In this section, the electromagnetic performances of the benchmark DTP PMSMs with IPM and AIPM rotors are compared, including air-gap flux density, back EMF, cogging torque, torque, loss, and efficiency. It should be mentioned that all the analyses presented below are based on the results obtained from JMAG-Designer by using 2-dimensional (2D) finite element (FE) method.
3.1. Open-Circuit Characteristics
The flux line distributions of the DTP PMSMs with IPM and AIPM rotors under OC are firstly calculated and compared, as shown in
Figure 4. As can be seen, due to the middle-side small magnet and the outside flux barrier in one AIPM rotor pole, closed flux lines can be observed. The waveforms and spectra of the radial flux densities along air-gaps air-gap under this condition are shown in
Figure 5 (a) and (b). In
Figure 5 (a), the fluctuations can be explained by the asymmetric rotor layout and the closed flux lines in one AIPM rotor pole. From
Figure 5 (b), it can be clearly seen that the AIPM rotor has higher fundamental component, which can be attribute to the flux-focusing effect caused by the flux barrier in the AIPM rotor. However, the AIPM machine also shows more harmonic contents compared with the IPM counterpart, which may result in larger eddy current loss in the AIPM machine. Hence, the flux density distributions of the benchmark PMSMs under OC suggest that the loss and efficiency of the DTP PMSMs with IPM and AIPM rotors need more attention in the following analyses.
In the DTP PMSMs with IPM and AIPM rotors, assuming rotor speed is 200 rpm, the waveforms and spectra of phase back electromotive forces (EMFs) of Phases A1 and A2 are shown in
Figure 6. From
Figure 6(b), it can be seen that similar to the OC air-gap flux density, the amplitude of the fundamental back EMF in the AIPM machine is higher than that in the IPM machine.
For the DTP PMSMs with IPM and AIPM rotors, the waveforms and spectra of the cogging torques are given in
Figure 7 (a) and (b). Due to the same slot/pole number combination, the fundamental orders of cogging torque in IPM and AIPM machines are exactly the same, which is 48 in mechanical angle (the smallest common multiple between slot number, 48, and pole number, 8) and 12 in electric angle, but the amplitudes of the same harmonic order are different in IPM and AIPM machines. In the analyzed DTP PMSMs, the cogging torque produced by the AIPM rotor is much larger than that produced by the IPM rotor.
3.2. Torque Characteristics
In this part, the torque characteristics of the DTP PMSMs with IPM and AIPM rotors are compared under full load firstly. In the Toyota Prius 2010 machine, the phase current amplitude under full load is 236 A, and in the benchmark DTP PMSMs, due to different winding configurations, the phase current amplitude for the full load is 118 A. In the DTP PMSMs with IPM and AIPM rotors, the variations of average torque with current advancing angle under full load (IA1 = 118Apk) are shown in
Figure 8. It can be seen that the maximum average torques are obtained when current advancing angle = 53° in IPM machine, and 62° in AIPM machine.
As mentioned before, in IPM and AIPM machines, the variations of PM and reluctance torque components with current advancing angle are quite different. With the help of frozen permeability method [
32,
33,
34], the PM and reluctance torque components can be separated from the total average torque. The variations of PM and reluctance torque components with current advancing angle are also presented in
Figure 8. It can be found that the optimal current advancing angles for the maximum PM torque component are 24° in IPM machine, and 53° in AIPM machine. To achieve the maximum reluctance torque component, the optimal current advancing angles are 58° and 65° respectively in IPM and AIPM machines. The optimal current advancing angles for different torque components are summarized in
Table 2. In the IPM machine, the difference between the optimal current advancing angles for the maximum PM and reluctance torque components is 34°, but in AIPM machine, the difference is only 12°. It can be concluded that compared with IPM rotor, the PM and reluctance torque components in the DTP PMSMs can be better utilized by using AIPM rotor.
