With growing demand for high-performance and high-efficiency motors, Axial Flux Permanent Magnet Motors (AFPMs) have received significant attention. These motors typically use rare-earth magnets due to their high magnetic and energy density. However, rare-earth magnets face challenges such as limited availability and price volatility, prompting research into reducing magnet usage. This study aims to reduce magnet consumption by applying a Consequent Pole (CP) structure to AFPMs. While CP structures improve magnet efficiency, they also introduce significant back-EMF ripple. To address this, an Intersect Consequent Pole (ICP) structure is proposed, which reduces ripple through alternating magnet placement within the rotor. Since ICP implementation is difficult in single-rotor AFPMs, a double-rotor, single-stator configuration was used. Simulation results show that the proposed design effectively reduces magnet usage and back-EMF ripple, demonstrating its potential for maintaining high performance with reduced rare-earth dependency.

Demand for high-speed motors is increasing. Surface-mounted permanent magnet synchronous motors (SPMSM) used in high-speed applications have magnets attached to the rotor, so there is a risk of damage and scattering due to centrifugal force as the speed increases. For this reason, applying the retaining sleeve to the rotor is essential. However, when using sleeves, there is a problem of reducing efficiency due to eddy current loss. In this paper, a study was conducted on a motor for a 100 kW building air conditioning system operating at a speed of 20,000 rpm. The purpose of the study is to reduce eddy current loss by optimizing the sleeve geometry. To this end, 3D finite element analysis (FEA) using JMAG 22.1 was conducted to analyze eddy current loss, the minimum safety factor was analyzed through mechanical stiffness analysis using ANSYS Workbench, and the validity of sleeve shape was proved through cause analysis. Through the research results, it is expected that the shape change of the sleeve will have the effect of reducing eddy current loss.

Permanent magnet synchronous motors (PMSMs) are highly affected by magnetization, which determines the magnetization level in the permanent magnet (PM). There are three main magnetization methods: single-unit, stator coil, and post-assembly magnetization. Post-assembly magnetization is widely used in PMSM mass production due to its ability to achieve high magnetization performance using a separate magnetizing yoke. However, spoke-type PMSMs with ferrite PMs face challenges when using the post-assembly method. The structural configuration of two magnets located radially hampers effective magnetized field transmission to the rotor’s interior due to the narrow space between the magnets. Maximizing the magnetization rate becomes crucial, but the limited space in the spoke-type structure complicates this. This paper addresses the issue and analyzes factors influencing post-assembly magnetization characteristics. A novel yoke structure is proposed, reducing the distance between the coil and magnet, leading to more efficient magnetization. The parametric and performance comparative analysis shows an impressive 17.1%_p increase in magnetization rate with the proposed yoke structure compared to the existing yoke. This outcome contributed to a solution for enhancing the magnetization performance of spoke-type ferrite PMSMs.

Interior permanent magnet synchronous motor (IPMSM) for traction applications have attracted significant attention due to their advantages of high torque and power density as well as a wide operating range. However, these motors suffer from high electromagnetic vibration noise due to their complex structure and structural rigidity. The main sources of this electromagnetic vibration noise are cogging torque, torque ripple, and radial force. To predict electromagnetic vibration noise, finite element analysis (FEA) with flux density analysis of the air gap is essential. This approach allows for the calculation of radial force that is the source of the vibration and enables the prediction of vibration in advance. The data obtained from these analyses provide important guidance for reducing vibration and noise in the design of electric motors. In this paper, the cogging torque and vibration at rated and maximum operating speed are analyzed, and an optimal cogging torque and vibration reduction model, with rotor taper and two-step skew structure, is proposed using the response surface method (RSM) to minimize them. The validity of the proposed model is demonstrated through formulations and FEA based entirely on numerical analysis and results. This study is expected to contribute to the design of more efficient and quieter electric motors by providing a solution to the electromagnetic vibration noise problem generated by IPMSM for traction applications with complex structures.

Conventional surface mounted permanent magnet synchronous motor (SPMSM) at high speed has large iron loss in the stator and eddy current loss in the rotor. The higher the eddy current loss, the higher the rotor temperature. Therefore, a plan to reduce the loss must be devised. Also, weight at high speed is related to mechanical stiffness and electromagnetic vibration noise. Therefore, a plan to reduce the weight must be devised. In this paper, we propose to change the shape of the conventional 15 kW 110 000 rpm class into a slotless shape. A process of protocol change was proposed, and the sizing design of the rotor and stator was devised. The advantages of the proposed shape were verified through performance comparison through finite element analysis (FEA) and mechanical stiffness analysis.

In spoke-type permanent magnet synchronous motors (PMSMs), an asymmetric rib structure has been investigated as a method to reduce cogging torque. However, such rotor asymmetry tends to an increase in the axial force, which limits its applicability in precision and low-vibration systems. To overcome this limitation, this study proposes a new motor design method that introduces a skew factor as an additional design variable. The skew factor, defined as the ratio of the skewed region to the total stack length, enables simultaneous control of cogging torque and axial force by adjusting the degree of asymmetry along the rotor stack. Using parametric modeling and finite element analysis (FEA), the combined effects of the asymmetric rib and skew factor were investigated, and an optimized motor structure achieving balanced cogging torque and axial force characteristics was derived. The proposed design approach provides an effective method for simultaneously considering cogging torque and axial force in spoke-type PMSMs.