1080 IEEE TRANSACTIONS ON MAGNETICS, VOL. 28, N0.

2, MARCH 1992
The Influence of Finite Element Discretisation on the Prediction of Cogging Torque
in Permanent Magnet Excited Motors
D. Howe and Z.Q. Zhu
Department of Electronic and Electrical Engineering
University of Sheffield, PO Box 600
Mappin Street, Sheffield S1 3JD, England
Abstract---The accuracy of the predicted torque from a finite
element calculation is determined largely by the level of discreti-
sation, as well as t h ~ evaluation method employed. The stored
energy is used to gauge the adequacy of the meshing density in a
finite element model for the prediction of the cogging torque in
permanent magnet excited motors. The relationship between the
stored energy and the torque predicted by both the energy method
and Maxwell Stress integration is discussed and demonstrated by
case studies, and recommendations for their implementation
presented.
I. IN1RODUCTION
Finite element analysis is now used as a matter of routine
by most motor designers to check the performance charac-
teristics of a likely successful design synthesised from analyti-
cal equations linking design parameters to the specification.
However, whilst much useful information can be extracted even
from rather poorly discretised models, eg. flux-linkage, flux
density etc., the calculation of performance factors such as the
cogging torque is extremely sensitive to the discretisation
[1][2][3]. This paper reports on the calculation of cogging
torque in radial-field permanent magnet motor topologies by
both the energy method and Maxwell Stress.
ll. TORQUE CALCULATION
Electromagnetic force can be calculated in a variety of ways,
such as by the Maxwell Stress method [2], and the virtual work
and energy methods [3][4]. In general, however, they require
accurate field solutions, and thus a high level of mesh discreti-
sation, since the calculations are dependent upon local field
quantities.
In order to calculate the torque at a particular rotor position
the virtual work method usually requires that accurate field
solutions be calculated for two different rotor positions, dis-
placed by an incremental angle. Therefore the technique may
suffer from cancellation problems since it relies on the dif-
ference between quantities of nearly equal magnitude. Al-
though this disadvantage can be overcome by prededucing the
spatial derivative of energy in formulating the finite element
equations [4], when only a single field calculation is required
for each force (torque) calculation, in this paper the more usual
implementation of the energy method is described since its
application to permanent magnet machines is somewhat differ-
ent from that for wound field machines. The evaluation of the
torque by Maxwell Stress poses similar practical problems since
it relies on a detailed knowledge of the field vectors and can be
Manuscript received July 7, t99t
dominant by localised inaccuracy associated with the discreti-
sation.
By conservation of energy the total system energy change
due to an angular displacement of the rotor can be expressed as:
L\ Eelec = L\ Estored + L\ Emech (1)
viz, a variation of the electrical input energy will cause a
variation of the stored magnetic energy, and at the same time
result in mechanical work given by the product of the torque T
and angular displacement L\9. In a permanent magnet excited
motor, the input energy is the electrical energy supplied to the
windings from the power supply which is zero in the calculation
of cogging torque, whilst the magnetic energy is stored in: i)
Non-magnetic regions, such as air and copper; ii) Soft-magnetic
regions; and iii) Permanent magnet regions.
Therefore T = - L\ Estored I L\ 9 (2)
where L\ Estored = !1 ( Eair + Eiron + Emagnet ) (3)
In general the stored energy is calculated from:
B
E = J w dv where w =energy /unit volume= J H dB (4)
0
which is calculated according to the material properties. For
non-magnetic regions, since B= J.1.0 H, it becomes:
Wair = B
2
/2J.1.0
(5)
In soft magnetic regions where the magnetisation characteristic
can be modelled as:
B = J.1.o H + starctan (at H)+ sz arctan ( az H) (6)
where ar, az, st, sz are constants, and the stored energy
density is: Wiron = BH- Wcoe (7)
H
2
n 2
Wcoe = J.1.0 2 + H Sl arctan ( at H ) - 2m In [ 1 + ( a1 H ) ]
+ H sz arctan ( az H ) -
2
s
2
In [ 1 + ( az H )
2
] (8)
az
In permanent magnet regions, the stored energy is associated
with the flux density components Bpar and Bper which are
respectively parallel and perpendicular to the direction of mag-
om R-9464/92$03.00 1992 IEEE
netisation, the energy associated with Bper being obtained by
approximating the magnet characteristic in the non-preferred
direction to that of air. Therefore, assuming a linear major
demagnetisation characteristic with remanence Brand recoil
permeability J.lD Jlpar, the stored energy density is given by:
2 2
Wmagnet = ( Br- Bpar) /2 J.1D Jlpar + Bper 12 J.1D Jlper (9)
III. INFLUENCE OF MESH DISCRETISA TION ON COGGING
TORQUE PREDICTION
Because of the short wavelength of the cogging torque wave-
form, typically less than one stator slot-pitch, the calculation of
the cogging torque by both the Maxwell Stress integration and
the energy methods necessitates a very fine spatial discretisa-
tion. In order to establish the reliability of the results from a
finite element calculation five different meshes have been used
to model one pole-pitch of a radial-field motor, which has 12
poles and 36 stator slots and a bonded NdFeB permanent
magnet internal rotor as shown in Fig. 1. The motor parameters
are given in Table I. Since the motor was not highly saturated,
established by finite element analysis, in order to simplify the
study its stator yoke was represented by infinitely permeable
iron. The main features of the meshes employed, which are