From
Figure 8 and
Table 2, under full load (IA1 = 118 Apk), to achieve the maximum average torque, the optimal current advancing angles are 53° and 62° respectively in IPM and AIPM machines. With the optimal current advancing angles, the waveforms and spectra of the instantaneous torque in the DTP PMSMs with IPM and AIPM rotors are shown in
Figure 9. The average torque and torque ripple characteristics of the PMSMs under full load are summarized in
Table 3. It can be seen that compared with the DTP IPM machine, the DTP AIPM machine can increase the average torque by 9.25% and reduce the torque ripple by 47.62% under full load.
The prototype DTP PMSMs in this paper is modified from the STP PMSMs in [
30] by changing winding configurations and optimize rotor design. With the STP windings, the torque characteristics of the STP PMSMs under full load are provided in
Table 4. The results for DTP and STP PMSMs can be compared. Under full load, the STP AIPM machine can increase the average torque by 8.35% and reduce the torque ripple by 34.08% compared with the STP IPM machine. Hence, by employing AIPM rotor, DTP PMSM can achieve better improvement in average torque and more reduction in torque ripple than those in STP PMSM.
Under other load conditions, the optimal current advancing angles can also be obtained based on maximum torque per amplitude (MTPA) control strategy. In the DTP IPM and AIPM machines, assuming IA1 varies from 25 Apk to 250 Apk to cover the load conditions from light-load to over-load, the variations of average torques and torque ripples with phase current amplitude are shown in
Figure 10(a) and (b), respectively. It can be seen that the average torque of the DTP PMSM can always be improved significantly by using the AIPM rotor and the average torque improvements are presented in
Figure 10(c). In addition, when the phase current ≥ 75 Apk, not only the average torque can be improved, the torque ripple can also be reduced by the AIPM rotor. Hence, the AIPM rotor can greatly improve the torque performance of the DTP PMSM.
3.3. Loss and Efficiency
In this paper, the losses and efficiencies of the DTP PMSMs with IPM and AIPM rotors are obtained by using the method in [
36,42]. The copper loss is calculated by using Joule’s law, as
where
R0 is the phase resistance of the DTP windings, and
Ia is the phase current amplitude.
In the calculation of iron losses, it consists of hysteresis and eddy current iron losses, which are calculated by:
where
PHyst-base and
PEddy-base are the hysteresis and eddy current iron losses at the base speed, i.e., 3000 rpm in this study.
f and
fbase are the frequencies of the operating condition and the base speed.
For other losses, PM eddy current losses are obtained from FE simulations directly, and mechanical losses are estimated by [43]
Overall, the loss characteristics of the DTP PMSMs with IPM and AIPM rotors under the full-load (
IA1 = 118 Apk, speed = 3000 rpm) are summarized and compared in
Table 5.
It can be seen that copper loss is the most dominant loss in both IPM and AIPM machines. Since the IPM and AIPM machines share the same stator and armature windings, the copper losses of the two DTP PMSMs are identical. Due to similar iron loss and higher PM eddy current loss, the total loss in AIPM machine is slightly higher than that in IPM counterpart. However, considering that the output torque and output power of the AIPM machine is obviously larger than those of the IPM counterpart, and the AIPM machine still has higher overall efficiency than the IPM counterpart under this condition.
To analyze the loss and efficiency characteristics of the DTP PMSMs with IPM and AIPM rotors at other speeds, the torque and power-speed curves of the two DTP PMSMs are calculated under the constraints (DC link voltage ≤ 650Vdc and phase current ≤ 118Apk), as shown in
Figure 11. Similarly, the variations of the maximum d- and q-axis currents (I
d and I
q), and phase currents (I
a) with speed are shown in
Figure 12. It can be clearly seen that the AIPM machine can produce higher torque than the IPM counterpart not only in constant torque region (low-speed), but also in constant power region (high-speed).
Based on (1), (2),
Figure 11, and
Figure 12, the copper loss and iron loss maps of the DTP PMSMs with IPM and AIPM rotors are calculated, as shown in
Figure 13 and
Figure 14, respectively. The mechanical losses of the DTP IPM and AIPM machines are calculated by using (3), as shown in
Figure 15.
