2023 5th International Conference on Intelligent Control, Measurement and Signal Processing (ICMSP)

Design of Spindle Permanent Magnet Synchronous

Motor and Comparative Analysis of Different Core
Materials
2023 5th International Conference on Intelligent Control, Measurement and Signal Processing (ICMSP) | 979-8-3503-3603-0/23/$31.00 ©2023 IEEE | DOI: 10.1109/ICMSP58539.2023.10171042

Junyong Chen
Logistics Service Group, Beijing Jiaotong University, Beijing, China
[email protected]

Abstract—Aiming at the problem of high loss and low materials, the core loss is reduced to 2/5 of the original loss [2].
efficiency of the spindle motor for machine tools in high-speed Using finite element analysis, S. Okamoto et al [3] compared
and high-frequency operation, the characteristics of high the core losses of silicon steel motors and amorphous alloy
frequency and low loss of amorphous alloy materials are used to motors at different speeds. The results show that amorphous
replace the traditional silicon steel sheet of motor, to reduce the alloy can reduce core loss of motors by more than half, and the
core loss of motor and improve the efficiency of the motor. In this prototype was processed and verified by experiment. To
paper, a 20 kW high-speed spindle permanent magnet compare the core loss of amorphous materials in different
synchronous motor is taken as the research object. Combined
forms, scholars from the Ghent University of Belgium, etc.
with the characteristics of amorphous materials, the influence of
simulated a 1.5kW motor and analyzed the influence of
different structural parameters on the performance of the motor
is analyzed. The electromagnetic structure of the motor is
conventional processes on the performance of amorphous
designed, and the finite element analysis model of the materials [4]. The references [5-10] focused on the temperature
electromagnetic field is established. The no-load condition and field distribution of the motor after the adoption of amorphous
load condition of a motor are both simulated and analyzed, and materials. In the reference [11], the various losses of a 7 kW
the prototype is designed and manufactured. The correctness of permanent magnet synchronous motor were analyzed, the stator
the simulation results is verified, which provides a certain winding end potting process was added, and a experimental
reference value for the application of amorphous alloy materials prototype was established to study and verify the temperature
in the high-speed high-frequency motor. field of this motor.

Keywords- spindle; high speed permanent magnet synchronous This paper presents the analysis and design of a 20 kW
motor; amorphous alloy; electromagnetic design stator iron core synchronous permanent magnet engine made
from amorphous alloy materials. A comparison and analysis of
the influence of the amorphous alloy core and silicon steel core
I. INTRODUCTION on the electromagnetic performance of the permanent magnet
At present, motors in the field of high-performance drives synchronous motor is presented, and the prototype is processed
are developing toward high-speed and high-frequency to verify this.
operating conditions, and the core loss of traditional silicon
steel motors in high-frequency operating conditions accounts II.DESIGN OF PERMANENT MAGNET SYNCHRONOUS MOTOR
for a relatively large proportion, which has a greater impact on
the operating efficiency of the motor and the motor's power A.Selecting a Template Electromagnetic design of permanent
density improvement. Amorphous alloy materials have the magnet synchronous motor
characteristics of low core loss and high magnetic permeability,
and the core loss in motor applications is one-third or less than Design of the motor stator: The inner and outer diameter of
that of silicon steel, especially in high-frequency situations, the a stator are two important parameters of motors, which have a
low core loss advantage of amorphous alloy materials is more great influence on the performance of motors. The influence of
obvious. However, amorphous alloys also have the D1 outer diameter of motor stators on motor efficiency is
disadvantage of low saturation magnetic density, resulting in shown in Fig. 1.
reduced motor performance at low speeds and high torque
operating conditions, so it is necessary to combine the
advantages and disadvantages of amorphous alloy materials to
carry out motor design research [1].
Extensive and detailed research work on the application of
amorphous alloy materials in electric motors has been carried
out by both domestic and foreign researchers. Scholars from
the Toyota Institute of Technology in Japan have carried out a
comparative study of the application of silicon steel materials
and amorphous materials in permanent magnet synchronous
motors using numerical analysis. The results show that after Figure 1. Variation curve of efficiency with stator outer diameter
replacing amorphous materials with silicon steel sheet

