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Manuscript received December 7, 2004; revised September 27, 2005. This A. PM Motor Prototype
paper was presented at the 35th IEEE Power Electronics Specialists Conference
(PESC’04), Aachen, Germany, June 20–25, 2004. Recommended by Associate
Fig. 2 shows some details of the PM slotless motor proto-
Editor M. A. Rahman. type. Fig. 2(a) shows the stator winding, before the insertion
N. Bianchi and S. Bolognani are with the Department of Electrical Engi- within the stator core. It has been obtained by copper coils, pre-
neering, University of Padova, Padova I-35131, Italy (e-mail: bianchi@die. pared separately and then assembled together. Fig. 2(b) shows
unipd.it).
F. Luise is with ASI-Robicon, s.p.a., Monfalcone 34074, Italy. the assembled stator. The winding has been inserted in the stator
Digital Object Identifier 10.1109/TPEL.2006.876824 core; the latter is composed of a series of powder iron magnetic
0885-8993/$20.00 © 2006 IEEE
1084 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 21, NO. 4, JULY 2006
Fig. 5. Computed airgap flux density distribution at no-load and full-load op-
eration: (a) with slotless stator and (b) with slotted stator.
(1)
(2)
E. Motor Torque
winding coils have been not impregnated with resin, a higher
value is expected after an industrial resin treatment. The torque is due to the interaction between the PM flux den-
As regards the maximum temperature rise of the PM, the slot- sity and stator currents. The predicted torque [9], [10] is in a
less motor is not favourite with respect to the slotted motor. In good agreement with the measured value, as shown in Fig. 9. It is
fact, the iron teeth reduce the thermal resistance between the possible to observe that the torque varies linearly with the stator
winding and the iron. Thus, at the same maximum temperature current, due to the low value of the iron flux density, that limits
rise of the winding, the PM operating temperature is lower in the the saturation effect. An unexpected low torque value has been
slotted motor, as shown in Fig. 6(a). Conversely, in the slotless tested, that required a further analysis. In fact, the slotless solu-
motor, the temperature rise of the PM is the same of the winding, tion shows a very high effective airgap. Because of that, there
as highlighted in Fig. 6(b). Rotor losses can be neglected since is an additional component of leakage flux flowing through the
they are very low in this motor. shaft along the axial direction. It is about 5% to 10% of the main
From a thermal test it is possible to obtain the main flux.
thermal parameters of the motor. In the case of Fig. 7 (nat- The slightly lower value of the measured torque has been at-
ural cooling with 8 W and 0 W) they result tributed to the leakage flux at the edges of the PM rotor, that
5.6 C/W 7 Ws C 18 W Cm . Using a has not be considered in analytical computation. Such a leakage
BIANCHI et al.: HIGH SPEED DRIVE 1087
F. Stator Losses
Iron and copper losses occur in the stator. The iron losses
are essentially caused by the PM flux and do not depend on the
torque, while the copper losses are proportional to the square of
the required torque. Despite the low iron flux density, the iron
losses are often dominant due to the high frequency. Fig. 11. Computed Joule rotor losses vs. rotor speed with different retaining
Different soft magnetic materials may be used in soft mag- sleeve materials: sintered NdFeB ( =0.7 MS/m), copper ( = 58 MS/m),
netic composite (SMC) [18] instead of the laminated silicon- = =
titanium ( 1.8 MS/m), stainless-steel ( 1.33 MS/m and =20).
(3)
Fig. 13. Measured voltage waveform (curve 1) and current waveform (curve
while the ratio between the peak-to-peak torque and the average
2) in a test motor at 158 Hz and reduced voltage. torque is
(4)
the back e.m.f. of the non-energized phase is used as a feedback
to lock a PLL commutation loop. Not only the voltage zero-
crossing is sensed, but the IC integrates this voltage over a 60
B. Strategies for Increasing the Drive Reliability
interval. With an ideal commutation no net change of integrator
output voltage appears, while a delayed or early commutation To the aim of improving the original IC control, and in-
modifies the output voltage level which consequently forces the creasing the drive reliability, further control strategies have
next commutation to anticipate or to delay, respectively. been studied and implemented. They include a temperature
The tests were satisfactory both for starting and for sensor- protection, an under-voltage protection and a self-restarting
less synchronization. Conversely, some troubles were observed system. However, since this is a motor for a low-cost applica-
in terms of loss of synchronization due to harsh load torque tion, the adopted strategies should require a minimal additional
variations. cost.
In addition, a reasonable dependence of the motor perfor- i) The temperature protection is obtained switching off the
mance on the phase delay has been observed. Fig. 13 shows the mosfet of the converter by using the brake IC command,
phase current waveform (signal 2) in a test motor running at using a simple comparator driven by a thermal sensor,
158 Hz and reduced voltage, to highlight the saturated voltage NTC and OA3 in Fig. 15. Positioning the sensor in prox-
operation. The current waveform is distorted due to the delay of imity of the iron core, it protects also the windings, thanks
synchronization, and this waveform causes an unwanted torque to the low thermal resistance between the two parts. The
oscillation. This phenomenon has to be minimized by means of comparator output resets the alignment capacitor while
an accurate adjustment of the circuit parameters. keeping active the brake command.