Considering that PM eddy current loss under other speeds cannot be estimated directly from the base speed and the PM eddy current loss is very small in total loss, as indicated in
Table 5, the ignorance of PM eddy current loss in the calculation of resultant efficiency is still acceptable. Thus, when ignoring PM eddy current loss, the total loss maps of the DTP IPM and AIPM machines can be obtained from
Figure 13,
Figure 14, and
Figure 15, as shown in
Figure 16. The total loss difference between AIPM and IPM machines is given in
Figure 16(c). In
Figure 16(c), the operating conditions can be classified into three conditions, i.e., low speed and low torque, low speed and high torque, and high-speed conditions. It can be observed that at high speed, iron loss is the dominant loss and the AIPM machine has higher total loss, while at low speed and high torque, copper loss is the dominant loss and the IPM machine has higher total loss. At low speed and low torque, the AIPM and IPM machines show similar total losses.
In
Figure 14, it can be observed that the iron loss in the AIPM machine is higher than that in the IPM counterpart at high speed and low speed and low torque. However, in
Table 5, it is shown that the iron loss of the AIPM machine is slightly lower than that of the IPM counterpart at full load (low speed and high torque). Considering that the phase currents under different operating conditions are different, it is necessary to further analyze the effects of electric loadings on iron losses in the DTP AIPM and IPM machines.
Assuming the phase currents varying from 0 to 250 Apk, the iron losses of the DTP PMSMs with IPM and AIPM rotors at 3000 rpm are compared in
Figure 17. It can be observed that the iron loss in the DTP AIPM machine is higher than that in the IPM counterpart at low currents (≤ 50 Apk), but lower than that in the IPM counterpart at high loads (≥ 75 Apk). This phenomenon can be explained by the different air-gap MMF harmonic contents in the AIPM and IPM machines. When electric loading is low, the air-gap MMF is mainly produced by rotor PMs. Under open-circuit, the air-gap flux densities of the DTP AIPM and IPM machines are shown in
Figure 5. From
Figure 5(b), it can be obtained that the AIPM machine has higher fundamental component (0.77 T in IPM machine, and 0.92 T in AIPM machine) and more abundant harmonic contents (THD = 42.66% in IPM machine, 68.42% in AIPM machine). Hence, the iron loss of the DTP AIPM machine is significantly higher than that in the DTP IPM machine under low-load. However, with the increase of phase currents, the air-gap flux densities of the DTP AIPM and IPM machines are mainly affected by armature windings, and less affected by rotor PMs. Under full-load (I
A1 = 118Apk), the air-gap flux densities of the DTP AIPM and IPM machines are compared in
Figure 18.
It can be seen that the air-gap flux densities of the DTP IPM and AIPM machines are close to each other under this condition. In addition, due to different rotor layouts, the harmonic contents in the AIPM machine are even lower than those in the IPM counterpart under this condition (THD = 41.57% in IPM machine, 38.44% in AIPM machine). As a result, compared with DTP IPM machine, the DTP AIPM machine shows higher iron loss when electric loading is low (under low speed and low torque, and high-speed conditions) and lower iron loss when electric loading is high (at low speed and high torque).
Based on
Figure 16, the efficiency maps of the DTP PMSMs with IPM and AIPM rotors are calculated, as shown in
Figure 19(a) and (b), respectively. The efficiency difference between the AIPM and IPM machines is presented
Figure 19(c).
It can be found that the DTP AIPM and IPM machines show higher efficiencies under different operating conditions. Due to the more abundant PM MMF harmonics in the DTP AIPM machine, DTP AIPM machine shows higher iron loss and lower efficiency than IPM counterpart at high-speed. However, when electric loading is higher, the iron losses due to armature reaction field become more significant and hence the iron losses in IPM and AIPM machines become similar to each other. Thus, the investigated DTP AIPM topology exhibit higher efficiency than the IPM counterpart at high torque and high load conditions due to the optimization goal only focusing on higher torque density [
36].