III-1.2.

HIGH POLE NUMBER, PM

SYNCHRONOUS MOTOR WITH
CONCENTRATED COIL
ARMATURE WINDINGS
Antonino Di Gerlando, Roberto Perini and Mario Ubaldini
Dipartimento di ElettrotecnicaPolitecnico di Milano Piazza Leonardo da Vinci, 32-20133
Milano, Italy
antonino.digerlando@polimi.it, roberto.perini@polimi.it, mario.ubaldini@polimi.it

Abstract. A high pole number, PM synchronous motor is presented, employing novel two-layer,
special armature windings consisting of concentrated coils wound around the stator teeth. This kind
of machine is characterized by excellent e.m.f. and torque waveform quality: it is well suited not only
as an inverter driven motor, but also for mains feeding, self-starting, applications. In the paper, the
main features of the machine are shown, together with some design, FEM, and test results.

General features of the windings

In recent times, a large attention has grown toward the electrical machines equipped with
concentrated coils, thanks to their great constructional and functional advantages [112];
nevertheless, a general approach to the concentrated winding theory seems not fully developed yet. In the proposed paper, a PM machine is considered, with two-layer, armature
concentrated windings [13].
The features of this kind of machines are (see Figs. 1 and 2):

r uniformly distributed and equally shaped magnetic saliencies of the structures (stator
teeth and rotor PMs);

r practical equality among tooth pitch t and PM pitch m (it can be m < t or m > t , but
m = t );

r series inverted connection of coils belonging to adjacent teeth of the same phase (controverse coils).
By adopting the representation of Fig. 1 (right) to specify the winding sense of each coil
around its tooth, a typical three-phase, two-layer, winding appears as shown in Fig. 2.
Referring to Fig. 2, the following quantities and properties should be defined and considered:

r cycle: space period (periphery portion at which bounds the faced structures show the
same mutual disposition);
S. Wiak, M. Dems, K. Komeza (eds.), Recent Developments of Electrical Drives, 307320.

C 2006 Springer.

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Figure 1. Left: basic structure of a PM synchronous machine, with tooth coil armature winding.
Right: coil winding senses around teeth.

r cycle-phase: referring to a layer, portion of one cycle including adjacent coils belonging to
the same phase; parent coil: in each layer, the first coil of every cycle-phase; its succession
assignment defines the winding;
r the no. of teeth/cycle Ntc and the no. of coils/cycle Ncc must be multiple of the no. of
phases Nph ;
r links about no. of teeth/cycle-phase Ntcph and no. of coils/cycle-phase Nccph : Ntc =
Nph Ntcph ; Ncc = Nph Nccph ;
r in case of controverse coils, the no. of coils/cycle-phase Nccph coincides with the no. of
teeth/cycle-phase Ntcph ;
r the optimal no. of PMs/cycle Nmc differs by one with respect to Ntc : Nmc = Ntc 1 (
highest winding factor);
r the optimal displacement among layers equals a no. of teeth Nts nearest to Nccph /2 (low
harmonic distortion);
r the no. of cycles Nc equals the maximum no. of parallel paths a of each phase;
r the total no. of PMs Nm = Nmc Nc of a rotating machine must be even; thus, if Nmc is
even, the no. of cycles Nc can be any integer; if Nmc is odd, Nc must be even;
r the no. of coils/cycle-phase Nccph can be any integer;

Figure 2. Double layer winding (two coils/tooth), with controverse tooth coils: Ntc = 12; Ncc = 12;
Nph = 3; Ntcph = Nccph = 4; Nts = 2.

