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Purpose: This study provides a detailed investigation on the prediction and diagnosis of unsteady electromagnetic vibroacoustic performance of IPMSMs for electric vehicles under typical unsteady operating conditions with consideration of rotor step skewing and current harmonics. Methods: Firstly, the control model considering the influence of PWM carrier modulation and rotor step skewing is established. Based on this, the currents of the IPMSM under unsteady operating conditions (driving condition and feedback braking condition) are obtained. Accordingly, the currents calculated through the control model are used as the excitation source of electromagnetic finite element. Then, the electromagnetic vibroacoustic performance under unsteady operating conditions is calculated through electromagnetic force subsection mapping and acoustic transfer vector (ATV) method. Moreover, the conditions where resonance vibroacoustic occurs are diagnosed. Finally, the results of prediction and diagnosis are fully verified by experiments of multiple physical fields. Results and Conclusions: The amplitude errors between prediction results and test results are less than 3.2 % . The influence of current harmonics on electromagnetic vibroacoustic can be predicted. The frequency range and speed range of predicted peak vibroacoustic are consistent with the experimental results. The rotor step skewing can be used to weaken the vibroacoustic amplitude of IPMSMs under typical unsteady conditions in the full speed range. This study provides guidance for prediction and diagnosis for electromagnetic vibroacoustic performance of IPMSMs under typical unsteady operating conditions. [ABSTRACT FROM AUTHOR]

By measuring the open-circuit radial stray magnetic flux density (RSMFD) of three spatial points, a novel diagnostic method for the eccentricity of interior permanent magnetic motors (IPMSMs) in electric vehicles is proposed. Outperforming traditional methods, the proposed method can noninvasively diagnose not only the severities of static eccentricity (SE), dynamic eccentricity (DE), and mixed eccentricity (ME), but also the eccentricity location. In this article, diagnosis results are described through three eccentricity parameters: SE ratio, DE ratio, and SE angle. First, an analytical model of the open-circuit RSMFD of the IPMSM is proposed, with its accuracy validated by experiments. The pattern of the impact of the eccentricity parameters on the open-circuit RSMFD is analyzed to form the basis of the proposed method. Then, an eccentricity prototype motor, which can continuously emulate the eccentricity according to any listed eccentricity parameters, is developed. A test rig is built to collect the open-circuit RSMFD and validate the analytical calculation results. Finally, an eccentricity diagnostic model based on the open-circuit RSMFD is established. The diagnosis results proved the noninvasiveness, effectiveness, and viability of the proposed method. [ABSTRACT FROM AUTHOR]

In an interior permanent magnet synchronous motor (IPMSM) with segmented skewed poles, the armature reaction magnetic field (AR-MF) changes nonlinearly due to the saturation of the rotor magnetic barrier. Meanwhile, this varies under different excitation currents. As a result, it is difficult to be calculated by means of analytical methods. In this paper, the calculation model of AR-MF of IPMSM is first established by vector superposition method, without considering the saturation effect of rotor and the slotting effect of stator. In the second step, the virtual magnetic field of the rotor is introduced to quantitatively calculate the influence of local inhomogeneous saturation on the AR-MF. The latter is derived by combining both the subdomain method and equivalent magnetic circuit method. The complex relative permeance is also introduced to establish the AR-MF accounting for the stator slotting effect. To validate the AR-MF calculation method proposed, an 8-pole 48-slot IPMSM with segmented skewed poles is considered as a case study, showing a comparison by both with finite element (FE) results and the electromagnetic torque measured on a test bench. The model proposed in this paper shows high accuracy and fast computation with respect to FE analysis. [ABSTRACT FROM AUTHOR]

