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UNIVERSITI PUTRA MALAYSIA
AMI NURUL NAZIFAH BINTI ABDULLAH
FK 2011 55
DEVELOPMENT OF MULTI-TYPE INTERIOR PERMANENT MAGNET MOTOR
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DEVELOPMENT OF MULTI-TYPE INTERIOR PERMANENT MAGNET
MOTOR
By
AMI NURUL NAZIFAH BINTI ABDULLAH
Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia
in Fulfillment of the Requirements for the Degree of Master of Science
MAY 2011
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Dedication
TO MY BELOVED ~ HUSBAND MOHD KHAIRUL CHE KAMKAH, MY
BELOVED PARENTS ~ MUHANIZAH MUSTAPHA, LATE FATHER CHE
ABDULLAH CHE MAT AND MY FAMILY.
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Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfillment
of the requirements for the degree of Master of Science
DEVELOPMENT OF MULTI-TYPE INTERIOR PERMANENT MAGNET
MOTOR
By
AMI NURUL NAZIFAH BINTI ABDULLAH
MAY 2011
Chairman: Assoc. Prof. Norhisam Misron, PhD
Faculty: Engineering
A new three-phase Multi-type Interior Permanent Magnet Motor (MT-IPM) is
proposed in this research. The type of motor is designed for high torque performance
with diameter of 200mm and thickness of 30mm. The main advantage of this motor
is to act as two types of motor as a Permanent Magnet Stepper Motor (PMST) and as
a Permanent Magnet Brushless DC Motor (BLDC).
BLDC operates in bi-directional variable speed operation in full torque mode. In
BLDC, the speed is simply controlled by DC supply voltage. However the BLDC
motor requires essentially an input feedback from rotor position sensor unlike PMST
that controls commutation sequences by using a frequency controller technique.
PMST is usually run at high torque at low speed. Unfortunately, PMST is suitable
only for large step angles applications as it is stepped by pulse frequency technique.
Also missing or over stepping in the sequence of commutation occurs during the
rotor rotation in a PMST for smaller step angles.
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With this aim, the development of a three-phase multifunctional motor that act as
brushless and stepper motor is proposed. This research also proposes new pitch
arrangement of three-phase motor. The coils were arranged in a group according to
their respective phases. Analyzing torque characteristic and motor performance of
MT-IPM on various sizes of magnet and rotor are essential. The optimum model is
derived and fabricated for various experimental testing to validate the performance of
the proposed motor.
At the early stage, simulation analysis using finite element method (FEM) is
performed to analyze the magnetic circuit on various sizes of rotor and magnet. The
analysis parameters include the magnetic field flux, the cogging force and the
developed torque. Further study on the research is then done to analyze the
performance of the MT-IPM by using related mathematical model. The parameters
considered are no load speed, no load current, stall torque and efficiency of the
motor. Heat increment in coil is also taken into account during the observations.
Overall analyses are done based on volume of magnet. Thus, the MT-IPM proposed
is based on optimum result for testing in a laboratory environment.
As the result, optimized model are identified for the motors with volume of magnet
between 2000mm3 to 4000mm
3. The permanent magnet volume chosen for this MT-
IPM is 3600mm3 with the selected size of rotor as 50mm. Based on the measurement
results, the optimum output torque with low cogging force of 6.5 Nm is achieved at
phase current of 5A. Also the coil current when run as PMST motor is higher than
BLDC motor.
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Abstrak thesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai
memenuhi keperluan untuk ijazah Master Sains
MEMBANGUNKAN MOTOR PELBAGAI-JENIS MAGNET KEKAL
DALAMAN
Oleh
AMI NURUL NAZIFAH BINTI ABDULLAH
MEI 2011
Pengerusi: Prof. Madya Norhisam Misron, PhD
Fakulti: Kejuruteraan
Motor baru Tiga-Fasa Magnet Kekal Pelbagai Jenis (MT-IPM) telah dicadangkan
dalam penyelidikan ini. Motor jenis ini direka untuk mendapatkan prestasi daya kilas
yang tinggi dengan ukuran diameter 200mm dan ketebalan 30mm. Kelebihan utama
motor ini adalah boleh berfungsi sebagai dua motor iaitu Motor Magnet Kekal
Berlangkah (PMST) dan sebagai Motor Arus Terus Magnet Kekal Tanpa Berus
(BLDC).
BLDC beroperasi dalam keadaan kelajuan dua-arah boleh ubah iaitu dalam keadaan
daya kilas penuh. Bagaimanapun, BLDC pada asasnya memerlukan maklum balas
input dari alat pengesan posisi rotor yang mana tidak seperti PMST yang mana
mengawal jujukan-jujukan penukaran dengan menggunakan teknik kawalan
frekuensi. PMST biasanya beroperasi pada daya kilas tinggi dan pada kelajuan
perlahan. Malangnya, PMST hanya bersesuaian untuk aplikasi sudut langkah besar
memandangkan ianya berlangkah dengan teknik denyutan frekuensi. Malah, untuk
sudut-sudut langkah yang lebih kecil, PMST akan kehilangan atau terlebih langkah
dalam jujujan penukaran semasa rotor PMST berputar.