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309

r it can be shown that the winding factor kw

of a three-phase tooth coil machine (with

two-layer windings) equals the product of a distribution factor kd times a displacement
factor ks ;
r for the phase winding e.m.f. of the jth order harmonic (j = 1, 3, 5, . . . ), we have:
kwj = kdj ksj
kdj =

with

sin(j /6)
,
Nccph sin[(j/Nccph ) /6]

ksj = cos(j (Nsp /Ndcf ) /6;

(1)
(2)
(3)

a traditional machine, with two-layer distributed windings, q slots/(pole-phase) and coil

pitch shortening of ca slots, exhibits a winding factor fa equal to the product of a distribution
factor fd times a pitch factor fp :
faj = fdj fpj , with

(4)

sin(j /6)
,
q sin[(j/q) /6]

(5)

fpj = cos(j (ca /q) /6);

(6)

fdj =

these expressions and the previous ones are exactly corresponding each other, provided that
we associate Nccph with q and Nts with ca : the difference lies in the fact that, with a traditional
machine, good quality performances (high winding factor and good e.m.f. waveform, no
cogging, teeth harmonics, magnetic noise, and vibrations) can be obtained by adopting
structures with q 56, while a tooth coil machine (with the described features) exhibits
similar performance quality with q values practically equal to 0.33: thus, machines with a
given no. of poles can be realized with armature structures with a very low no. of slots;

r the other main advantages of these machines are:

the stator assembly is simplified: no skewing is required; only concentrated coils are
used, that can be prepared separately (no endwindings overlapping; reduced copper
mass; and armature losses);
the torque is high at low speed, allowing to eliminate any gears.
Table 1 shows some combinations of Nt and Np (i = inferior; s = superior), for three-phase
windings.

Design analysis of a basic prototype

In order to study the basic features of this kind of machine, we have decided to modify
an existing induction motor, by re-winding its stator according to the previous theory and
designing a new rotor, equipped with surface mounted PMs: of course, this choice has
prevented from obtaining an optimized stator core, but, besides to easily provide a first test
motor, it has also allowed to evaluate the suitability of existing laminations for the new
machine. The main data of the used stator core are given in Table 2.

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310

Table 1. Combinations of Nt and Np (i = inferior; s = superior) of

three-phase controverse windings, for some values of Nccph and Nc
(Ncmin = 2); Scph = sequence of the parent coils within two cycles
Nccph

Ntc

Nc

Nt

Npci

Npi

Scph.i

Npcs

Nps

Scph.s

2
3
4
5
6

6
9
12
15
18

2
3
2
3
2

12
27
24
45
36

5
8
11
14
17

10
24
22
42
34

AcBaCb
ACBACB
AcBaCb
ACBACB
AcBaCb

7
10
13
16
19

14
30
26
48
38

AbCaBc
ABCABC
AbCaBc
ABCABC
AbCaBc

About the rotor design, the available degrees of freedom are air-gap width and PM sizes
and material: their choice is made by considering the operating point of the PM and the flux
density Bt in the stator teeth. Considering the alignment condition between the PM axis
and the tooth axis, from the analysis of the equivalent magnetic circuit concerning a zone
extended to a tooth pitch, the no-load peak tooth flux t0 can be expressed as follows:
t0 = r PM = (Br bm )

1
,
1 + (1 +  ) rPM g/hm

(7)

where r = Br bm  is the PM residual flux, PM the air-gap magnetization efficiency

of the PM,  , rPM , and hm the PM leakage, the relative reversible permeability and the
PM height respectively, g the air-gap width.
We adopted a NdFeB PM material (MPN40H: Br = 1.2 T; HcB = 700 kA/m at 80 C),
choosing Nc = 2, Ntcph = 6, Nm = 34, bm = 10 mm, central air-gap g = 0.65 mm: with
these values, hm = 3 mm is suited to gain an acceptable no-load magnetization (in fact,
with  0.15, it follows: PM 0.75; Bt = 1.32 T; tooth flux t0 = 0.761 mWb); FEM
simulations [14] confirmed (7) (tanalytical = 1.012 tFEM ).
Fig. 3 shows the designed rotor during the construction process: the PMs are glued on
the steel surface, inserted in suited slots for their correct and accurate positioning.
As the stator yoke, also the rotor yoke results definitely oversized (in fact, it was designed
for a four pole motor).
Table 2. Main constructional data of the stator
magnetic core used for the PM machine (obtained
from an available standard induction machine
lamination); main PM data
Stator internal diameter, Di
Stator external diameter, De
Stator yoke width, hy
Lamination stack length,
No. of stator teeth, Nt
No. of PMs, Nm
Slot opening width, ba
Slot opening height, ha
Tooth body width, bt
Tooth body height, ht
Tooth head width, be
PM polar arc, m