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 As can be seen from Fig. 1, increasing the stator outer winding from a high-frequency power source, a larger diameter
diameter can improve the efficiency of the motor, but the of the stator winding wire may cause a proximity effect
improvement in efficiency is no longer evident as the stator between adjacent wires, but also lead to the current skin
outer diameter is increased to 110mm. The motor efficiency collection of the conductor. These two phenomena will reduce
hardly increases when the stator’s outer diameter exceeds 115 the effective cross-section area of the conductor and increase
mm. Considering the working environment of the motor and the equivalent resistance value, which will increase the copper
the dimensional requirements during installation and shipment, loss of the stator winding, resulting in lower motor efficiency
the stator outer diameter should be within a reasonable range. and higher stator winding temperature. Therefore, in the design
For the design of permanent magnet synchronous motors, the of permanent magnet synchronous motors, the wire diameter
value of D1 is 115mm which meets the engineering should be limited to a reasonable range.
requirements.
 Combined with a series of parameters such as slot full
The high-speed permanent magnet synchronous motor ratio, slot type and stator slot size of the motor, a
designed in this paper uses a half-open pear groove, the double-layer winding is adopted, in which the diameter
structure of which is shown in Fig. 2. of the winding is 0.66mm, the number of parallel
branches is 2 and the pitch is 5.
 Design of the motor rotor: High-speed permanent
magnet synchronous motors generally include two types
of structures: surface-mounted pole and built-in pole.
The built-in pole structure is difficult to manufacture,
easy to damage, and expensive to produce, and is not
suitable for the motor designed in this paper. Therefore,
the surface-mounted pole structure is chosen for this
design.
Figure 2. Stator slot type
The rotor outer diameter is associated with the air gap, and
To ensure the magnetic density of all parts of the motor changing the rotor outer diameter is equivalent to changing the
within a reasonable range, cogging torque, core loss, and eddy air gap thickness. Fig. 4 gives the effect of changing only the
current loss will be controlled in a smaller range, while the rotor outer diameter D2 on the overall motor performance.
maximum output power and efficiency of the motor will be as As can be seen from Fig. 4, the change in rotor outer
large as possible. The final size of the stator slot is as follows in diameter makes the air gap thickness also change, as the air gap
Table 1. thickness decreases, the air gap magnetic flux density increases,
so the air gap should not be too small when designing the
TABLE 1 STATOR SLOT SIZE motor, otherwise, it will make the stator magnetic density too
large, or even reach saturation, and the air gap is too small will
Parameter Value
affect the sheathing processes on the rotor. The rotor outer
H S0 /mm 0.8 diameter selected in this paper is 56 mm.
BS0 /mm 1.6
H S1 /mm 1
BS2 /mm 7.32
H S2 /mm 9.5

（a）Air gap flux density （b）Efficiency

Figure 4. Curve of motor performance with rotor outer diameter

Neodymium-iron-boron (N42SH) is selected as the

permanent magnet material. For the surface-mounted
（a）Resistance （b）Thermal load permanent magnet synchronous motor, there are two main
Figure 3. Variation curve of motor parameters with wire diameter parameters, pole arc coefficient, and thickness, which affect the
performance of the whole motor. Fig. 5 shows the influence of
Fig. 3 shows the effect of winding diameter on motor the permanent magnet pole arc coefficient on the motor.
parameters. It can be seen from the diagram that with the wire
diameter increasing, the efficiency of the motor will be
improved, the winding resistance decreases, the copper loss of
the winding decreases slowly, and the thermal load of the
winding also decreases. However, because the high-speed
permanent magnet synchronous motor is powered by a given

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 pole arc
Winding Double-layer 0.73
coefficient
Winding wire
Pitch 5 0.66mm
diameter /mm

III.FINITE ELEMENT ANALYSIS OF HIGH-SPEED PERMANENT

MAGNET SYNCHRONOUS MOTOR
（a）Air gap flux density （b）Stator teeth flux density
A.Establishment of the finite element model
The 1/4 model of a 20kW high-speed permanent magnet
synchronous motor established in the FEA software is shown in
Fig. 7.

(c) Efficiency (d) Cogging torque

Figure 5. Curve of motor performance with pole arc coefficient

Fig. 6 shows the effect of the thickness of the permanent

magnet on the motor.

Figure 7. Motor model diagram

(a) Air gap flux density (b) Stator teeth flux density
B.Amorphous alloy materials and silicon steel materials
Fig. 8 shows the variation curves of core loss for silicon
steel and amorphous materials at different frequencies with the
change of magnetic induction strength. With the increase of
magnetic induction strength and frequency, the iron loss of
different motor materials is increasing, and the iron loss of
(c) Motor efficiency (d) Cogging torque silicon steel materials is higher than that of amorphous
Figure 6. Variation curve of motor performance with permanent magnet materials at low frequency, but the difference is not very
thickness obvious, the iron loss and magnetic induction strength of
silicon steel materials are much higher than that of amorphous
It can be deduced from the above figure that the maximum alloy materials at high frequency, and the difference is
output power increases gradually with the increase of the pole especially obvious. And the saturation magnetic induction
arc coefficient and the thickness of the permanent magnet. The strength of amorphous materials is lower than that of silicon
stator teeth magnetic density, yoke magnetic density, air gap steel materials. Therefore, when designing motors and
flux density, and cogging torque reach the maximum value conducting finite element analysis, it is necessary to focus on
when the thickness of the permanent magnet is 6 mm, and then the effect of amorphous materials’ magnetic saturation on
decreases, and the efficiency of the motor also increases first permanent magnet synchronous motors.
and then decreases. To make the motor more efficient, the pole
arc coefficient is determined to be 0.7 and the thickness of the
permanent magnet is determined to be 5 mm.

