Design and Comparison of an Optimized Permanent

Magnet-Assisted Synchronous Reluctance Motor

(PMa-SynRM) with an Induction Motor with
Identical NEMA Frame Stators
Robert Vartanian Hamid A. Toliyat
IEEE,Student Member IEEE, Fellow

Advanced Electric Machine and Power Electronics Laboratory
Department of Electrical and Computer Engineering
Texas A&M University
College Station, Texas 77843-3128
E-mail: Toliyat@ece.tamu.edu
Phone: (979) 862-3034
Fax: (979) 845-6259

AbstractThe performance of a synchronous reluctance motor
(SynRM) depends on the direct axis inductance (L
d
) and the
quadrature axis inductance (L
q
) of the machine. To achieve high
torque density and power factor, increasing the saliency ratio
L
d
/L
q
and making the difference of these inductances (L
d
-L
q
)
large enough are well known methods. Otherwise, the
performance of the motor will remain below that of a similar
induction machine using similar stator. By placing a proper
amount of permanent magnets inside of the rotor in proper
position it will be possible to achieve a significant improvement in
performance of this permanent magnet assisted SynRM (PMa-
SynRM) which will be comparable with induction machines with
same stators. This PMa-SynRM will have benefit of reduced
price due to use of conventional induction machines stators. This
study investigates the characteristic of an optimized PMa-SynRM
rotor for a specific 36-slot NEMA-Frame stator used in 7.5 HP
induction motor and the paper presents the comparison results
between the PMa-SynRM, SynRM, and the induction motor
obtained from FEM analysis.
Keywords: PMa-SynRM, Induction Motor, SynRM, NEMA-Frame.
I. INTRODUCTION
One of the U.S. Navys primary principles for future ships
and submarines is to become electric, where electric
technologies will replace hydraulic and pneumatic fluid power
systems that are currently supporting operating equipment. A
major component needed for both existing vessels and future
electric ships and submarines is the electric motor and
generator. The requirement for the development of
inexpensive, flexible and reliable motor and generator systems
has expanded in the last few years, due to growth in the
electrification of ships, automobiles, etc. The development of a
universal design of stators laminations which can be used
across various motors and generators is a way to reduce the
cost of manufacturing and maintenance. In addition, using the
SynRM will decrease the cost of the machine but in order to
achieve a wide constant-power and a high power-factor
operation in this machine drive, a large saliency ratio is
required.
Achieving such design using lumped parameter model of
the motor is very difficult. A large saliency ratio can be
achieved by both axially and transversally laminated rotor
structures. An axially laminated rotor can present a high-
anisotropy and provide a very high unsaturated saliency ratio.
However, from the mechanical stress point of view, this rotor
has some drawbacks over the transversally laminated one. The
effective saliency ratio of transversally laminated rotors can be
enhanced by proper placement, proper shape and proper
number of the flux barriers.
Adding the proper quantity of permanent magnets into the
SynRM rotor core is another way to improve the operating
performance of this machine. In this case, the motor is similar
to an interior permanent magnet (IPM) machine. However, the
amount of permanent magnets used and the permanent magnet
flux-linkages are smaller with respect to the conventional IPM.
Thus, the proposed motor can be called a permanent magnet
assisted synchronous reluctance motor (PMa-SynRM) [1,2,3].
In this paper, an optimized PMa-SynRM based on the same
frame as a specific NEMA frame induction motor is designed.
Its design and performance characteristics are compared with
the specific NEMA frame induction motor which was used for
the design and conclusions are made.
II. REFERENCE INDUCTION MACHINE
One of the initial steps to design a universal stator proper
for both induction machine and SynRM is the investigation of
the NEMA frame laminations being used in induction motors
in the market. The performance characteristics of the induction
machine is obtained and the operating conditions such as the
line voltage and winding current will be available for designing
the rotor of the PMa-SynRM. The benefit of this method will
be the existence of a reference machine for comparison with
978-1-4244-3439-8/09/$25.00 2009 IEEE 107
other newly designed machines. For this purpose, in this study
a 7.5 HP, 4 poles, 3-phase squirrel cage induction motor has
been selected. The NEMA frame of this motor is C213T. Table
I includes the specifications of the motor with stator main
information coming from the manufacturers data sheet and
from experiments. The stator lamination of this induction
motor is used in the design of the PMa-SynRM. To keep the
new machines main characteristics the same as the induction
machine, the air gap width, the inner diameter and the outer
diameter of the rotor are kept the same as the reference
induction motor.
TABLE I. PARAMETERS OF THE INDUCTION MOTOR.
Output Power (HP) 7.5
Voltage(V) 460
Current(A) 10.5
Shaft Torque (Nm) 30.88
Efficiency (%) 89.1
Power Factor 0.81
Shaft Speed (rpm) 1730
Minimum Air Gap (inch) 0.016
Rotor Inner Diameter (inch) 1.551
Rotor Outer Diameter (inch) 4.968
Stator Inner Diameter (inch) 5.00
Stator Outer Diameter (inch) 9.00
Number of Stator Slots 36
Stator Winding Coil Pitch 8
Number of Winding Turns per Slot 60
Number of Winding Layers Per Slot 2