140 mm
220 mm
19.5 mm
85 mm
36
34
2.7 mm
0.55 mm
6.7 mm
20.00 mm
9.5 mm
0.77 pu

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311

Figure 3. Picture of the PM rotor, during the assembling process: just some PMs are glued on the rotor
surface; small slots (0.3 mm deep) allow a precise and reliable PM positioning, without appreciable
increase of the flux leakage among adjacent PMs.

The complete cross section of the machine is represented in Fig. 4, that shows also
the adopted winding disposition (in it, a layer displacement Nts = Nccph /2 = 3 has been
adopted).
The FEM evaluated distribution [14] of the no-load flux density amplitude in the toothed
zone (at half stator tooth height) is shown in Fig. 5; the following remarks are valid:

r the FEM peak value Bt confirms the analytical result;

r the peripheral amplitude distribution of |Bt0 | appears substantially sinusoidal, thanks to
the gradual displacement among PMs and teeth within each cycle.

Figure 4. Top: magnetic structure and winding arrangement of the analyzed and constructed concentrated coil PM motor. Bottom: disposition conventions of coils and PMs.

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Di Gerlando et al.

Figure 5. Peripheral amplitude distribution of the no-load flux density Bt0 in the stator teeth (evaluated
by FEM simulation, at half the tooth height) for the machine described in Table 2.

This sinusoidal distribution allows to express the r.m.s. no-load fundamental flux linkage

0 as follows:

0 = (kw1 Nc 2 Ntcph t0 / 2) Ntuc =

01 Ntuc ,
(8)
where the dependence on the no. of turns of each coil (Ntuc ) is evidenced. In a two-layer
winding, the no. of turns around each tooth Ntut is even: in fact, Ntut = 2 Ntuc occurs.
The no-load flux linkage
0 can be evaluated also by FEM: some simulations have shown
the accuracy of (8).
Of course, Ntuc is included also in the expressions of the equivalent resistance R and
synchronous inductance L:
R = R1 N2tuc

(9)

L = L1 N2tuc .

(10)

01 ,R1 , and L1 are the corresponding parameters of a phase winding consisting of one-turn
series connected coils, being the same the coil total copper cross section:
  
R1 = 22 Ntcph Nc a2 cu [tu /(cu (As /2))],
(11)
  
L1 = 22 Nc a2 Ntcph e ,

(12)

with: a = no. of winding parallel paths, equal to Nc , or sub-multiple of it (here a = 1 has

been chosen); tu = average turn length; As = slot cross section; cu = slot filling factor;
e = per tooth equivalent permeance.
While R1 is simple to be evaluated, L1 can be analytically evaluated only with some
approximation; on the other hand, it can be obtained with energy calculations by a magnetostatic FEM simulation, substituting the PMs with passive objects, with the same permeability
of the PMs.
For the machine of Table 2, Fig. 4, the values of Table 3 have been obtained.

III-1.2. High Pole Number, PM Synchronous Motor

313

Table 3. Calculated parameters of a PM motor with the

data of Table 2, Fig. 4, equipped with single turn per
coil windings
Flux linkage,
01 (equation 8)
Resistance, R1 (equation 11)
Inductance, L1 (equation 12)

11.5 mWbrms
8.03 m
51.5 H

The choice of Ntuc is a key design issue, greatly affecting the performances. In the
following, just the Joule losses will be taken into account, neglecting the core Pc and
mechanical losses Pm , that can be considered separately. To evaluate the influence of Ntuc ,
the phasor diagram of Fig. 6 must be considered, analyzing the machine operation under
sinusoidal feeding, at voltage V.
It is useful to define the quantities E and Ik as follows:
E

