This article has been accepted for publication in a future issue of this journal, but has not been

fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2432738, IEEE Transactions on Magnetics
FY-16 1

Analysis of Electromagnetic Torque and Effective Winding Inductance in a

Surface-Mounted PMSM during Integrated Battery Charging Operation
Chunyan Lai1, Student Member, IEEE, K. Lakshmi Varaha Iyer1, Student Member, IEEE,
Kaushik Mukherjee2, Member, IEEE, and Narayan C. Kar1, Senior Member, IEEE
1
Department of Electrical and Computer Engineering, University of Windsor, Ontario, Canada - N9B 3P4
2
Indian Institute of Engineering Science and Technology, Shibpur, Howrah, West Bengal, India - 711103
During integrated charging (IC) operation employing permanent magnet machines, the magnetic field produced by the sinusoidal
AC current passing through the stator windings, a) affects the effective winding inductance used in the charger circuit as a function of
different stator winding combinations; and b) produces oscillating torque of varying magnitudes as a function of rotor position.
Understanding the above challenges, this paper exclusively investigates the electromagnetic effects inside a surface-mounted
permanent magnet synchronous machine (SPMSM) when it is used for IC operation in electric vehicles. Variation of oscillating
electromagnetic torque magnitude as a function of rotor angle is investigated through finite element analysis and recommendations are
provided to determine the lowest torque position favorable for IC operation. Thereafter, numerical investigations are conducted for
five different stator winding combinations to analyze the issue of varying effective inductance as a result of magnetic coupling in the
motor. Furthermore, a mathematical model is developed to obtain these inductances in the five winding configurations. Finally, the
numerical investigations are validated by performing experimentations on a 21 hp SPMSM.
Index Terms Electromagnetic Torque, Inductance, Finite Element Analysis, Integrated Battery Charging, Magnetic Coupling,
Permanent Magnet Motor.

I. INTRODUCTION element analysis (FEA) as presented in section II.

The battery pack in an electric vehicle (EV) supplies
electric power to the traction AC machine through a DC-DC
converter followed by a DC-AC inverter. Permanent magnet
synchronous machines (PMSMs) are widely used as traction
motors in EVs. Both interior and surface PMSMs are being
developed for EV applications. An independent on-board
battery charger is needed to charge the battery pack, which can
add significant cost, weight, and volume to the vehicle. Since,
the electric machine and the converters are not engaged when
the vehicle is being charged from the power grid, with some
modifications, they can be used to charge the battery pack in
order to avoid the extra cost, weight, and volume of the EV.
This concept of integrated battery charging is attracting
attention nowadays due to the aforementioned benefits.
To design a motor drive system with integrated charging
(IC) capability, the machine windings can be reconfigured to
be used as an AC side inductor. Along with the solid state
switches of the drive meant for feeding power to the traction
machine, the AC side inductors can help in realizing a boost
AC-DC converter to improve the power factor while charging.
Most of the existing literatures on IC focus on various circuit
topologies [1]-[5] and charger performances [5], [6]. This
paper rather aims to explore the happenings inside a PMSM
when AC current is flowing through its armature windings.
More specifically, the interactions between the electro-
magnetic field produced by the AC current excitation and the
rotor magnetic field can cause pulsating electromagnetic
torque and variations of the effective winding inductance. In
this investigation, these two aspects, the torque produced and
the impedance due to different winding configurations under a
single-phase IC operation employing a 21 hp surface-mounted
PMSM (SPMSM) drive system, are investigated.
The electromagnetic torque is analyzed first using
mathematical equations, and then results elicited through finite
Manuscript received March 20, 2015. Corresponding author: Chunyan Lai
(e-mail: lai112@uwindsor.ca).
Digital Object Identifier inserted by IEEE
Recommendations are also provided to determine the lowest
torque position favorable for IC. Five different stator winding
configurations are presented in section II and a method of
calculating and measuring their effective inductances are
formulated in section III. Section IV presents the experimental
results validating the developed equations and methods to
obtain the winding inductances for the winding combinations
under consideration.
I. ANALYSIS OF THE ELECTROMAGNETIC TORQUE UNDER
INTEGRATED CHARGING OPERATION
Theoretically, for a battery charger circuit with a boost
power factor correction, near-unity power factor of 0.99 and
above can be achieved with very low total harmonic distortion
(THD) [7]. Therefore, the AC side charging current, i,
ignoring the current harmonics, is considered as a pure
sinusoidal waveform, which is i=Imsint, where Im is the peak
value of the current and is the electrical frequency in
rad/sec. For a PMSM, the instantaneous torque can be written
as follows [8].
P Lmd Lmq 2 1 2 1 2
Te ia ib ic ia ib ia ic
2 3 2 2
ib ic 2ia ib 2ia ic cos 2r
3 22
2ib ic sin 2r (1)
2
1 1 3
m ia ib ic cos r ib ic sin r
2 2 2
where P is the number of poles of the machine, Lmd and Lmq are
the d-axis and q-axis magnetizing inductances, ia, ib, and ic are
the phase currents flowing through the machine windings, r is
the rotor position, and m is the amplitude of the flux linkage
established by the rotor permanent magnet. In the case of a
SPMSM, Lmd is equal to Lmq. Since the motor is at standstill
while charging, the rotor position r is some arbitrary constant.
Then, the torque equation in (1) can be simplified as in (2),