III. OPTIMIZED ROTOR PROPOSED FOR THE PMA-SYNRM
The synchronous reluctance motor (SynRM) has several
advantages such as low cost, high-speed capacity, and
durability to temperature. Because the reluctance torque is the
main operational source of SynRM, it is important to design the
optimal rotor geometry by using appropriate barriers [2,3]. In
fact, the PMa-SynRM is a permanent magnet rotor
synchronous machine with a multilayer flux barrier, or in other
words an interior multilayer permanent magnet rotor machine.
The standard interior permanent magnet machine has only one
permanent magnet rotor layer per pole, and the permanent
magnet contribution to torque is predominant.
The high magnetic saliency created by the multiple flux
barriers in the rotor make reluctance torque predominant at low
speeds when highest torque is required. The stator core of the
machine is provided with uniform slots that host concentrated
short pitched windings. The rotor core is built of conventional
transverse laminations with stamped multiple flux barriers per
pole, filled with permanent magnet layers. The transverse
lamination rotor with multiple flux barriers requires magnetic
bridges to leave the lamination in one piece and provide
enough mechanical resilience up to maximum design speed
[4,5,6].
Fig. 1 shows a modern transversally laminated rotor for
SynRM. This rotor lamination is used for initial step of the
design and is optimized for the design of PMa-SynRM in order
to have the maximum performance with the stator of the
induction motor. Fig. 2 shows the optimized rotor for this
study. Using finite element analysis of the rotor of the NEMA
frame stator, the magnetostatic and transient torque of the
machine has been obtained. The main objective of the
optimization is to obtain maximum average torque and
minimum torque ripple which is done by changing the barrier
size and position of the permanent magnets. Also, in each case
the rotor geometry was modified to provide a better path for the
flux lines avoiding the high flux density. This method of
optimization reduces the reluctance torque to some degree.
However, because of the reduced saturation in the core of PMa-
SynRM, the torque generated by the magnets increases and less
core losses is expected. The stator currents in all cases are the
same as in the rated condition of the original induction motor.
The magnet used is NdFe30 and its data is given in Table II [7].
Using this type of magnet causes high saturations in the ribs,
however it improves the performance of the machine
significantly.
IV. IMPROVEMENT INVESTIGATION OF L
D
AND L
Q
USING
FLUX LINKAGE COMPUTATION
As previously mentioned, to increase the output torque of a
SynRM, increasing the saliency ratio is an effective way. To
show the effect of the magnet on L
d
and L
q
of SynRM and
PMaSynRM the flux linkage of both machines in phase A are
investigated.
For SynRM, it is possible to find L
d
and L
q
by applying the
maximum current to phase A and obtaining the flux linkage of
phase A when the rotor is running by external primary mover.
The maximum and minimum of the flux linkage will be
proportional to L
d
and L
q
, respectively [8]. Fig. 3 shows the
flux linkage of phase A when the excitation of phase A is at its
maximum and the rotor rotates at 1800 RPM using transient
FEM analysis in Maxwell 2-D software. The phase A is excited
with the maximum line current which is I
a
=14.85 (A) and
I
b
=I
c
= -0.5I
a
(the line current RMS is 10.5 (A)).
To calculate the saliency ratio of the PMa-SynRM the flux
linkage due to excitation of the stator has been obtained and the
flux linkage due to the permanent magnets has been deducted
from that. Fig. 4 shows the resultant waveform.