0

01
=
=
Ntuc
V
V
V

(13)

V
V
V

=
=
:
2
2
Z
R + (X)
N2tuc R21 + ( L1 )2

(14)

E =
Ik =

they represent the e.m.f./voltage ratio and the locked rotor current respectively, and depend
on the number Ntuc .
The input current in loaded operation is given by:

I = Ik 1 + E2 2 E cos (),
(15)
where is the load angle (see Fig. 6).
Called p = Nm the no. of poles, the torque T is given by:
T = 3
0 (p/2) Ik [cos (z ) E cos (z )],

(16)

z = atan(X / R) = atan( L1 / R1 )

(17)

where

is the characteristic angle of the motor internal impedance (independent on Ntuc ) and the
load angle (see Fig. 6).
From (16), the load angle in loaded operation follows:
= z acos{T / [3
0 (p/2) Ik ] + E cos(z )}.

(18)

Figure 6. Phasor diagram for the analysis of the tooth coil synchronous motor, in sinusoidal feeding
operation, at voltage V.

Di Gerlando et al.

314

Moreover, (16) shows that the max. torque Tmax (pull-out torque) occurs for the static
stability limit angle max :
max = z ,

(19)

Tmax = 3
0 (p/2) Ik [1 E cos(z )].

(20)

Imposing the condition T = 0 in (18) leads to evaluate the no-load angle 0 and the
corresponding no-load current I0 :
0 = z acos(E cos(z )),
I0 = Ik

1 + E2 2 E cos(0 ).

(21)
(22)

Assuming a suited value of the rated current density Sn , the rated current In can be
expressed as follows:
In = Sn [(cu As )/(4 Ntuc )]

(23)

(in our motor, thermal status suggested: Sn = 6.5 A/mm ). Substituting (23) in (15) gives
the rated load angle:



n = acos 1 + E2 (In /Ik )2 /(2.E) ,
(24)
and inserting (24) in (16) gives the rated torque Tn .
The reactive power absorbed by the motor is expressed by:
Q = 3 V Ik [sin(z ) E sin(z + )];

(25)

while the ideal input power Pi equals (Pc , Pm neglected):

Pi = T + 3 R I2 .
From (25) and (26), the power factor:


1 + (Q/Pi )2 .

cos = 1

(26)

(27)

is a function of E and Ntuc , by (9), (15), and (16).

As concerns the transient model, the differential equations in terms of Park vectors are
as follows:

dt 

diP
p
(28)
L
= vP R iP j 3
0 e j p/2 :

dt
2

J d = p 3
Im i ej p/2 T
tot
0
P
load
dt
2
is the mechanical angle between PM and phase a axes; Jtot = Jrot + Jload the total inertia,
Tload the load torque.
In the following, the diagrams in Figs. 712 will show the effect of Ntuc changes on the
previously defined quantities: all the curves refer to steady state operation under sinusoidal
feeding (V = 380 Vrms, f = 50 Hz).

III-1.2. High Pole Number, PM Synchronous Motor

315

Figure 7. Input current I of the motor of Table 2 and Fig. 4, as a function of the torque T, in
sinusoidal operation under V = 380 Vrms, f = 50 Hz, for different values of the no. of turns/coil Ntuc .

Figure 8. Ratio E as a function of Ntuc , together with the curves of the ratios 0 /z and n /z (see
equations (13), (21), and (24)), in sinusoidal operation under V = 380 Vrms, f = 50 Hz, for different
values of the no. of turns/coil Ntuc .

Figure 9. Locked rotor (Ik ), rated (In ), and no-load (I0 ) input currents of the motor of Table 2 and
Fig. 4, as a function of the no. of turns/coil Ntuc (sinusoidal feeding: V = 380 Vrms, f = 50 Hz).