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Dengan tujuan ini, pembangunan satu motor tiga-fasa pelbagai fungsi yang dapat
berfungsi sebagai motor pelangkah dan motor tanpa berus adalah dicadangkan.
Penyelidikan ini juga mencadangkan susunan jarak larasan baru bagi motor tiga fasa.
Kumparan pada motor telah diatur dalam secara berkumpulan mengikut fasa masing-
masing. Menganalisis ciri-ciri daya kilas dan prestasi MT-IPM pada berbagai saiz
magnet dan rotor adalah sangat penting. Model optimum diterbitkan dan dihasilkan
untuk pelbagai ujian eksperimen bagi mengesahkan prestasi motor yang
dicadangkan.
Pada peringkat awal, simulasi analisis menggunakan kaedah unsur terhingga (FEM)
dilakukan untuk menganalisis litar magnet pada pelbagai saiz rotor dan magnet.
Parameter analisis adalah meliputi fluks medan magnet, daya ‘cogging’ dan daya
kilas yang telah dibangunkan. Kajian yang lebih lanjut tentang kajian ini kemudian
dilakukan untuk menganalisis prestasi MT-IPM dengan menggunakan kaedah
mathematik yang berkaitan. Parameter ini adalah kelajuan tanpa beban, arus tanpa
beban, daya kilas terhenti dan kecekapan motor. Pemerhatian terhadap peningkatan
haba dalam gegelung juga diambil kira dalam analisis matematik. Keseluruhan
analisis dinilai berdasarkan isipadu magnet. Kemudian, MT-IPM yang dicadangkan
berdasarkan keputusan optimum tersebut akan diuji dalam persekitaran makmal.
Sebagai keputusannya, model yang optimum dikenalpasti sebagai motor yang
mempunyai isipadu magnet antara 2000mm3 untuk 4000mm
3. Isipadu magnet kekal
yang dipilih untuk MT-IPM ini adalah 3600mm3 dengan saiz rotor yang dipilih
adalah 50mm. Berdasarkan keputusan ekperimen, hasil daya kilas optimum dengan
daya ‘cogging’ rendah iaitu 6.5 Nm dicapai pada arus fasa 5A. Arus pada belitan atau
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gegelung berfungsi sebagai Motor Magnet Kekal Berlangkah (PMST) adalah lebih
tinggi dari Motor Arus Terus Magnet Kekal Tanpa Berus (BLDC).
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ACKNOWLEDGEMENTS
All praise to supreme Almighty Allah swt, the only creator, cherisher, sustainer, and
efficient assembler of the world and galaxies whose blessings and kindness have
enabled the author to accomplish this project successfully.
The author also would like to take this opportunity to gratefully acknowledge the
guidance, advice, support and encouragement she received from her supervisor,
Assoc. Prof. Dr. Norhisam Misron who keeps advising and commenting throughout
this project until it turns to real success.
A great appreciation is expressed to Assoc. Prof. Dr. Ishak Aris for his valuable
remarks, help, advice, and encouragement. Furthermore, the author would like to
thanks to colleagues Norafiza, Raja Nor Firdaus, Suhairi Rizuan, Siti Khodijah and
Mohd Syahril for their kind assistance and guidance. Appreciation also to the Faculty
of Engineering for providing the facilities and the components required for
undertaking this project.
Finally, words alone cannot express the thanks she owes to her beloved mother,
Muhanizah Mustapha and also her husband, Mohd Khairul Che Kamkah for helping
her in so many ways.
The author understands that the intellectual property of this research belongs to Dr.
Eng. Norhisam Misron and Universiti Putra Malaysia. Both of them have rights at
any aspect of design and finding throughout this research.
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I certify that a Thesis Examination Committee has met on May, 23 2011 to conduct
the final examination of Ami Nurul Nazifah binti Abdullah on her thesis entitled
“Development of Multi-type Interior Permanent Magnet Motor (MT-IPM)” in
accordance with the Universities and University Colleges Act 1971 and the
Constitution of the Universiti Putra Malaysia [P.U.(A) 106] 15 march 1998. The
committee recommends that the student be awarded the degree of Master of Science.
Members of the Thesis Examination Committee were as follows:
Mohd Zainal Abidin Ab. Kadir, PhD
Associate Professor
Department of Electrical & Electronics Engineering
Faculty of Engineering
Universiti Putra Malaysia
(Chairman)
Hashim Hizam, PhD
Associate Professor
Department of Electrical & Electronics Engineering
Faculty of Engineering
Universiti Putra Malaysia
(Internal Examiner)
Norman Mariun, PhD
Professor Ir.