Figure 1. Modern Transversally Laminated Rotor for SynRM.
108

Figure 2. 3-D Model of PMa-SynRM Rotor Optimized for the Study.
TABLE II. DATA OF THE PERMANENT MAGNET USED IN DESIGN.
PM type NdFe30
Mag. Retentivity (Br) (tesla) 1.1
Relative Permeability 1.0045
Mag. Coercivity (Hc) (kA/m) -838
Magnetization (Mp) (kA/m) 875.35
Mass Density(kg/m^3) 7550
Thickness(mm) 5.1


Figure 3. Flux linkage of the SynRM (Phase A).

Figure 4. Flux linkage of the PMaSynRM Due to the Stator Excitation.
It is obvious that the saliency ratio is not too high for
SynRM because the rotor geometry has been improved by
using permanent magnets. The ratio of maximum and
minimum of the waveform in Fig. 4 is about 5.4 which shows a
significant improvement of the saliency ratio of SynRM using
permanent magnets. Also, it is interesting to see that the
maximum of the flux linkage waveform in Fig. 4 is less than
the maximum of the waveform in Fig. 3. Fig. 5 and Fig. 6 show
the flux line distribution for the maximum torque angle. In
SynRM, the flux lines are more and the density is higher in
some teeth whereas they are reduced in PMa-SynRM. As a
result, less core loss is expected in comparison with the
SynRM.
The d-axis flux linkage drop in PMa-SynRM is due to
saturation in the stator teeth and rotor ribs. This is caused by
the permanent magnets. Table III compares the saliency ratio of
SynRM and PMa-SynRM and the improvement obtained using
the permanent magnets.
TABLE III. SALIENCY RATIO OF SYNRM AND PMASYNRM.
Machine Saliency Ratio
SynRM 3.3
PMa-SynRM 5.4
Saliency Ratio Increment 66%

109

Figure 5. Flux Line Distribution in SynRM.

Figure 6. Flux Line Distribution inPMaSynRM.
V. FEA ANALYSIS OF PMA-SYNRM AND COMPARISON
WITH INDUCTION MOTOR
After finding the maximum torque angle of the rotor in the
magnetostatic analysis in Maxwell 2-D, the transient analysis
has been done to obtain the transient torque and the back- EMF
of the machine. Because the stator is the same as the induction
motor, the current used for excitation is 10.5A. The speed of
the PMa-SynRM is considered to be the synchronous speed
which is 1800 RPM for 4-pole machine supplied at 60Hz.
The stator current is the same in order to keep the copper
losses the same as is the reference induction motor and make
sure that the windings are loaded properly. In addition, to
compare performance of the motors, the transient analysis of
the induction motor at rated operating point has been done.
Fig. 7 shows the transient torque for both synchronous
machines and the reference induction motor with the same
stator currents. It is interesting to note that the average torque
and the torque ripple of the SynRM is more than the induction
motor. However, it is obvious that the power factor of the
SynRM will be low. The optimized PMa-SynRM generates
more torque in comparison with the SynRM and the induction
motor. The torque ripple of the PMa-SynRM is higher due to
the cogging torque caused by the permanent magnets but it is
still less than the induction motor. Table IV contains the results
of the FEM analysis.