1
0.9
0.8
0.7
0.6
0.5
0.4

Figure 10. Power factor (cos), rated (Tn ) and maximum torque (Tmax ) of the motor of Table 2 and
Fig. 4, as a function of the no. of turns/coil Ntuc (sinusoidal feeding: V = 380 Vrms, f = 50 Hz).

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Di Gerlando et al.

Figure 11. Rated torque (Tn ) of the motor of Table 2 and Fig. 4, as a function of Ntuc (sinusoidal
feeding: V = 380 Vrms, f = 50 Hz).

Fig. 7 shows the current-torque characteristics, for some Ntuc values, traced by (15) and
(16), for 0 max = z .
The adoption of high Ntuc values (Ntuc 61, corresponding to E 1) allows to reduce
the no-load current, but reduces also the maximum torque and, thus, the motor overloading
capability and the self-starting performances.
Fig. 8 shows E as a function of Ntuc , together with the curves of the ratios 0 /z and
n /z (see equations (13), (21), and (24)), in sinusoidal feeding with V = 380 Vrms, f = 50
Hz: it is worth to observe that 0 is negative, approaching unity when E approaches unity
too (E V).
Fig. 9 confirms the remark concerning the no-load current I0 as a function of Ntuc , also
showing the change of the rated current In and of the locked rotor current Ik .
Fig. 10 illustrates the decrease of the power factor cos when lowering Ntuc , while the
maximum torque shows a significant increase. As the rated torque, it shows an almost flat
maximum around Ntuc = 48, as better visible in Fig. 11.
On the other hand, a correlative property is shown in Fig. 12, showing that the ratio
among the Joule losses and the output power has a minimum for Ntuc = 48.
As regards losses, rated torque and power factor, the best choice would be Ntuc = 48;
considering also the importance of Tmax , a lower Ntuc value can allow better overloading
and self-starting features: for this reason, we have chosen Ntuc = 46 (wire diameter:
0.63 mm).

Figure 12. Ratio between stator Joule losses and output power of the motor of Table 2 and Fig. 4, as
a function of Ntuc , in sinusoidal feeding (V = 380 Vrms, f = 50 Hz).

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317

Figure 13. Measured waveform of the no-load e.m.f. at the terminals of a probe coil of Np = 10
turns, disposed around one stator tooth: the typical trapezoidal shape can be observed.

Simulation and experimental results

Several simulations and experimental tests have been performed on a constructed prototype
based on the previous data, in order to validate the design and operation models and to
verify the achievable performance levels.
Fig. 13 shows the measured waveform of a tooth e.m.f., i.e. the no-load e.m.f. at the
terminals of a probe coil of Np = 10 turns, disposed around one stator tooth: even if a
certain distortion can be observed, the amplitude estimable from (8) is fairly confirmed.
Fig. 14 shows the measured waveform of the no-load phase-to-neutral e.m.f. eph : the
amplitude evaluated by (8) is confirmed; moreover, it is evident the great shape improvement
compared with the tooth e.m.f.
It is particularly noticeable the absolute absence of slotting effects, in spite of the very
low no. of slots/(pole-phase). The phase-to-neutral e.m.f. is almost sinusoidal: in fact, the
harmonic analysis eph has evidenced limited harmonics, except for an appreciable, even if
low, third harmonic e.m.f.; but, as known, this component is cancelled in the line-to-line
voltage, while the actual lowest order harmonics (fifth, seventh order) are reduced by the
layer displacement (see (3)).

Figure 14. No-load phase-to-neutral measured e.m.f., for the constructed motor (data of Table 2,
Fig. 4, Ntuc = 46 turns/coil)

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Di Gerlando et al.

Figure 15. Simulated and test results of the motor of Table 2 and Fig. 4, with Ntuc = 46, in sinusoidal
feeding (380 Vrms, 50 Hz); x axis: torque (from no-load to Tmax ); y axis: input current; : analytical
simulation, by (15), (16), 0 max = z : : experimental result; x: FEM simulation result [14].

