IEEE TRANSACTIONS ON MAGNETICS, VOL. 48, NO. 6, JUNE 2012
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A New Concept of Modular Permanent Magnet and Soft Magnetic
Compound Motor Dedicated to Widespread Application
C. Henaux, B. Nogarede, and D. Harribey
University of Toulouse, INPT—LAPLACE Toulouse 31071, France
This paper deals with the design and test of a permanent-magnet machine based on a novel modular stator concept. The manufacturing and recycling costs are minimized thanks to the use of composite magnetic materials (plastic bonded magnets, soft magnetic
composites). The main properties of composite magnetic materials, from a magnetic and mechanical point of view, are briefly presented
in the first part of this paper. After focusing on their thermal properties by detailing a thermal experimental study, the proposed concept
of a modular permanent-magnet machine is described. Experimental characterization of the realized prototype, in static and dynamic
operating modes, demonstrates its advantages compared with conventional structures.
Index Terms—Brushless motor, economic cost, lamination, manufacturing process, permanent-magnet motors, prototype, soft magnetic materials, temperature measurement, thermal analysis.
I. INTRODUCTION
ORE than 150 years after the first electrical machine
prototypes were introduced, electromechanical energy
conversion remains closely linked with four main concepts:
DC, synchronous, induction, or switched reluctance machines.
Generally based on the use of laminated magnetic circuits,
classical machine structures fundamentally lie on a two-dimensional magnetic flux circulation.
Manufacturers of electrical machines with low cost and mass
production applications are faced with economic realities that
lead to structural choices. The main objectives were first to reduce volume of materials used and manufacturing costs. To get
good performance, progress in magnetic materials process manufacturing has been made in the last twenty years. We can cite
in particular the use of high performance magnets in brushless
motors which have replaced DC motors in most applications.
Now, environmental features must be taken into account. In
particular the features of recycling, which have an economic impact, cannot be ignored. If we consider the conventional structure of machine with laminated steel and classical winding coil,
recycling is quite difficult or impossible. Claw pole machines
provide a solution to this dilemma. Those actuators which are
based on simple concentric coils integrated in a preformed stator
armature are now mounted with an automatic manufacturing
process that significantly reduces the cost. This configuration
allows one to easily dismantle the stator and collect the coils to
recycle the copper.
However, their efficiency remains relatively low compare
with that of the permanent-magnet brushless machine [1], [2].
The emergence of new composite magnetic materials (plastic
bonded magnets, soft magnetic composites) may radically
modify this situation by enabling the development of innovative machine topologies. These materials are already used in the
M
Manuscript received June 10, 2011; revised October 07, 2011, December 08,
2011; accepted December 12, 2011. Date of publication December 23, 2011;
date of current version May 18, 2012. Corresponding author: C. Henaux (e-mail:
Carole.henaux@laplace.univ-tlse.fr).
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TMAG.2011.2181530
field of static conversion [3], and electromechanical actuation
[4]–[8]. Their magnetic characteristics, such as the permeability
and the saturation level and their tensile strength, are still lower
than the laminated steel ones. But research studies carried out
in chemical compound and manufacturing (thermal cycles,
compression phase, etc.) allow for significant progress [32],
[33]. Replacing in conventional laminated structures by soft
magnetic composites with any change of the magnetic circuit
cannot yet improve the performances. But those conveniences
can be compensated by the diversity of the magnetic composites manufacturing process (molding, injection or compression
of massive pieces) which allows the definition of relatively
sophisticated magnetic circuits making the flow of magnetic
flux in three dimensions in nonconventional structures possible.
In this paper, a new concept of machine made of composite
magnetic materials is presented. This structure is devoted to a
widespread domestic or automotive application.
In Section II, the different composite magnetic materials used
are studied, particularly their magnetic and thermal characteristics. The structure of the machine is then described from a technological point of view in Section III. The experimental capabilities of the prototype are given in Section IV and compared with
conventional solutions. Finally, Section V describes the conclusion and perspectives of the work.
