current density, JZ ,
in (29) is uniformly distributed in the stator armature and field
windings. The finite element computations were performed on
one-half of the machine geometry with the appropriate boundary
conditions applied along the boundaries M 1M 2 and N 1N 2, see
Fig. 5. The TSFE model was used to compute the set of all parameters of interest from nonlinear magnetic field solutions. In
this work, the parameters of interest include the air-gap flux density waveforms, periodic and nonsinusoidal winding inductance
profiles, and elemental flux density waveforms for core-loss
computations [7], [8].
The effectiveness of the design equations derived in this paper
are validated by comparison of the air-gap flux density waveforms and winding inductance profiles computed using (10) and
(11) and the TSFE model. The air-gap flux density waveforms
computed analytically using (10) for MMFA = 1480 AT and
MMFF = 1480 AT are compared with those computed from
TSFE nonlinear magnetic field solutions as shown in Figs. 9
through 11, respectively. Meanwhile, the corresponding TSFEmodel-computed flux plots of the magnetic field distributions
at the aligned and nonaligned rotor positions are shown in
Fig. 12. The analytically computed and TSFE-computed unsaturated self- and mutual inductances of and between the armature and field windings are depicted in Figs. 13 and 14,
respectively. Meanwhile, the saturated self- and mutual inductances corresponding to the armature and field MMFs given
above are given in Fig. 15. Examining these figures, it is clear
that there is appreciable agreement between the analytically and
TSFE-computed parameters, thus validating the efficacy of the
design equations used for computing the machine parameters.
The effects of magnetic saturation on the machine inductances
are clearly discernable from comparison of Figs. 14 and 15.

Fig. 11. Computed flux density distributions at r = 60 .

Fig. 12. TSFE-computed magnetic field distributions.

B. The ABM
The ABM is a multiport network formulation of the FS motor
drive system. The ABM technique essentially describes the set
of equations that represent the circuit relationships between the

Fig. 13. Analytically computed unsaturated inductances.

BANGURA: DESIGN OF HIGH-POWER DENSITY AND RELATIVELY HIGH-EFFICIENCY FS MOTOR

Fig. 14.

423

TSFE-computed unsaturated inductances.

Fig. 16. The TSFE-ABM representation of the FS motor drive system.

Fig. 15.

Similarly, the effect of electromechanical torque on the dynamic behavior of the motor drive system can be incorporated
by using the relationship

TSFE-computed saturated inductances.

physical machine windings flux linkages and terminal voltages

as well as the effects of electromechanical torque on motor performance. The nature of the formulation assures the inclusion
of all the significant space harmonics due to the physical design and nature of the motor as well as time harmonics due
to the converter switching. The ABM technique utilizes devices
such as resistors, inductors, capacitors, linear and nonlinear controlled voltages, and current sources to describe the FS motor
drive system equations. This makes it easy to implement using
commonly available circuit simulators, for example, CSPICE,
PSPICE, SIMPLORER, Saber, Simulink, etc.
In general, the terminal voltages in terms of the induced Faraday voltages and currents of the armature and field windings can
be expressed as
dA
(30)
dt
dF
VF = RF iF +
.
(31)
dt
Here VA , VF , iA , iF , A , and A denote the terminal voltages,
currents and flux linkages of the armature and field windings,
respectively. The flux linkages can be expressed in terms of the
inductances and currents as
VA = RA iA +

A = LA iA + LAF iF

(32)

F = LF iF + LFA iA .

(33)

Based on the ABM technique, the derivatives of the flux

linkages in (30) and (31) are represented using 1.0 H inductors
connected across nonlinear current sources whose values are
given by the expressions in (32) and (33), respectively. The
ABM representations of (30) through (33) are given in the flux
linkage model and flux linkage derivative model in Fig. 16,
respectively. The motor flux linkages are the parameters through
which the TSFE model of the machine is coupled to its externally
associated power electronic converter.

dm
= Tdev TL .
dt

(34)

Here, J is the inertia of the rotor, m is the rotor speed, Tdev is

the instantaneous developed torque profile, and TL is the load
torque profile. The expression for the developed torque term,
Tdev , of (34) is given in (1). Similarly, the ABM representation
of the inductance derivatives of (1) is given in the inductance
derivative model of Fig. 16. Finally, the ABM representation of
(34) is given in the torque model of Fig. 16. The complete ABM
representation of the FS motor drive system shown in Fig. 16
was implemented using CSPICE [9].
VI. MODEL VERIFICATION
To compute the performance parameters and characteristics,
such as inductances, input current, input power, output power,
efficiency, and power factor, etc., at any given load-operating
point, involves an iterative process that is continued until convergence is achieved. The iterative process requires the TSFE
and ABM algorithms to constantly and automatically exchange
data, which are primarily the winding inductance profiles and
currents. The winding inductance profiles are computed by the
TSFE algorithm and the currents are computed by a SPICE circuit simulator [9]. The nature of the iterative process is similar
to that detailed in [7], [8]. It should be emphasized here that
the developed system model has been extensively utilized to
refine the prototype design. That is, a parametric study in which
the parameters, which include power circuit component values
of the controller, device current and voltage ratings, maximum
pulse width, advanced angle, pole widths, slot geometry, air-gap
height, winding turns and turns ratio, were varied one at a time to
quantify their effects on the FS drive with regards to maximum
output power and maximum efficiency.
The power electronic converter shown in Fig. 2, including
its microprocessor-based controller, were designed and built to

424

Fig. 17.

IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 21, NO. 2, JUNE 2006

Computed and measured armature open-circuit voltage.