Figure 7. Compariosn of Transient Torque of PMa-SynRM, SynRM, and the
Induction Motor.
TABLE IV. PARAMETERS OF THE INDUCTION MOTOR AND THE
PMASYNRM.
Parameter Induction
PMa-
SynRM
SynRM
Operating Speed (rpm) 1730 1800 1800
Rated RMS Phase Current (A) 10.5 10.5 10.5
Rated Torque (Nm) 30.88 39.8 32
Ripple Torque (%) 20 16 8
Rated Output Power (kW) 5.6 7.5 6.0
Power Factor 0.8 0.85 0.55

The results show that the output power of the PMa-SynRM
is 33% more than the induction machine. This result shows
that the input voltage of the PMa-SynRM should be higher
because the input current is the same although the estimated
efficiency and power factor of the PMa-SynRM is more than
the induction machine. One solution can be decreasing the
length of the stator and rotor stacks or decreasing the input
current to have the same power as the induction motor.
VI. FLUX DENSITY INVESTIGATION- IN INDUCTION
MAHCINE AND PMA-SYNRM
After finding the average torque for the new design, the
flux density in the rotor and stator core should be checked to
make sure that there is no heavily saturated area in the cores. In
this study, the material used for both SynRM and PMa-SynRM
110
is M-45 steel (same material as used in the induction motor)
with the knee point approximately at 1.4 Tesla.
At rated operating point, the flux density has been
measured in a radial path in PMa-SynRM and the induction
machine. The paths have been selected in such a way to contain
the maximum flux lines in the stator yoke. Fig. 8 shows that the
maximum flux density in the stator yoke of the induction
machine is less than 1.24 T and Fig. 9 shows that the maximum
flux density in the PMa-SynRM stator yoke is less than 1.35 T.


Figure 8. Flux Density in the Induction Motor in a Radial Path.

Figure 9. Flux Density in PMaSynRM in a Radial Path.
For better comparison of the flux density in the three
machines, the flux densities have been measured in the stator
teeth, stator yoke, and in the air gap and compared in Table V.
Results show that the flux density in the stator teeth of the
PMa-SynRM is high because of the magnet used in the rotor
core but it is not local or fixed. Also, in the air gap the SynRM
and PMa-SynRM have higher flux densities compared with the
induction motor. The flux density in the PMa-SynRM is higher
than the induction machine but because it generates more
torque, it is possible to reduce this flux density by decreasing
the stator current. Because the rotor of PMa-SynRM has a low
core loss and no copper loss, the increased power loss in the
stator might be ignored.

TABLE V. COMPARISON OF FLUX DENSITIES OF ALL MOTORS.
Maximum Flux Density Induction
PMa-
SynRM
SynRM
Stator Teeth (Tesla) 1.38 1.64 1.58
Stator Yoke (Tesla) 1.24 1.35 1.46
Air Gap (Tesla) 1.32 1.58 1.49

VII. BACK-EMF OF THE PMA-SYNRM
Since the permanent magnet used in the rotor core
generates high flux density, it is important to find the back-
EMF generated by the motor. For this purpose, the rotor of the
PMa-SynRM has been rotated at the rated speed of 1800 RPM
in transient analysis to find the voltage induced in the winding
of the stator. Fig. 10 shows the waveform of one phase of the
stator and the three-phase rms value is about 275 V. This also
shows that the machine is suited for high speed operation.