With the back e.m.f. of Fig. 4, an additional oscillating torque ii) A similar action is performed by the comparator OA1 in
occurs when the motor is fed by squarewave phase currents, Fig. 15, in order to prevent over-current (and then over-
BIANCHI et al.: HIGH SPEED DRIVE 1089
heating) in the motor. It is activated when the dc bus [3] A Castagnini and I Leone, “Test results of a very high speed PM brush-
voltage falls down a given voltage threshold. Actually the less motor,” in Proc. Int. Conf. Elect. Machine, Brugges, Belgium, Aug.
2002, pp. 25–28.
controller has an internal under-voltage lockout, but this [4] D. E. Hesmondhalg, D. Tipping, and M. Amrani, “Design and construc-
operates on the control dc supply level (12 V). tion of a high-speed high performance direct-drive handpiece,” Proc.
iii) Finally, the motor self-restarting system is based on the Inst. Elect. Eng. B, vol. 134, pp. 286–294, 1987.
[5] Z. Q. Zhu, K. Ng, and D. Howe, “Design and analysis of high-speed
IC behavior occurring after a loss of synchronization. In brushless permanent magnet,” in Proc. EMD’97 Conf., Sep. 1–3, 1997,
healthy condition, the rotor is synchronous with the IC pp. 381–385.
internal VCO, and the gate drivers of the low side inverter [6] N. Boules, “Impact of slot harmonics on losses of high-speed perma-
nent magnet machines with a magnet retaining ring,” Elect. Machines
legs describe a squarewave voltage. Electromech., vol. 6, pp. 527–539.
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The voltage VCO input increases, then the commutation fre- imising rotor losses in high-speed high-power permanent magnet syn-
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reached under rated operation), and the control nullifies the eddy current losses in permanent magnet machines,” in Proc. EMD’93
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behaviour is adopted to detect the rotor arrest. high speed PM brushless motors,” in Proc. Power Electron. Intell.
Three diodes have been connected to the low side switch (PCIM’03), Nurnberg, Germany, 2003, [CD-ROM].
[10] ——, “Analysis and design of a brushless motor for high speed op-
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an RC integrator, so that an average value of the commutating Madison, WI, Jun. 2–4, 2003, pp. 44–51.
frequency is obtained in the form of a dc voltage. Fig. 15 shows [11] N. Bianchi, S. Bolognani, and F. Luise, “Potentials and Limits of the
High Speed PM Motors,” IEEE Trans. Ind. Appl., vol. 40, no. 6, pp.
that such a signal is compared in OA2 with a fixed reference. 1570–1578, Nov./Dec. 2004.
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commutes from 0 to 1. A peak detector formed by OA3 and ratio of permanent magnet machines,” Elect. Machines Power Syst.,
vol. 22, pp. 521–531, 1994.
two capacitors is connected to the output of OA2 and provides [13] D. E. Hesmondhalgh and D. Tipping, “Torque availability from small
a single pulse to the right controller to reset the capacitors. synchronous motors using high coercivity magnets,” Proc. Inst. Elect.
Eng., vol. 132, no. 5, pp. 279–288, Sep. 1985.
[14] D. E. Hesmondhalgh and D. Tipping, “A miniature transformer-cou-
pled high-speed synchronous motor,” Proc. Inst. Elect. Eng., vol. 132,
V. CONCLUSION no. 6, pp. 319–326, Nov. 1985.
[15] T Lu and A Binder, “Analytical and experimental analysis of losses
in inverter-fed permanent magnet high-speed machines with sur-
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analyzed. The advantages and drawbacks have been high- Brugge, Belgium, Aug. 2002, [CD ROM].
[16] K. Ng, Z. Q. Zhu, and D. Howe, “Open-circuit field distribution in a
lighted. Regardless of its low no-load flux density and the brushless motor with diametrically magnetized PM rotor, accounting
complex winding manufacturing, the slotless motor appears for slotting and eddy current effects,” IEEE Trans. Magn., vol. 32, no.
to be a preferable solution, thanks to the limited effect of the 5, pp. 5070–5072, Sep. 1996.
[17] E Levi, Polyphase Motors. New York: Wiley, 1984.
current reaction: it is less sensitive to the PM demagnetization [18] P Jansson, “Application of soft magnetic composite materials to elec-
and is characterized by lower rotor losses, due to eddy currents tric motors,” in Proc. EPE PEMC, 2002, [CD ROM].
caused by current reaction and PWM. Experimental tests have [19] N. T. Irenji, S. M. Abu-Sharkh, and M. H. Harris, “Effect of rotor sleeve
conductivity on rotor eddy-current loss in high-speed machines,” in
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ACKNOWLEDGMENT
Silverio Bolognani (M’98) received the Laurea de- Fabio Luise received the Laurea and Ph.D. degrees in
gree in electrical engineering from the University of electrical engineering from the University of Padova,
Padova, Padova, Italy, in 1976. Padova, Italy, in 1999 and 2003, respectively.
In the same year, he joined the Department of In 1999, he received a boursary scheme at the Lab-
Electrical Engineering, University of Padova. He oratory of Electric Drives, Department of Electrical
is presently a Full Professor of electrical drives Engineering. In 2004, he joined ASI-Robicon s.p.a.,
and he is engaged in research on advanced control Monfalcone, Italy, as an R&D Engineer. His main
techniques for motor drives and on the design of field of interest is in the design of brushless machines
ac electrical motors for variable speed applications. for special and custom applications.
He is author of more than 100 technical papers on
electrical machines and drives.
Mr. Bolognani is the President of the IEEE IAS-IES-PELS North Italy Joint
Chapter.