II. THE COMPOSITE MAGNETIC MATERIAL
In the field of magnetic materials, the technology of composites is subdivided into two main classes which respectively correspond to “passive” materials (Soft Magnetic Composites) or
“active” materials (Plastic Bonded Magnets).
A. The Soft Magnetic Composite—SMC
SMC materials are basically iron powder particles separated
with an electrically insulated coating. Those insulating particles
can be pressed to form simple or complex magnetic parts. From
a magnetic point of view, those compounds give the best of an
interesting performance compromise in terms of magnetic saturation level and low eddy current losses. Moreover, they offer
a 3-D flux carrying capability and a cost efficient production
0018-9464/$26.00 © 2011 IEEE
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IEEE TRANSACTIONS ON MAGNETICS, VOL. 48, NO. 6, JUNE 2012
Fig. 1. B -H curves of FeSi alloys (N020) [9] and soft magnetic composite
(Somaloy_700, Somaloy_550, Somaloy_700_3P), [10], Atomet EM-1 [11].
TABLE I
MAIN CHARACTERISTICS OF SAMPLE
process for complex 3-D parts. The last generations of soft magnetic materials are also very attractive when considering thermal
and mechanical properties.
1) Magnetic Characteristics: Considering first static magnetic properties, - characteristics of SMC appear now to
be relatively close to rolled material with high performances as
shown in Fig. 1.
2) Thermal Characteristics and Behavior: Concerning the
thermal characteristics, manufacturers provide close value of
) and lamithe thermal conductivity for SMC (20 W
and 30 W
nated material (between 20 W
in the plane of the laminated steel). But if considering the manufacturing process of massive pieces from SMC, one can expect
a lower difference between the transverse conductivity and the
in-plan conductivity than for laminated magnetic circuit. Consequently a better heat dissipation could be expected in the machine structure using SMC, which makes possible the increase
of the electric loading in the winding.
So as to quantify this design opportunity, specific experiments have been carried out on elementary bulk parts made
of various materials. The aim of those tests is not to determine the thermal conductivity of magnetic materials which is
given by manufacturers, but to analyze the thermal behavior of
generic magnetic parts used in magnetic circuits and build respectively from SMC and laminated material. Two SMC samples have been tested (Somaloy_700 and Somaloy_700_3P) and
compared with a sample of laminated material (FeSi NO20).
Their electromagnetic characteristics are summarized in Table I
The Somaloy 700 and Somaloy 700_3P are manufactured in
Sweden by Hoganas and are dedicated to motors. The Somaloy
700_3P compound includes organics binders and is optimized
during the manufacturing process in order to get high permeability and high strength. The FeSi NO20 lamination is nonoriented silicon iron laminated material (thickness: 0.20 mm) manufactured by Arcelor industry. This thinner lamination is dedi-
Fig. 2. Ferromagnetic plots with concentric coils dedicated to plan experiments
for the study of thermal behavior of SMC and lamination.
Fig. 3. Water-cooled dissipator fixed first at the end of the plot (test configuration no 1).
cated to applications which operate at high frequency and expect
low iron losses.
The comparison is made on elementary concentric coil illustrated in Fig. 2.
Each coil is supplied by a constant direct current. A set of
temperature sensors is implemented in the samples to measure
the evolution of temperature at several locations: interior copper
, coil–magnetic core interface
, lateral , and transcoil
core surfaces. Heat is dissipated at one side of the core,
verse
due to a water-cooled dissipator. This dissipator has first been
fixed at the end of the plot as illustrated in Fig. 3, (test configuration no 1) and secondly on its lateral surface (test configuration
no 2). Experiments have been carried out with a current varying
from 2 A to 5 A.