Due to the local inhomogeneous magnetic saturation of the core of the interior permanent magnet synchronous motor (IPMSM), the magnetic field changes nonlinearly, which makes the analytical calculation of the magnetic field difficult. Therefore, the calculation of the magnetic field mostly relies on the finite element method (FEM). However, the high computation cost of FEM restricts the efficiency of the design and analysis of IPMSM. In this article, an analytical model (AM) of slotless open-circuit air-gap magnetic field (OC-AG-MF) of IPMSM with V-shaped segmented skewed poles is derived by combining the subdomain method (SDM) and the magnetic equivalent circuit (MEC) method, and then, the AM of slotted OC-AG-MF of IPMSM with V-shaped segmented skewed poles is obtained by introducing the complex relative permeance. To show the effectiveness of the novel AM, the OC-AG-MF and cogging torque of an IPMSM with V-shaped segmented skewed poles for electric vehicles are calculated by the AM and FEM, respectively. The spatial order, amplitude–frequency characteristics, and the 3-D spatial distribution of the OC-AG-MF are analyzed. Finally, the accuracy of the AM is experimentally verified by direct measurement of OC-AG-MF and no-load back electromotive force (EMF) of the motor. The AM proposed in this article is shown to accurately calculate the radial and tangential components of OC-AG-MF of IPMSM with V-shaped segmented skewed poles considering rotor magnetic bridge saturation effect and stator slotting effect. Meanwhile, the efficiency of the design and analysis of the motor is expected to be improved due to the reduced computational effort compared to the prevalent FEM. [ABSTRACT FROM AUTHOR]

An eccentric position diagnosis method of static eccentricity (SE) fault of external rotor permanent magnet synchronous motor (ER‐PMSM) is presented. Firstly, an analytical model of no‐load radial magnetic field of ER‐PMSM is established. Analytical models of no‐load Back‐EMF of both unit motors and the whole motor are carried out and are verified by finite element method (FEM) and experimental measurements. Then, the influences of SE ratio, SE circumferential angle, winding distribution mode and number of parallel branches on no‐load radial magnetic field and no‐load Back‐EMF are analyzed based on these analytical models. The results show that SE does not affect the frequency characteristics of no‐load radial magnetic field, but changes space order characteristics. On one hand, for ER‐PMSM, of which the number of unit motors is equal to 1, SE causes no‐load Back‐EMF distortion. On the other hand, for ER‐PMSM, of which the number of unit motors is greater than 1, SE does not affect no‐load Back‐EMF of the whole motor, but it still leads to no‐load Back‐EMF distortion of unit motors. Therefore, based on total harmonic distortion (THD) of no‐load Back‐EMF of unit motor, a projection method of intersection lines for SE fault diagnosis of ER‐PMSM is proposed finally. [ABSTRACT FROM AUTHOR]

In this study, the air gap magnetic field characteristics of external rotor permanent magnet synchronous motors (PMSMs) under both the stator and rotor coordinate systems considering low‐order current harmonics and high‐order sideband current harmonics are analysed. A direct measurement technique (DMT) for air‐gap magnetic field is proposed. First, an analytical model of air gap magnetic field of external rotor PMSMs is established. The spatial order and frequency characteristics of stator/rotor air gap magnetic field are revealed. Then, a 24‐pole 27‐slot external rotor PMSM is taken as an example. The analytical and finite element (FE) results are compared and analysed. The difference of the spatial order and frequency characteristics between the stator and rotor air gap magnetic field are verified. Next, a new DMT is proposed, which can detect the precise distribution and local microscopic characteristics on the order of 10−1 mm with high resolution. The accuracy of analytical and FE model are verified by the DMT and an indirect experimental test of no‐load back electromotive force. Finally, the mechanical challenges of in‐wheel motors and the practicablility of DMT for eccentricity detection are further discussed. [ABSTRACT FROM AUTHOR]

3-D analytical model and direct measurement method (DMM) of ultra-thin open-circuit air-gap field (OCAGF) of interior permanent magnet synchronous motor (IPMSM) with multi-segmented skew poles (MSP) and multi-layered flat wire windings (MFWW) for electric vehicles (EV) are proposed. Basis functions of slotless OCAGF are derived through field reconstruction method (FRM). In order to consider MSP and slotting effects, a complex relative permeance function is extended from 2-D to 3-D. Based on the magnetic potential and permeance method, 3-D analytical model of OCAGF is obtained. Then the back electromotive force (BEF) is calculated through Faraday's Law and the cogging torque is obtained through Maxwell stress tensor method. Furthermore, spatial order and amplitude-frequency characteristics of OCAGF are revealed. Additionally, influence of local inhomogeneous saturation caused by PM materials on analytical accuracy is discussed. Finally, the proposed analytical model is verified through both the traditional indirect measurement methods (BEF measurement and cogging torque measurement) and a novel direct measurement method, in which ultra-thin OCAGF of 10−1 mm order of magnitude can be measured directly. Local microscopic characteristics of OCAGF in some important locations, such as tooth top and magnetic bridge, can be accurately detected by using of the direct measurement method. [ABSTRACT FROM AUTHOR]

