Design and Performance Optimization of Flux-Focusing PMSMs With Consequent-Pole Rotor Considering PM Utilization Ratio

This article investigates the utilization of a consequent-pole (CP) rotor design in the interior permanent magnet (IPM) motor to enhance the permanent magnet (PM) utilization ratio material and reduce leakage flux. Compared to the spoke-type IPM motor, the proposed rotor design utilizes a strong flux-focusing effect to improve performance. The evolutionary mechanism of the proposed flux-focusing rotor from flat-type and spoke-type IPM rotors is illustrated, resulting in a higher PM utilization ratio. The multiobjective genetic algorithm is employed to optimize the design of the proposed CP motor, aiming to maximize the PM material utilization while minimizing torque ripple. The optimization process begins with sensitivity analysis, exploring geometric variables of the rotor and determining their respective ranges and step sizes. Furthermore, a set of Pareto front are generated to identify optimal outcome. Finite element analysis is utilized to compare the electromagnetic performance of the two motors. The obtained results indicate that the proposed structure achieves 2.1% increase in output torque and reduction of approximately 40.2% in PM volume compared to the spoke-type motor. Finally, a 3000 r/min 10 kW prototype was manufactured and tested for confirming the effectiveness of the proposed configuration.

Automated summary

This article investigates the utilization of a consequent-pole (CP) rotor design in the interior permanent magnet (IPM) motor to enhance the permanent magnet (PM) utilization ratio material and reduce leakage flux. The proposed design utilizes a strong flux-focusing effect to improve performance. The optimization process using a multiobjective genetic algorithm achieves a higher PM material utilization and reduced torque ripple.