The obtained results are presented in Figs. 4 and 5 with the
calculated difference between the temperature lamination
and SMC temperature
as expressed in (1)
(1)
The results show that, in all the cases when considering the
, the lateral temperature
and the
interface temperature
, the Somaloy_700 have a better
interior coil temperature
capability of heat dissipation than laminations (the differences
HENAUX et al.: NEW CONCEPT OF MODULAR PERMANENT MAGNET AND SOFT MAGNETIC COMPOUND MOTOR
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Fig. 5. Curves of temperature difference between lamination and SMC (test
configuration no 2). (a) Magnetic core interface T . (b) Interior coil T .
(c) Transverse core surface T .
Fig. 4. Curves of temperature difference between lamination and SMC (test
configuration no 1). (a) Magnetic core interface T . (b) Interior coil T .
(c) Lateral core surface T . (d) Transverse core surface T .
observed in terms of interface temperature reach 30% in favor
of composite materials).
results, specific
Considering the transverse temperature
added tests have been carried out on a laminated sample. The
contact surface between the temperature sensor and the thickness of the laminated part cannot be as good as the contact in the
case of the SMC pieces (the lateral side of the laminated stack
is not plane). Consequently several series of measurements have
been made on the laminated piece, each corresponding to a different location of the thermal sensor on the transverse face. Average temperature from those measurements has been computed
to draw the final curves shown in Figs. 4(d) and 5(c). In each
case, the SMC is characterized by lower temperatures.
Considering the Somaloy_700_3P sample, results are less
significant. Specific heat treatment, manufacturing process, and
organic binders added in this type of SMC permit to improve
the saturation level and the mechanical strength but globally deteriorate the thermal behavior [12].
When the heat dissipator is located on the lateral side of
the sample (test configuration no 2), the results show that the
thermal conductivity in the transverse direction is better in the
SMC samples (the differences observed in terms of interface
reach 30% in favor of composite materials).
temperature
The set of results show that the SMC have a better capability of
heat dissipation than lamination.
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TABLE II
MECHANICAL PROPERTIES OF SMC AND LAMINATED
MATERIALS [10], [15], [16]
Fig. 6. Shapes of plasto magnets available by injection process—Arelec manufacturer [20]. (a) Drop indicator, (b) speedometer, (c) pressure sensor.
3) Mechanical Properties: Considering the mechanical
properties, the transverse rupture strength of compacted pieces
is lower than in laminated materials and depends strongly on
the manufacturing process and added organics binders [13],
[14], [34]. A basic sample of SMC can be characterized by
transverse rupture strength near 40 MPa. But the progress in
manufacturing process has permitted to achieve a higher level
than 100 MPa as illustrated in Table II.
Concerning economics features, the energy consumption required to manufacture those soft magnetic compounds are lower
than those required in the laminated material manufacturing.
First the number of stages in manufacturing is limited to five
for the soft magnetic compound (melting, cruding, pressing, sintering, machining). In the laminated material this number can be
even higher (melting, cruding, casting process, rerolling mills,
specific heat treatments, scratching, etc.) if high performances
of iron steel are needed. Studies demonstrated that the energy requirements per Kg of finished part reach 25 MJ for the sintered
soft magnetic compound and 50 MJ for the steel [10], [34].
Fig. 7. Shapes of feasible molded pieces (a) and unfeasible molded pieces (b).
TABLE III
ELECTROMAGNETIC CHARACTERISTICS OF
PLASTIC BONDED MAGNETS [17]–[19]
B. The Plastic Bonded Magnet
If considering widespread applications, sintered Neodymium
magnets still suffer from a poor tolerance in terms of high
operating temperature capabilities (maximum operating temperatures to the order of 150 C). They are also extremely brittle.
Therefore, taking into account corrosion problems, they do not
constitute yet an adequate product for low cost applications
subjected to hard environmental and mechanical conditions.
Much less expensive than sintered magnets, plasto-magnets
offer two attractive features, namely easy handling with satisfying magnetic characteristics (cf. Table III). Currently the
manufacturing processes available (such as injection molding,
compression molding, or calendering) provide materials which
are more convenient to mass production processes. A large
variety of shapes is accessible as illustrated in Fig. 6, particularly if injection process is used. The sizes and the shape of
molded pieces are limited as shown in Fig. 7 by the matrix in
the power press. Machining is even possible (subject to some
precautions), which is very attractive for prototyping.
