Flux-Focusing Permanent Magnet Machines With Modular Consequent-Pole Rotor

In this paper, the modular consequent-pole (MCP) rotor is adopted in the fractional-slot interior permanent magnet (IPM) machine to utilize the strong flux-focusing effect and reduce the leakage flux. Hence, the torque density and utilization ratio of permanent magnet (PM) material can be improved. However, the unacceptable unbalanced magnetic force (UMF) may arise due to asymmetric airgap flux density produced by consequent-pole topology. Thus, a pole-shaping method based on three-sectional arcs is proposed to suppress it. Due to the relatively complex rotor structure, the multiobjective optimization combined finite-element method with genetic algorithm is performed in this paper. Furthermore, the electromagnetic performance of the IPM machine with MCP rotor (namely IPM-MCP machine), including the open-circuit airgap flux density, phase back EMF, torque, PM utilization ratio, efficiency, flux-weakening capability and UMF, are compared with the conventional surface-mounted PM (SPM), IPM, and consequent-pole IPM (IPM-CP) machines. It is demonstrated that the IPM-MCP machine obtains the largest output torque in these machines. Meanwhile, the IPM-MCP and IPM-CP machines respectively have >30% and >20% higher PM utilization ratio than the conventional SPM and IPM machines while they obtain similar torque ripple and efficiency. Moreover, the IPM-MCP machine can obtain much lower UMF than the IPM-CP machine due to the effective suppression of asymmetric airgap flux density. Finally, a 12-slot/10-pole IPM-MCP machine is fabricated to verify the analyses.