based on first-order elements and shown in Fig.l, are:
a) Mesh 1: three layers in the airgap; (348 nodes,618
elements)
b) Mesh 2: as Mesh 1, with mesh density along the radius
doubled near the tooth tips and in the magnet; ( 466
nodes, 846 elements)
c) Mesh 3: as Mesh 2, with mesh density around the
circumference doubled near the tooth tips and in
the airgap, as well as in the portion of the magnet
nearest the airgap; (718 nodes, 1350 elements)
d) Mesh 4: as Mesh 3, the only difference being that the
discretisation pattern of the elements in the airgap
is different; (718 nodes; 1350 elements)
e) Mesh 5: as Mesh 3, but with the mesh density doubled
along the radius through the airgap. (901 nodes,
1710 elements)
Fig.2 compares the cogging torque predictions obtained by
both the energy method and Maxwell Stress integration evalu-
ated over paths through layers of elements near the magnets, in
the centre of the airgap, and near the stator bore. Fig. 3 shows
a comparison of the cogging torque obtained by Maxwell Stress
integration over a circular path through the central layer of
airgap elements for the different meshes, whilst Fig. 4 shows
the cogging torque obtained by the energy method for the
different meshes. Not only are the results obtained by Maxwell
Stress integration extremely dependant on the local discretisa-
tion of the mesh but they are also sensitive to the location of the
integration path, as reported elsewhere in the literatures[1][2].
Nevertheless when employing Maxwell Stress it is always
better to integrate through the central layer of airgap elements
in order to get the most accurate results. In addition it remains
necessary to employ a fine mesh discretisation.
1081
TABLE I
PARAMETERS OF PROTOTYPE MOTOR
surface mounted
parameters
internal rotor motor
unit
pole number 12
remanence 0.56 .T
pole-arc/pole-pitch ratio 1.0
radius at stator bore 0.07327 m
airgap 0.0013 m
height of magnets 0.0091 m
slot opening 0.0038 m
stator slot number 36
axial length 0.095 m
The variation of total energy against the total number of
nodes and elements is shown in Fig. 5. In theory, if the problem
is formulated in terms of the magnetic vector potential, then as
the mesh is refmed, ie., the number of degrees of freedom is
increased, the total stored energy will gradually reduce (or
increase for a scalar potential calculation ) and ultimately attain
the exact value [5]. Fig. 6 shows a comparison of the cogging
torque calculated by both the Maxwell Stress and energy meth-
ods for meshes 3, 4, and 5, together with the measured result It
shows that the results obtained from both methods converge as
the mesh is refined and that the total energy converges to a
constant value, though, with the same accuracy requirement of
torque prediction, a coarser discretisation can be used in the
calculation by the energy method than in that by Maxwell Stress
integration.
Fig. 6 also shows that given two meshes having the same
element density but with one having 'reversed' discretisation in
the airgap region improved accuracy is obtained by averaging
the two Maxwell Stress integration values. It is also observed
in Fig.6 that even with the finest mesh, ie. Mesh 5, a constant
offset in the cogging torque still results in the Maxwell Stress
prediction since the refinement of the mesh is mainly restricted
to the airgap region, whilst the mesh elsewhere is almost ident-
ical for all the mesh discretisations. It is also noted in Fig.6 that
due to the short wavelength of the cogging torque waveform, it
is difficult to obtain the peak value of cogging torque in the
prediction by both the Maxwell Stress integration and the
energy methods. In order to capture the peak value very fine
circumferential displacements must be employed. It is also
found that for a motor with a 180 magnet pole-arc the cogging
torque is maximum when the edges of its magnets align with
the edges of the motor teeth and a minimum when the edges of
magnets algn with the centre of either a tooth or slot opening.
For example, for the particular motor being analysed the edges
of the magnets align with the edges of teeth to give the peak
cogging torque at an angle position of 3.54, as confrrmed by
both finite element analysis and measurement.
IV CONCLUSIONS
The effect of mesh discretisation on the prediction of cogging
torque in permanent magnet motors by both the energy method
and Maxwell Stress integration have been discussed. The rela-
tionship between the total stored energy and the meshing den-
1082
sity provides a useful means to gauge the adequacy of the
meshing density in a finite element model for the prediction of
torque in permanent magnet excited motors, as well as in other
classes of machine, and may be convenient to incorparate into
an adaptive meshing algorithm.
REFERENCES
[1] MJ. DeBortoli and SJ. Salon, "Computation of forces and
torques in electromagnetic devices using the fmite element
method", ICEM'90 Proc., USA, 1990, pp.699-705.
(2] J. Mizia, K. Adamiak, A. R. Eastham, and G. E. Dawson,
"Finite element force calculation: comparison of methods
half periodic boundary
(a) Boundary conditions (b) Mesh 1
(c)Mesh2
(d)Mesh3
(e)Mesh4 (t)Mesh5
Fig 1 Finite element model and mesh discretisation
forelectrical machines", IEEETrans.Magn.,Vol.24, 1988,
pp. 447- 450.
[3] M.Marinescu and N. Marinescu, "Numerical computation
of torques in permanent magnet motors by Maxwell stress
and energy method", IEEE Trans. Magn.,Vol.24, 1988,
pp.463-466.
[4]J.L.Coulomb and G.Meunier, "Finite element
implementation of virtual work principle for magnetic or
electric force and torque computation", IEEE Trans.
Magn.,Vol.20, 1984, pp 1894- 1896.
[5] J .Penman and M.D.Grieve, "Efficient calculation of force in
electromagnetic devices", lEE Proc., pt B, Vol.133, 1986,
pp. 212- 216.
10,------,,------,-------.-------.-------,
-cunH01