Another important effect connected to the PM winding arrangements adopted in this

kind of machine is the very low level of cogging: by manually handling the rotor of the
unfed motor, we have verified no appreciable cogging torque, as confirmed also by FEM
simulations [14].
Fig. 15 shows simulated and test results of the input current in loaded operation with
sinusoidal feeding (V = 380 Vrms, f = 50 Hz), with the torque ranging from zero to Tmax : the
analytical result (see also Fig. 7) is confirmed both by measurements and FEM simulation,
for no-load, rated torque and pull-out torque conditions.
The rated operation has been verified also by a thermal test (Fig. 16), that indicated
acceptable temperature levels.
Figs. 17 and 18 report some simulations, performed by integrating equation (28), aimed
to show the motor dynamic behavior, evidencing its self-starting capabilities, under mains
sinusoidal supply, in loaded conditions.
Considering that the rotor inertia equals Jr = 0.023 kgm2 , we have considered to drive a
load with the same inertia ( Jtot = 0.046 kgm2 ); several simulations have been performed,
with different mains voltage phase conditions.

Figure 16. Experimental thermal test of the motor of Table 2, Fig. 4, Ntuc = 46, running with sinusoidal feeding (380 Vrms, 50 Hz), with rated torque (Tn = 53 Nm); the points are the temperatures
measured by a thermocouple put in contact with the endwindings (ambient temperature: Ta = 25.5 C).

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319

Figure 17. Simulated transient of the motor of Table 2, Fig. 4, Ntuc = 46, with sinusoidal feeding
(V = 380 Vrms, f = 50 Hz): synchronization from zero speed with rated torque (Tn = 53 Nm); total
inertia: 0.046 kgm2 ; response to torque steps of DT = 40 Nm.

Fig. 17 refers to a synchronization from zero speed with rated torque (Tn = 53 Nm),
followed by two opposite torque steps of T = 40 Nm: the response appears stable and
acceptable, both at starting and after load variations.
Fig. 18 shows another starting transient under the same conditions of Fig. 17, except
for the initial values of the supply voltages (in opposition to the previous one): the starting
transient has the same duration as before (roughly 0.4 s), but torque and speed show different
instantaneous values, even significantly negative. At t = 0.5 s, a torque ramp is applied,
up to the pull-out torque, that occurs exactly at the analytically estimated torque value
(Tmax = 101 Nm), with the consequent loss of synchronization.
Corresponding results have been obtained also by FEM transient simulations: these
simulations gave the additional information of the absence of torque ripple: this result,
confirming the absence of cogging of the unfed machine, appears particularly interesting,
also considering that no skewing have been applied between teeth and PMs.
Experimental starting tests in loaded conditions demonstrated the correctness of the
simulations, with a satisfying behavior, both at starting and during steady state operation:

Figure 18. Simulated electromechanical transient of the motor of Table 2, Fig. 4, Ntuc = 46, with
sinusoidal feeding (V = 380 Vrms, f = 50 Hz): synchronization from zero speed with rated torque,
with initial voltages in opposition to those in Fig. 17; application of a torque ramp, up to the pull-out
torque (Tmax = 101 Nm).

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Di Gerlando et al.

the sinusoidal nature of the machine is confirmed by the practical absence of noise in any
operating condition.

Conclusion
A PM synchronous motor equipped with special, two-layer, concentrated coil windings have
been described, capable of self-starting in loaded conditions with mains supply: the winding
structure have been illustrated, together with some design criteria, developing useful figures
of merits for the best choice of the main constructional parameters.
Several simulations by analytical and FEM models have demonstrated the interesting
performances of the machine, confirmed also by corresponding experimental tests.
The activity will be intensively continued, both as regards the optimization of the motor, and concerning the application of the developed winding theory to different machine
configurations.

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[2]
[3]
[4]
[5]

[6]
[7]
[8]
[9]
[10]

[11]
[12]
[13]

[14]

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