0018-9464 (c) 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See
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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2432738, IEEE Transactions on Magnetics
FY-16
Te K sin t
where K and are constants related to the motor parameters,
amplitude of the excitation current and the initial rotor
position. From (2), the average torque should be zero, for all
different rotor positions and winding configurations as shown
in Fig. 1, when a single-phase AC current in the grid-side for
level 1 or level 2 charging is used. This means that utilizing
the machine windings for a single-phase IC operation cannot
cause rotation of the motor shaft. However, a pulsating torque
will be produced, which can cause vibrations and acoustic
noise that can be mitigated by minimizing the parameter K.
Since the motor parameters and the charging current are pre-
designed, directing the rotor to a proper position will be the
solution to reduce the pulsating torque.
To be more specific, considering the first configuration in
Fig. 1, AC current flows only through phase a. Hence,
ia=Imsint and ib=ic=0. Then, the parameter K in (2) is
(P/2)mIamcosr, and =0. By using the stator winding of a
SPMSM, with P=8, m=0.23, in the converter circuit for
charging, which consumes an rms current of 15 A from the
grid, K is equal to 19.5. Theoretically, a pulsating torque with
its peak at 19.5 Nm will be produced when r=0, which
means the rotor q-axis is aligned with stator phase a. Also, at
r=90, when the rotor d-axis is aligned with phase a, the
produced torque will be zero. However, from FEA, the
maximum instantaneous torque is found to be 16.4 Nm when
the initial rotor position is at 0 and a torque between 0.1 to
0.2 Nm can be seen at the predicted zero pulsating torque
position, which is 90. Magnetic flux densities produced by
the permanent magnet and the charging current at two
different rotor positions when the magnitudes of the
oscillating torque are maximum and minimum are presented in
Fig. 2. From this figure, the differences in the torques in both
cases can be attributed to the interaction between the magnet
flux and stator flux produced by the current in a phase
windings. To explore more about the relationship between the
instantaneous torque and the rotor position, four other rotor
positions are selected, and the corresponding torque
waveforms are presented in Fig. 3.
L1
iac L1 iac n
iac
n a
a b
b Case 1: Only phase a winding is used in the charger circuit
(i) (ii)
iac L1 iac L1
n b
a n b a
(iv) (v)
Fig. 1. Five different inductor configured by the stator windings.
(i) (ii)
Fig. 2. Magnetic flux density plots for maximum and minimum oscillating
torque positions. (i) Minimum torque (for 90o). (ii) Maximum torque (for 0o).
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2
(2)
Fig. 3. Instantaneous torque waveforms for different rotor positions.
These torque waveforms appear to be sinusoidal functions
and rotor position dependent as predicted by (2).Therefore, the
pulsating torque will be minimized when the magnetic field in
the rotor is aligned with the pulsating field produced by the
stator current. To direct the rotor into this specific position, a
DC current is required to flow through the configured inductor
before the machine windings are reconfigured to be used as
the AC boost inductor. This can fix the rotor to the minimum
pulsating torque position.
II. ANALYSIS OF THE WINDING INDUCTANCES FOR DIFFERENT
CHARGING CONFIGURATIONS
Based on the input voltage and current ratings of the
charger, the AC side inductor value can be designed for
specific current ripple criteria and to obtain near-unity power
factor operation. From the machine side, the three-phase
windings can be reconfigured to get different values of
inductances. Once we can find an inductance that matches the
required value and current rating of the charger circuit, a
proper battery charging operation can be ensured.
However, the equivalent impedances in the charger circuit
are influenced by the magnetic coupling effect when more
than one phase is used to form the equivalent inductor for
charging. Moreover, the effective inductance will influence
the THD level of the charging current and the kVA rating of
the inverter for a given charging power taken from the grid.
Hence, the analysis performed in this section focuses on the
determination of the effective inductance value of the AC side
inductor as a function of different winding combinations as
L1 presented in Fig. 1. Different combinations of the stator
a
n
windings presented in Fig. 1 are analysed henceforth under
five different cases as presented below:
c in this case. When an AC current is flowing only through the
(iii)
phase a winding, voltage can be induced in phases b and c. By
measuring these voltages and current, important parameters
c representing the machine can be derived from their current-
voltage relationship. When a voltage is applied across phase a
winding, phase a voltage and current, and phase b and c
voltages can be measured using an oscilloscope. The voltages
in phases a and b can be presented as in (3) and (4),
respectively. Where, Ra, La, LA Lls and Mba, are winding
resistance, total self-inductance of phase a, phase inductance
independent of the 2r variation (or the DC component of the
phase inductance), armature leakage inductance of the
machine, and the mutual inductance of phase b caused by
phase a magnetic field, respectively. Then, to avoid distortions
in the measured current and voltage waveforms, (3) and (4)
can be formatted as (5) and (6) through a fast Fourier
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2432738, IEEE Transactions on Magnetics
FY-16 3