0
10
8
6
E
e.
D
2- 4
.s
"'
12
0
-2
0
5

e
e.J
D
I 2
J
1
-curve 1
a-e-El CUnHO 2
+-+-+curve: 3

_cu.....,1

+-+-+ CUnH! 3
A-6-6 curve
2 J
angle pooltlon (degree)
(a) Mesh 1
2 3
angle position (degree)
(b}Mesh2
5
5
-1L_ ______ L_ ____ _J ______ _L ______ _L ______
0 2 J
angle position (degree)
(c) Mesh 3
'E1
3-
0
2

g'
"-2
-J
1
e-e-EJ curve 2
+-+-+ curve 3
2 3
angle position (degree)
(d)Mesh4

0 2 3
angle position (degree)
(e)Mesh5
Fig.2. Predicted cogging torque
cuiVe 1: predicted by energy method
cuiVe 2: bv Maxwell stress for an integration path
through the1ayer of elements nearest magnets
cuiVe 3: by Maxwell stress fqr an int!lgl'!ltiOil. Pllth
lhrough the layer ot elements m the In1Cidle of arrgap
cuiVe 4: predicted by Maxwell stress for an integration path
through the 1ayer of elements nearest stator
node number
300 400 500 600 700 800 900 1 000
5. 30 ,.----.----.----.--'-----.--,..------.------,
4

element number
Fig.S. Variation of tQtal stored energy with the number of nodes/elements
Zp: pole number,la: axial length
E'
6
Q)
::J
0"
'-
0
....
c>
c:
c.
c>
0
0
6
5
!4
v
::I

.s
C'l

C'l
0
0
mesh 1
13-a-B mesh 2
+-+-+ mesh 3
/r--lr-6 mesh 4
H-'V mesh 5
3 4
angle (degree)
Fig.3. Comparison of CSJ&ging tor.que for different
meshes by Maxwell Sfress
1083

mesh 1
5
13-a-B mesh 2
E'4
+-+-+ mesh.3
3
/r--lr-6 mesh 4
.,
mesh 5
::I

.s
C1
r::
g: 2
0
0

5
4
3
2
0
angle position (degree)
Fig.4. Comparisol} of cogging fQr different
meshes by the energy method
meshes 3,4,5 by energy method
mesh 5 by Maxwell stress
average value on meshes 3
and 4 by Maxwell stress

angle position {degree)
Fig.6. Comparison of cogging torque