Figure 10. Back EMF of the PMaSynRM at 1800RPM.
VIII. MATERIAL CONSUMPTION
One of the important criteria when electric motors are
compared is the material consumption in the motors. Since the
stator laminations and winding configurations are the same in
both motors, we just need to compare the rotor material used in
both machines. In Table VI, the material consumptions in both
machines are listed. These data are obtained from RMxprt and
Maxwel-2D.
TABLE VI. MATERIAL CONSUMPTION AND WEIGHT OF MAIN PARTS.
Object Induction PM-SynRM
Stator Copper Weight (lb) 14.7 14.7
Rotor copper Weight (lb) 5.13 N/A
Rotor End Ring Material Weight (lb) 3.50 N/A
Stator Core Steel Weight (lb) 37.75 37.75
Rotor Core Steel Weight (lb) 15.42 12.56
NdFe30 Wight (lb) N/A 1.14
Net Weight
Stator (lb) 52.45 52.45
Rotor (lb) 24.05 13.70
Total weight (lb) 76.50 66.15
111
By comparing the numbers in Table VI, it is obvious that the
rotor of the PMa-SynRM is lighter than the induction motor
rotor because it has no copper bar and end ring and therefore is
43% lighter. This means that it will have faster dynamic
response and better transient operation. These results are for 4
inches stack length but because the torque of the PMa-SynRM
is about 25% more than the reference induction machine rated
torque, we can decrease the stack length of PMa-SynRM to 3
inches and the output torque will be the same as the induction
machine. The material consumption in PMa-SynRM will be
decreased by 25%. Table VII contains material consumption
and weight of machine for reduced stack length of PMa-
SynRM.
TABLE VII. MATERIAL CONSUMPTION AND WIGHT OF MAIN PARTS
SHORTER PMASYNRM.
Object
Induction
(4 Stack)
PM-SynRM
(3 Stack)
Stator Copper Weight (lb) 14.7 13.3
Rotor copper Weight (lb) 5.13 N/A
Rotor Ring Material Weight (lb) 3.50 N/A
Stator Core Steel Weight (lb) 37.75 28.31
Rotor Core Steel Weight (lb) 15.42 9.42
NdFe30 (lb) N/A 0.86
Net Weight
Stator (lb) 52.45 41.61
Rotor (lb) 24.05 10.28
Total weight (lb) 76.50 51.89

This new stack length results in 32%lighter motor with the
same torque at rated speed. But the main point is that the rotor
is 57% lighter in this case which means a faster response time
and transient dynamics. Also the stator copper is reduced by
10% which means 10% less power loss in the stator
(considering that the stator current was the same in both
motors). Reduced iron loss in the stator and very small power
loss in the rotor of the PMa-SynRM due to rotating at
synchronous speed result in a high efficiency PMa-SynRM
motor.
The above analysis shows that the 3 inches stack length for
PMa-SynRM will generate same torque as in the induction
motor. But it uses NdFe30 permanent magnet which relatively
is an expensive type of magnets. By considering that the steel
cost is $1/kg, copper is $5/kg and permanent magnet NdFe30 is
$96/kg, the estimated cost of the material used in PMa-SynRM
will be $ 90.32 and in the induction motor will be $83.24.
These results show that the price of the PMa-SynRM is
only 8.5% more but the PMa-SynRM has higher efficiency.
Also, the price of iron and copper are increasing but the
technology of the permanent magnet manufacturing is
progressing and the price of PM might decrease (This
comparison was done only for the motors, and the power
electronic price needed to drive the PMa-SynRM is not
included)
IX. CONCLUSION
This study shows that a stator designed for induction motor
can be used in PMa-SynRM. The output torque of PMa-
SynRM is higher than the induction motor with the same stator
winding configuration and the current and the flux density in
the stator is a little bit higher. The high torque generated by this
machine shows that it is possible to use a shorter stack length to
get the same power from the machine at a higher efficiency. In
both simulations, the skew effect was not considered and
without a skewed rotor, the PMa-SynRM shows less torque
ripple than the induction motor and one can expect even less
torque ripple in actual experiment.
Less weight of the rotor will let the motor to respond to
dynamic transient faster than the induction motor and this will
be another benefit. The material cost comparison shows that
this type of machine is able to compete with traditional
induction motor because the power electronic and permanent
magnet costs are decreasing. In this study, the price of the
power electronics is not included. By considering the
applications in which a power electronic drive is needed for
induction machine, then using PMa-SynRM is completely
justified specially for naval applications where weight and
volume is of utmost importance.
ACKNOWLEDGMENT
This study is supported and sponsored by Office of Naval
Research (ONR) and the FEA software is provided by
Ansoft/ANSYS Inc.
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