The no‐load radial magnetic field and no‐load back electromotive force (EMF) of external rotor permanent magnet brushless DC motor (PMBLDCM) are calculated by applying the correction coefficient of magnetic conductance here, taking into account the stator slotting and static eccentricity effects. An external rotor PMBLDCM with 51‐slot/46‐pole, used as in‐wheel motor, is taken as an example, the analytical calculation results of the no‐load back EMF are validated by the finite‐element method and experiment. The influences of static eccentricity ratio on the no‐load radial magnetic field and no‐load back EMF are investigated based on the analytical model. The investigation shows that static eccentricity does not change the harmonic contents of no‐load radial magnetic field, so it does not change the harmonic contents of three‐phase no‐load back EMFs. However, static eccentricity changes the space order of no‐load radial magnetic field, resulting in the different total harmonic distortions of three‐phase no‐load back EMFs; in other words, the asymmetric distortions of three‐phase no‐load back EMFs are generated. The asymmetric distortions of three‐phase no‐load back EMFs are intensified with the increase in static eccentricity ratio. [ABSTRACT FROM AUTHOR]

Here, analytical expressions of the unbalanced magnetic force (UMF）of the stator and the rotor under static eccentricity (SE) are deduced by using complex relative magnetic conductivity method and Maxwell stress tensor method. The frequency characteristics of the UMF are obtained. Further the influence of different eccentricity ratio on the UMF is researched. Then, an external rotor permanent magnet brushless direct current motor (PMBLDCM) with 46 poles and 51 slots used as an in‐wheel motor is taken as an example to verify the frequency characteristics by finite element analysis (FEA). The research shows that the frequency characteristics of the UMF of the stator s related to electric frequency. The frequency characteristics of the UMF of the rotor are related to the power source frequency and the rotation frequency of the wheel. It does not introduce new frequency components when the motor SE occurs. As the SE ratio increases, the amplitude of the UMF increases. The UMF without eccentricity exists in all directions with the change of the time. However, as the eccentricity ratio increases, the direction of the UMF is closer to the eccentric direction. [ABSTRACT FROM AUTHOR]

An analytical method for calculating the no-load magnetic field of external rotor permanent magnet brushless direct current motor (PMBLDCM) used as in-wheel motor of electric vehicle in the stator static coordinate and the rotor motion coordinate is presented in this paper. First, the analytic formulas of slotless permanent magnetic field in both coordinate systems are derived, respectively. Then, the complex relative permeance of external rotor PMBLDCM in both coordinate systems is calculated. Finally, the analytical solution of the no-load magnetic field in both coordinate systems is derived by applying the magnetic potential multiplied by the complex relative permeance. In this paper, a 46-pole-51-slot external rotor PMBLDCM is taken as an example, and the accuracy of the proposed analytical model is verified by the finite-element results. Based on the analytical model, the influences of the stator slotting effect on the no-load magnetic field of the external rotor and the inner stator are analyzed. The spatial order characteristics and frequency characteristics of the no-load magnetic field of the external rotor PMBLDCM in both coordinate systems are revealed, respectively. [ABSTRACT FROM AUTHOR]

This paper presents a novel black and white box method for diagnosis and reduction of abnormal noise of the hub permanent-magnet synchronous motors (HPMSMs). The black and white box method is divided into three steps. In the first step, a black-box method is used to identify and diagnose all of the abnormal noise sources and corresponding working conditions including rotational speeds and loading moments of the HPMSM. The proposed black method is independent of the detailed internal parameters of the HPMSM. In the second step, considering the abnormal noise sources and the corresponding working conditions diagnosed by the black-box method, a white-box method is used to propose and verify the electromagnetic field model, the structure vibration model, and the acoustic computation model of the HPMSM. Then, the components of the HPMSM whose vibrations and/or acoustic emissions are the most important are predicted. In the third step, the noise reduction method, which is aimed at the diagnosed abnormal noise source under the corresponding working conditions and the diagnosed components, is proposed. The proposed method in this paper observably raises the efficiency of diagnosis and optimization for abnormal noise of the HPMSM. [ABSTRACT FROM PUBLISHER]