B.Design results of the motor

The dimensions and main parameters of this motor are
shown in Table 2.

TABLE 2 MAIN PARAMETERS OF MOTOR

Parameter Value Parameter Value
Number of
Power/kW 20 4
motor poles
Number of
D 1 /mm 115 24
slots
Structure of surface- Figure 8. Iron loss curves of amorphous alloy materials and silicon steel
D 2 /mm 56 materials
the rotor mounted

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C.Analysis of the back electromotive force 2)No-load magnetic field: Fig. 11 shows the no-load
Fig. 9 shows the waveforms of the back electromotive force magnetic field and teeth magnetic density distribution of the
of the two motors at no load and 35000r/min. two motors. As can be seen from Fig. 11, the peak magnetic
density of the teeth of the amorphous alloy motor is 1.09 T,
As can be seen from Fig. 9, the back EMF waves of silicon
and the peak magnetic density of the teeth of the silicon steel
steel and amorphous materials motors are similar, with little
difference between the RMS values of the two. motor is 1.10 T. The magnetic density distribution and the
peak of the two motors are basically the same.

(a) Silicon steel motor

(a)Magnetic field of silicon amorphous alloy motor

(b) Amorphous alloy motor

(b) Magnetic field of steel motor
Figure 9. No - load back electromotive force of two motors

D.Analysis based on no-load operating conditions

1)Cogging torque: Fig. 10 shows the cogging torque of the
two materials motors, and it can be seen from the figure that
the cogging torque waveforms of the two motors are almost
the same, and the cogging torque of the silicon steel motor is
slightly less than that of the amorphous alloy motor.
(c) Magnetic density of the teeth of the silicon steel motor

(a) Silicon steel motor

(d) Magnetic density of the teeth of the amorphous alloy motor

Figure 11. Stator Magnetic Field Distribution of Two Materials Motors

E.Analysis based on rated operating conditions

1)Distribution of the magnetic field ： Fig. 12 shows the
(b) Amorphous alloy motor
magnetic field distribution of the two motors at rated operating
Figure 10. Cogging torque conditions. As can be seen from Fig. 12, the peak load

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magnetic density for both motors is about 1.31 T, which has 4.0874×106W/m3, which is nearly 20 times more than the
not reached saturation. former.

(a) Silicon steel motor

(a) Silicon steel motor

(b) Amorphous alloy motor

(b) Amorphous alloy motor
Figure 12. Load magnetic density of two motors
Figure 14. Iron loss cloud map of two motors
2)Load torque ： Fig.13 shows the torque curves of two
motors under load. As can be seen from Fig. 13, the output IV.CONSTRUCTION OF PROTOTYPE AND EXPERIMENTAL
torque of the amorphous alloy motor and silicon steel motor PLATFORM
are 5.42N-m and 5.40N-m respectively, which are relatively
Fig. 15 shows the amorphous alloy stator core, the
similar.
amorphous prototype, and its experimental platform.

(a) Silicon steel motor

Figure 15. Amorphous stator and prototype experimental platform

A.Experiment of the motor back electromotive force

Fig. 16 gives a comparison of the no-load back
electromotive force between the prototype experiment and the
simulation as the motor rotation speed increases.

(b)Amorphous alloy motor As can be seen in Fig. 16, the no-load back electromotive
force of the motor is linearly related to the speed, and the
Figure 13. Output torque of two motors
simulation results are close to the results of the prototype
experimental platform. The no-load back electromotive force
3)Iron loss ： Fig. 14 shows the distribution of iron loss
from the simulation is larger than that from the experimental
density of the two motors under the same working conditions. platform.
It can be seen from the figure that under the same load, the
maximum iron loss density of the amorphous alloy motor is
2.8141×105W/m3, while that of the silicon steel motor is

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 result shows that the electromagnetic properties of the
amorphous alloy and silicon steel permanent magnet
synchronous motors are the same, the efficiency of the
amorphous alloy motor is higher than that of the silicon steel
motor, and its core loss and eddy current loss are both lower
than that of silicon steel motor. The experimental platform of
the amorphous alloy motor was established and the test results
of the amorphous alloy motor prototype under load conditions
were compared with the finite element simulation data, and the
error was within the accepted range.

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Based on the design requirements and theoretical knowledge, a
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diameter, and the structure type of stator slots is realized. The

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