The mechanical properties strongly depend on the binder and
the filling ratio. Tensile strengths can achieve 100 MPa [20]
which confers on this type of material a good mechanical stability and a relatively satisfactory behavior during rotation at
high speed. In this context, these new materials make it possible to reconsider basic electromechanical functions, in particular when a strong functional integration is required.
III. A RECYCLABLE PERMANENT-MAGNET ACTUATOR
One major opportunity for composite magnetic materials in
the field of electrical machines lies on new design opportunities
for low cost and recyclable structures. The ferromagnetic parts
in the machine can be designed to make it easy to partially cover
magnetic materials such as the molded pieces (without organics
binder) and copper. Even if the whole parts of the dismantled
machine cannot be reused, the cost of the total dismantling will
be significantly lowered. The need for an alternative solution
is particularly crucial in the context of a small sized machine
kW), due to an increasing techno-economic pressure and
(
new environmental considerations to be satisfied in domestic or
automotive appliances for instance.
A. The Zigmag Concept
1) A New Winding Configuration: The proposed structure is
based on a concept of a modular permanent-magnet (PM) synchronous machine with inserted winding. The stator configuration derives from a compromise between a conventional slotted
stator and a claw pole stator. The slotted armature as illustrated
in Fig. 8(a) permits to well magnetize the teeth which constitute
a good flux guide. However, the cost of the stator manufacturing
HENAUX et al.: NEW CONCEPT OF MODULAR PERMANENT MAGNET AND SOFT MAGNETIC COMPOUND MOTOR
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Fig. 10. Molded magnetic stator stack.
Fig. 8. Stator configuration of a usual permanent-magnet machine and a claw
pole permanent-magnet machine. (a) Usual slotted armature. (b) Claw pole
configuration.
Fig. 11. Structure of the Zigmag concept.
Fig. 9. Stator configuration of the Zigmag concept and resulting elementary
stator core. (a) The “zigzag” stator configuration. (b) The stator armature.
is relatively expensive for low cost mass production. In the opposite, the claw pole configuration as illustrated in Fig. 8(b) is
well adapted to a low cost mass production with a simple coil
inserted between two stator disks. But the magnetic configuration is less efficient due to the leakage flux.
In the Zigmag configuration presented in Fig. 9(a), preformed
coil turns around ferromagnetic stator poles. Compared with the
claw pole configuration, this zigzag shape permits to limit the
leakage flux by separating the poles. The stator armature can be
optimized by lying pole pieces at the end of the ferromagnetic
poles and by inserting the coil in two ferromagnetic stator disks
as presented in Fig. 9(b).
The resulting ferromagnetic stator shape shown in Fig. 10
is feasible if using SMC by molding. Two elementary molded
disks and one inserted coil are sufficient to build the stator of
a single phase motor. One can notice that it is very simple to
adapt the motor sizing to a wide range of power by varying the
number of juxtaposed stator modules.
2) The Zigmag Actuator Design: The basic Zigmag actuator
requires two stator stacks, as shown in Fig. 11. Such a stator
arrangement facilitates the winding process, but also makes easy
the recycling by a rapid dissociation of the various machine parts
(no overlap of the conductors in the slots).
The PM rotor consists of a “quasi-radial” magnetized ring
molded from plasto-magnet directly on the rotor shaft. A quasiradial magnetization means that the magnet is perfectly radially
magnetized along 97% of the pole pitch. It is impossible for
the manufacturer to impose an ideal vertical slope between two
consecutive pole for the sign inversion of the magnetic field. So
3% of the pole pitch is used to decrease the magnetic field until
the zero value. The PMs used are Neoplast from Arelec ComT,
pany and their characteristics are:
kJ/m . They belong to the Plasto-Neodymium family discussed
in Table III.