Transform, defined in (7), to extract the fundamental parallel. So, only the phase b voltage is written here in (16).
waveform of the signals. Hence, calculations become less The current relations are ib=ic=-0.5ia. Then the voltage
complicated. The resistance is the real part of the calculated equations are simplified by considering the current relations.
result and the inductance is the imaginary part divided by the The phase a voltage is found to be the same as the one in case
electrical frequency. The effective inductance in this case, four as in (14) and the phase b voltage is calculated using (17).
with only phase a winding, is equal to the self-inductance of The total resultant inductance is calculated to be
phase a winding, which is L1=La=Lls+LA. Also, the resistance L1=1.5Lls+2.25LA.
is the same as the phase a winding resistance. di di
va Ra ia La a M ab b (12)
di di
va Ra ia La a Ra ia Lls LA a (3) dt dt
dt dt di di
vc M ca a M cb b (13)
di L di dt dt
vb M ba a A a (4)
dt 2 dt 3L di
va Ra ia ( Lls A ) a (14)
V ( j) 2 dt
Ra jLa a1 (5)
I a1 ( j) di di di
va Ra ia La a M ab b M ac c (15)
Vb1 ( s) dt dt dt
jM ba (6)
I a1 ( s) di di di
vb Rb ib Lb b M ba a M bc c (16)
dt dt dt
F () f (t )e jt dt (7)
3L di
Case 2: If two of the machine phase windings are connected vb Ra ib ( Lls A ) b (17)
2 dt
in parallel to form an inductor, mutual coupling between Apparently, the effective inductance is higher when the
phases occurs due to two time-varying electromagnetic fields.
machine windings are connected in series. There are more
The voltages across phases a and b are equal since they are in
combinations, which can be achieved if all of the six terminals
parallel. The mutual inductance of phase a caused by phase b of the motor armature windings are independently accessible
magnetic field is Mab, and the ones of phase c are Mca and Mcb externally. Connecting all three phases in parallel as in Fig.
due to the time varying currents in phases a and b. Then, the 3(iii) offers minimum inductance and the case of only two
voltage-current relationship of phase a can be written as in (8).
phases connected in series presents the highest inductance
The induced voltage in phase c is presented as in (9). Since the
among the five cases.
three phase motor windings are considered as identical, the
current flowing through the phases a and b, which are in III. EXPERIMENTAL TESTING OF THE EFFECTIVE WINDING
parallel connection, will be the same. The voltage equations INDUCTANCE ON A SPMSM UNDER IC OPERATION
can be written as in (10) and (11). Following the same
procedures as in case 1, the effective inductance can be For all of the five reconfigured inductors presented in Fig.
1, a basic circuit diagram, as in Fig. 4(i), is used to test their
calculated to be L1=0.5(Lls+0.5LA), with two of the phase
actual inductance. Hence, the equivalent impedance of the
windings in parallel.
inductor, L1, written as Z1=R1+jL1, can be found out by an
di di
va Ra ia La a M ab b (8) AC current test. The calculated inductance L1 from the
dt dt previous section is presented in Table I as a function of the
di di original machine parameters, Ra, LA and Lls, which can be
vc M ca a M cb b (9)
dt dt taken as constants. Then, experimental tests were conducted
L di on a 21 hp in-house SPMSM, as shown in Fig. 4(ii), to verify
va Ra ia ( Lls A ) a (10) the calculated results. The calculated and the test results as
2 dt presented in Table I show that the effective winding
di inductance varies over a wide range due to the coupling effect
vc LA a (11)
dt caused by different winding combinations.
Case 3: When all three phase windings are connected in Taking the first configuration in Fig. 1, only phase a of the
parallel, the resultant inductance is much smaller and machine is connected in the charger circuit. The current
calculated to be only one third of the leakage inductance, Lls. flowing through phase a and the voltage across it were
Hence, L1=Lls/3. measured and plotted as in Fig. 5. The voltage va and current ia
Case 4: In this case, two of the phase windings are are the voltage and current of phase a, which can be read from
connected in series. Currents flowing through phases a and b, the data acquired. By conducting a Fast Fourier Transform, the
induce voltage in phase c. The corresponding voltage fundamental components Va1 and Ia1 are obtained. Then, the
equations can be written as in (12) and (13). Since ib=-ia, the equivalent impedance of phase a winding is calculated to be
simplified term for phase a voltage is presented as in (14) and Z1=0.13+j0.55, which means the winding resistance is R1=0.13
the induced voltage in phase c is zero. Therefore, the resultant ohm, and the inductance is L1=0.55/H. If the current
inductance is increased to a higher value, L1=2(Lls+1.5LA). increases to a higher value, following the same steps, the
Case 5: Figure 1(v) presents a combination of case one and corresponding waveforms are presented in Fig. 6, and the
two. The phase a voltage is presented in (15). Voltages across impedance can be calculated to be Z1=0.13+j0.57, which is
phases b and c are the same since they are connected in nearly the same as the previous one. This means that the