Fig. 20. FS and IM performance comparison.

Fig. 21. FS and UM performance comparison.

Fig. 18.

Fig. 19.

Output power versus torque.

Efficiency versus torque.

drive the prototype 8/4-pole FS motor. Performance tests were

performed on the bare motor in which the armature open-circuit
voltage, output power, and efficiency were measured. The computed and measured open-circuit armature voltages at various
levels of field currents versus motor speed are shown in Fig. 17.
The computed and measured output power and efficiency at
various load torque levels are displayed in Figs. 18 and 19,
respectively. The computed data compares very well with the
measured data. Clearly, the FS prototype motor offers relatively
high efficiencies over a wide range of output power or torque
levels. This is a highly desirable feature for the power tool machinery applications being considered. The maximum efficiency
obtained for the FS motor drive is about 75%.
Performance curves that include output power and efficiency
for the prototype 8/4-pole FS motor are compared with those of
equivalent IM and UM as shown in Figs. 20 and 21. It should be

mentioned that these motors are considered equivalent because

they have similar volumetric dimensions (inner diameter, outer
diameter, and stack length), and were designed and used for the
same applications as the FS motor. In these figures, the output
power is denoted as watts out (WO) and efficiency is denoted
as EFF. The maximum efficiency obtained for the IM is about
77% and that obtained for the UM is about 65%. Meanwhile,
the maximum output power obtained for the IM is about 0.58
per unit and that for the UM is about 0.70 per unit. Note that the
FS motor has a lot more reserved before reaching its maximum
output power capability. Clearly, the FS motor offers higher
output power than equivalent UM and IM, and high efficiency
comparable to that of the IM. Therefore, the FS motor is capable
of offering both advantages of high-power density of UMs and
relatively high efficiency of IMs.
VII. CONCLUSION
In this paper, the design and analysis of a new class of electronically commutated brushless FS motor has been presented.
The design equations that essentially describe the relationships
between the output power and the principal dimensions of the
machine, as well as the quantities (magnetic and electric loadings) that define the specific utilization of the materials of its
magnetic and electric circuits have been derived. These equations provide a practical way for the design engineer to make
initial calculations of the motor frame size, number of turns
and inductances. An initial design of a prototype 8/4-pole FS
motor based on these design equations was obtained, and subsequently refined using a more accurate model based on a 2-D
TSFE-behavioral modeling approach.

BANGURA: DESIGN OF HIGH-POWER DENSITY AND RELATIVELY HIGH-EFFICIENCY FS MOTOR

The final design of the prototype 8/4-pole FS motor was built

and tested. Comparison between the simulated and test results
demonstrated good agreement and correlation that clearly confirm the effectiveness of the design equations and approach.
Furthermore, the merits of the FS motor were demonstrated by
comparing its output power and efficiency curves with those of
equivalent IM and UM. The comparison demonstrates that FS
motors are capable of offering both advantages of high-power
density of UMs and relatively high efficiency of IMs.
Finally, the FS motor has tremendous potential for other applications where size and weight, power density, relatively high
efficiency, motor speed control, and other smart features, such
as overload protection, etc., are of interest.

425

[6] J. D. Wale and C. Pollock, Novel converter topologies for a two-phase

switched reluctance motor with fully pitched windings, in Proc. IEEE
Power Electron. Specialists Conf., vol. 2, Jun. 2327, 1996, pp. 1798
1803.
[7] N. A. Demerdash and J. F. Bangura, Characterization of induction motors
in adjustable-speed drives using a time-stepping coupled finite-element
state-space method including experimental validation, IEEE Trans. Ind.
Appl., vol. 35, no. 4, pp. 790802, Jul.Aug. 1999.
[8] J. F. Bangura and N. A. Demerdash, Simulation of inverter-fed induction
motor drives with pulse-width modulation by a time-stepping coupled
finite element flux linkage-based state space model, IEEE Trans. Energy
Convers., vol. 14, no. 3, pp. 518525, Sep. 1999.
[9] P. W. Tuinenga, SPICE: A Guide to Circuit Simulation & Analysis Using PSPICE, MicroSim Corporation, Ed., 2nd ed. Englewood Cliffs, NJ:
Prentice-Hall, 1992.

ACKNOWLEDGMENT
The author wishes to acknowledge the technical expertise and
support of the other members of the BLACBIRD Project team
at BLACK & DECKER, Inc.
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[1] C. Pollock and M. Wallace, The flux switching motor, a dc motor without
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Dec. 1996.

John F. Bangura (S96M99) received the B.S.E.E.

degree from Clarkson University, Potsdam, NY, and
the M.S.E.E. and Ph.D. degrees from Marquette University, Milwaukee, WI, in 1996 and 1999, respectively.
From 1999 to 2004, he was a Senior Engineer at
Black & Decker, Inc., Towson, MD, where he worked
on brushless ac/dc motor drives for power tool applications. From 2002 to 2004, he was an Adjunct
Professor with the Department of Mechanical Engineering, University of Maryland, Baltimore. From
2004 to 2005, he was with Alltrade Tools, Long Beach, CA, where he steered
the development of compressors, power equipment, and other related products.
In 2005, he joined the advanced development group at Pacific Scientific-Electro
Kinetics Aerospace Division, Danaher Corporation, Santa Barbara, CA, where
is currently working on permanent magnet and hybrid homopolar generators for
commercial and military aerospace applications. His current research interests
include modeling and designing of permanent-magnet and hybrid homopolar
machines as well as associated field control techniques.
Dr. Bangura is a member of the American Society of Engineering Education
and a member of Sigma Xi.