The stator is constituted by stacking axially two magnetically independent modules with a circumferential shift of 90
electrical degrees from each other. The SMC used is the Somaloy_550 manufactured by Hogänas (Somaloy550-Hogänas,
T). An SMC like Somaloy_700 would
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be a better choice than Somaloy_550 but at the time of our prototype building the first one was not available [21].
As for the design of Zigmag concept, a conventional machine
design approach is carried out, combining analytical and finiteelement methods.
The electromagnetic torque is classically calculated by using
the driving force resulting from applying the Laplace’s law. The
tensile stress acting on the stator soft magnetic yokes will be calculated by the Maxwell’s force tensor in numerical computation
by 3-D finite-element software.
The electromagnetic torque expression is
(2)
with
boring diameter;
average value of the flux density in the air gap;
Fig. 12. Mesh of Zigmag concept (only one phase).
electric loading (A/m);
effective axial length;
TABLE IV
SPECIFICATIONS AND DESIGN OF A ZIGMAG ACTUATOR
winding factor.
results
The average value of the flux density in the air gap
from the assumed sinusoidal spatial distribution of the magnetic
flux density generated by the permanent magnets on the boring
diameter. The molded rotor has been magnetized with six poles
so that the resulting magnetic field in the air gap is quasi-sinusoidal. The analysis of the back electromotive force will validate later this assumption. The value of the electric loading
has been chosen according to the natural convection during the
actuator operation.
The accuracy of the design mainly depends on the winding
factor which is not easy to evaluate. An alternative solution consists first, in using the theory of claw pole machine using analytical methods and equivalent magnetic network [22]–[24]. Secondly, to improve the resulting equations, 3-D numerical field
calculation like in many claw pole design methodology [25] is
necessary to better take into account the specific configuration
of the winding with preformed coils. We can see in Fig. 12 the
mesh we used in our 3-D FEM analysis performed with ANSYS
software.
In this type of inserted coil, the contact surface between the
conductors and the magnetic parts is smaller than conventional
winding in slotted armature. Consequently, to exploit the heat
dissipation capability of SMC (cf. Section II-A.2) by conductive
heat flow, it is necessary to minimize the free space between the
preformed coil and the magnetic parts. By this way the contact
surface between the bore and the coils are optimized to well
dissipate the losses generated in the copper using the thermal
conductivity of the SMC.
The resulting main dimensions are listed in Table IV.
B. Dynamic Torque/Speed Characteristics and Efficiency
1) Static Tests: The actuator prototype has been tested
to evaluate its electromagnetic characteristics in static and
dynamic operating mode. Fig. 13 shows the static torque
waveform when running the motor connected to a DC motor
Fig. 13. Measure of static torque with one phase supplied by a DC current
(2 A).
and supplying one phase with a DC current of 2 A. From this
which is the ration
test we can deduce the torque constant
between the peak torque and the current supply.
The cogging torque has been measured and one can notice
that its amplitude is less than 10% of the mean torque.
The back-EMF waveform presented in Fig. 15 is obtained by
running the motor connected to a DC motor at various speed and
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TABLE V
ELECTROMAGNETIC CHARACTERISTICS OF ZIGMAG
TABLE VI
COMPARISON WITH UNIVERSAL AND CLAW POLE ARMATURE [30]
Fig. 14. Measure of the cogging torque.
Fig. 15. Electromotive force under no load condition, N
= 750 rpm.
getting the phase voltage. From this measure we can deduce the
back EMF constant which is the ratio between the rms phase
to line voltage and the rotating speed.
To some extent, the preformed zigzag coil can be considered
as an intermediate configuration between a fully global winding
and a usual heteropolar winding. One of the major advantages
of such topology lies on the minimization of magnetic leakages,
compared with classical claw pole architectures [26]. The coil
which turns around the teeth allows to well canalize the magnetic field in the stator and the the shape of the tooth-tips has
been designed so that the leakage flux is minimized. This configuration provides a quasi-sinusoidal electromotive force from the
plasto-magnet injected rotor with a “quasi-radial” polarization.