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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TMAG.2015.2432738, IEEE Transactions on Magnetics
FY-16 4

A
AC R

L1 iac

V
(i) (ii) Fig. 8. Measured phase a and b voltages and total current when all three phase
Fig. 4. AC current excitation test. (i) The surface mounted PMSM used in the windings are connected in parallel under an rms current flow of 6 A (Case 3).
experimental investigation. (ii) Circuit diagram for inductance test.

magnitude of the charging current will not affect the winding

impedance. When connecting two phases in parallel as in Fig.
1(ii), the impedance of the formed inductor is much smaller,
which is apparent from the waveforms in Fig. 7, where the
voltage drop on the inductor is low when the same current is
passing through. In Fig. 8, the voltage across the inductor is
even lower than the one in Fig. 7, presenting a lower Fig. 9. Measured phase a, phase b and line voltages and line current when
phases a and b are connected in series with a 2 A rms current flow (Case 4).
impedance. Fig. 9 is the voltage and current responses for the
fourth case, in which, with higher impedances, the voltage to
current ratio is significantly higher than all other cases
mentioned above. In the last case, as a combination of case 2
and case 4, the total voltage across the inductor, vab, is at a
similar magnitude to the current flowing through it, as
presented in Fig. 10.
TABLE I. EQUIVALENT INDUCTANCES OF THE AC INDUCTOR FORMED BY THE
Fig. 10. Measured voltages across phase a, phase b and phases a and b, and
SPMSM WINDINGS (FIVE DIFFERENT COMBINATIONS AS IN FIG. 1)
line current when phase a is connected in series with the parallel combination
L1 [mH] of phases b and c for a total rms current of 4 A (Case 5).
Calculated Measured
i Lls +LA 1.44 1.45
IV. CONCLUSION
ii 0.5Lls +0.25LA 0.56 0.53
iii Lls/3 0.27 0.25 In this paper, it has been demonstrated that the surface-
iv 2 Lls+3 LA 3.52 3.32 mounted PMSM can be used in the single-phase integrated
v 1.5Lls +2.25LA 2.64 2.68 charging application since zero average torque is generated.
Also, the pulsating torque can be minimized by positioning the
rotor to a proper angle. To achieve higher inductance,
connecting two phase windings in series is the best case.
When more than one phase winding is used to form the
required inductor, the mutual coupling effects should be
considered in the inductance calculations.

Fig. 5. Measured three phase voltages and phase a current when only phase a
is used as the inductor, with an rms current of 2 A (Case 1).
Fig. 6. Measured three phase voltages and phase a current when only phase a
is used as the inductor, with an rms current of 5 A (Case 1).
Fig. 7. Measured three phase voltages and total current when phases a and b
are connected in parallel under an rms current of 4 A (Case 2).
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[2] A. G. Cocconi, Combined motor drive and battery recharge system,
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[3] H.-C. Chang and C.-M. Liaw, "Development of a compact switched-
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