High-specific-power permanent magnet synchronous machine : design, analysis, and validation
Canseven, Hüseyin Tayyer (2025-07-04)
Väitöskirja
04.07.2025
Lappeenranta-Lahti University of Technology LUT
Acta Universitatis Lappeenrantaensis
School of Energy Systems
School of Energy Systems, Sähkötekniikka
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In reference to IEEE copyrighted material which is used with permission in this thesis, the IEEE does not endorse any of Lappeenranta-Lahti University of Technology LUT's products or services. Internal or personal use of this material is permitted. If interested in reprinting/republishing IEEE copyrighted material for advertising or promotional purposes or for creating new collective works for resale or redistribution, please go to http://www.ieee.org/publications_ standards/publications/rights/rights_link.html to learn how to obtain a License from RightsLink.
Julkaisun pysyvä osoite on
https://urn.fi/URN:ISBN:978-952-412-271-9
https://urn.fi/URN:ISBN:978-952-412-271-9
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Tiivistelmä
The demand for high-specific-power permanent magnet synchronous machines (PMSMs) has grown significantly in application areas such as aerospace and electric mobility, where compactness, lightweight construction, and high efficiency are critical. However, designing machines that meet these requirements while ensuring reliable operation under highspeed and high-power conditions presents several challenges. Among these challenges are the reduction of rotor eddy-current losses, effective thermal management, and the development of cost-effective and practical testing methodologies for machines operating at high fundamental frequencies.
This dissertation presents a PMSM design that incorporates innovations to overcome these challenges. The proposed structure features an outer-rotor surface magnet configuration, slitted solid rotor cores, and asymmetric stator tooth tips. The outer-rotor topology is selected to maximize output torque while minimizing machine size and material usage, making it suitable for applications where volume and mass constraints are critical. The introduction of slitted rotor cores addresses the challenge of rotor eddy-current losses, while asymmetric stator tooth tips enhance manufacturability, reduce local saturation, and improve flux distribution within the stator core.
To address the thermal challenges inherent in high-power-density machines, direct liquid cooling (DLC) is integrated into the design. This advanced cooling technique enables higher current densities, ensuring efficient heat dissipation and maintaining the operational reliability of the machine under demanding conditions. In addition, a novel passive diode rectification system is proposed as an alternative testing methodology. This system, which incorporates parallel-connected capacitors, eliminates the need for converters that operate at a high fundamental frequency, thereby simplifying the testing process while ensuring reliable performance validation.
The research methodology combines analytical modeling, simulations based on finite element analysis (FEA), and experimental validation through a prototype machine. The comprehensive simulations and experiments validate the effectiveness of the proposed design in achieving high specific power, high efficiency, low torque ripple, and robust performance across a wide range of load conditions. This dissertation provides a strong foundation for the development of next-generation PMSMs, offering solutions to improve performance, manufacturability, and testing capabilities. The findings are expected to benefit industries where size, weight, and efficiency are critical.
This dissertation presents a PMSM design that incorporates innovations to overcome these challenges. The proposed structure features an outer-rotor surface magnet configuration, slitted solid rotor cores, and asymmetric stator tooth tips. The outer-rotor topology is selected to maximize output torque while minimizing machine size and material usage, making it suitable for applications where volume and mass constraints are critical. The introduction of slitted rotor cores addresses the challenge of rotor eddy-current losses, while asymmetric stator tooth tips enhance manufacturability, reduce local saturation, and improve flux distribution within the stator core.
To address the thermal challenges inherent in high-power-density machines, direct liquid cooling (DLC) is integrated into the design. This advanced cooling technique enables higher current densities, ensuring efficient heat dissipation and maintaining the operational reliability of the machine under demanding conditions. In addition, a novel passive diode rectification system is proposed as an alternative testing methodology. This system, which incorporates parallel-connected capacitors, eliminates the need for converters that operate at a high fundamental frequency, thereby simplifying the testing process while ensuring reliable performance validation.
The research methodology combines analytical modeling, simulations based on finite element analysis (FEA), and experimental validation through a prototype machine. The comprehensive simulations and experiments validate the effectiveness of the proposed design in achieving high specific power, high efficiency, low torque ripple, and robust performance across a wide range of load conditions. This dissertation provides a strong foundation for the development of next-generation PMSMs, offering solutions to improve performance, manufacturability, and testing capabilities. The findings are expected to benefit industries where size, weight, and efficiency are critical.
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