The resulting waveform contains only odd harmonics whose
magnitude is lower than 10% of the fundamental.
The main electromechanical characteristics of the prototype
are given in Table V.
One can notice that it is very easy and not expensive from a
designed structure to change the rated voltage by just changing
the number of turns in the preformed coil. It is not the case
in slotted armature which includes distributed and/or overlaps
coils in slots that makes it difficult and expensive to destroy the
original winding and to replace it with a new one.
2) Load Tests: To make the best of the electromagnetic stator
phases decoupling, two asymmetric bridge converters are used
to supply each phase coil separately. The control strategy is
based on a classical hysteresis-type current regulation. The two-
Fig. 16. Measure of dynamic torque on dynamic test bench.
phased current references are elaborated from an integrated Hall
effect position sensor, which makes it possible to drive the machine at its maximum torque. Square waves voltage are applied
to each phase even though the natural waveforms generated at
the output terminals are sinusoidal. Load tests are carried out
with a dynamic test bench presented in Fig. 16.
Considering the closed loop control operating, Figs. 17, 18,
and 19 present the evolution of losses, torque, and efficiency
function of the rotating speed. These results are obtained with a
constant current supply of 4 A.
The efficiency achieves 80% at the rated current supply. Compared with the usual efficiency obtained with classical brush
DC universal or claw pole machine designed in the same power
range, the efficiency of the Zigmag concept is relatively attractive with an optimal value 10% higher [27]–[29], [31].
Table VI summarizes a comparison between the Zigmag actuator and conventional universal and claw pole motors respectively mounted with SMC and laminated material.
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IEEE TRANSACTIONS ON MAGNETICS, VOL. 48, NO. 6, JUNE 2012
Fig. 17. Copper, magnetic, and stray losses for a 4 A power supply current.
Fig. 20. Current and voltage waveforms at load operation (open loop control).
Fig. 18. Torque versus speed curve for a power supply current fixed to 4 A.
Fig. 19. Global efficiency (motor and power supply) for a constant 4 A supply
current.
In the same power range, compared with the optimized brushless motor, the efficiency of the Zigmag concept is lower. But
the manufacturing process of the Zigmag concept which can be
built by molding or injection, can be very attractive in widespread application where the manufacturing cost is paramount.
One can observe on Figs. 17 and 19 a singular point near 8500
rpm. This is due to the magtrol dynamic test bench which is
unstable for this rotating speed. The resulting raise on the losses
does not come from the Zigmag actuator operating.
A sensorless control has been tested in the application to compare the Zigmag concept with the other kind of machines mentioned previously used in widespread appliances. When the sensorless and open loop control is applied, the current waveforms
are still quasi-sinusoidal as shown in Fig. 20.
Those quasi-sinusoidal natural waveforms (EMF shown in
Fig. 15 and line current shown in Fig. 17) permit to limit the
torque ripple in the machine (12% of the rated torque). The efficiency decreases from 80% as presented in Fig. 18 to 65% at
a rated rotating speed of 8000 rpm.
IV. CONCLUSION
A new concept of machine based on composite magnetic materials and modular stator has been presented. This concept potentially constitutes an alternative to classical DC brush actuators in the 0.1–1 kW power range for low cost and widespread
application. The specificity of the proposed topology lies on the
use of SMC stator parts to constitute a modular, low cost, and
recyclable motor structure.
These SMC materials have been characterized from a thermal
and mechanical point of view and compared to laminated material. The thermal characteristics of SMC seem to be more
attractive than laminated material in the three dimensions of
space. On the other hand, the mechanical characteristics are less
interesting.
The characterization of the realized prototype demonstrates
the promising capability of the Zigmag concept when considering in particular its relatively high efficiency at high speed.
From these first and promising results, a shape optimization of
the stator parts, including the preformed “zigzag” coil, is now
to be carried out.
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