Department of Electrical & Electronics Engineering
Faculty of Engineering
Universiti Putra Malaysia
(Internal Examiner)
Nasrudin Abd Rahim, PhD
Professor
Department of Electrical Engineering
Faculty of Engineering
Universiti Malaysia
(External Examiner)
________________________________
BUJANG KIM HUAT, Ph.D
Professor and Deputy Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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This thesis was submitted to the Senate of Universiti Putra Malaysia and has been
accepted as fulfilment of the requirement for the degree of Master of Science. The
members of the Supervisory Committee were as follows:
Norhisam Misron, PhD Eng.
Associate Professor
Faculty of Engineering
Universiti Putra Malaysia
(Chairman)
Ishak Aris, PhD
Associate Professor
Faculty of Engineering
Universiti Putra Malaysia
(Member)
___________________________________ HASANAH MOHD GHAZALI, PhD
Professor and Dean
School of Graduate Studies
Universiti Putra Malaysia
Date:
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DECLARATION
I declare that the thesis is my original work except for quotations and citations which
have been duly acknowledged. I also declare that it has not been previously and is
not concurrently, submitted for any other degree at Universiti Putra Malaysia or other
institutions.
____________________________________
AMI NURUL NAZIFAH BINTI
ABDULLAH
Date: 23 May 2011
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TABLE OF CONTENTS
Page
DEDICATION ii
ABSTRACT iii
ABSTRAK v
ACKNOWLEDGEMENTS viii
APPROVAL ix
DECLARATION xi
LIST OF TABLES xv
LIST OF FIGURES xvi
LIST OF ABBREVIATIONS xix
CHAPTER
I INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 3
1.3 Scope of Work 4
1.4 Objectives 5
1.5 Thesis layout 5
II LITERATURE REVIEW 7
2.1 Permanent Magnet 7
2.1.1 Applications of Permanent Magnet 8
2.1.2 Permanent Magnet Machines 10
2.2 Overview on Other Published Result of BLDC
and PMST 11
2.3 Finite Element Method as Simulation Package
Software 15
2.3.1 Finite Element Method on Other
Research 16
2.4 Summary 17
III METHODOLOGY 19
3.1 Research Methodology 19
3.2 Introduction of MT-IPM 21
3.2.1 Basic Operation of MT-IPM 22
3.2.2 Basic Principle of BLDC Configuration 24
3.2.3 Basic Principle of PMST Configuration 26
3.2.4 Structural Features of MT-IPM 27
3.3 Modeling of MT-IPM 31
3.3.1 Structure Modeling 33
3.3.2 Simulation Parameter 35
3.3.3 Magnetic Circuit Analysis 37
3.4 Cogging and Torque Analysis 40
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3.4.1 Cogging Torque Characteristic 42
3.4.2 Torque Characteristic 43
3.4.3 Cogging Percentage over Torque
Characteristic 44
3.5 Performance Analysis 45
3.5.1 Stall Torque Characteristic 52
3.5.2 No Load Current Characteristic 53
3.5.3 No Load Speed Characteristic 54
3.5.4 Motor Efficiency Analysis 55
3.6 Coil Heat Increment Analysis 56
3.6.1 Heat Characteristic on Difference Size
of Rotor Outer Radius 59
Heat Characteristic on Increment Valu
of Coil Current 60
3.7 Analysis Evaluation 61
3.7.1 Torque and Performance Analysis on
Various Sizes of Magnet for Rotor Outer
Radius 50mm. 62
3.7.2 Analysis Evaluation on Various
Volumes of Magnet. 63
3.8 Summary 65
IV RESULTS AND DISCUSSION 66
4.1 Design and Evaluation of MT-IPM 66
4.2 Prototype of MT-IPM 68
4.2.1 Structure of optimum MT-IPM 68
4.3 Frequency Characteristic 71
4.4 Static Torque Characteristic 74
4.4.1 Measurement Setup 74
4.4.2 Torque Characteristic on Commutation
Sequence 82
4.4.3 Torque versus Rotor Positioning
Characteristics 82
4.4.4 Torque versus Phase Current
Characteristic 84
4.5 Coil Current Characteristic 85
4.5.1 Measurement Setup 85
4.5.2 BLDC Characteristic 86
4.5.3 PMST Characteristic 87
4.6 Torque Speed Characteristic 88
4.6.1 Measurement Setup for BLDC 88
4.6.2 Torque Speed Characteristic for BLDC 89
4.7 Comparison to Other Published Results 91
4.8 Summary 92
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V CONCLUSION AND RECOMMENDATION 93
5.1 Conclusion 93
5.2 Future Recommendation 95
REFERENCES 97
APPENDICES 102
A Multi-type Interior Permanent Magnet Motor
Technical Drawing 103
PUBLICATIONS 113
BIODATA OF STUDENT 114