Design of a synchronous machine with

concentric stator windings and permanent

magnets in focusing configuration
S. Hlioui1, 2, L. Vido3, Y. Amara2, M. Gabsi1, A. Miraoui2, M. Lcrivain1
1
SATIE, UMR CNRS 8029, ENS de Cachan
61, Av. du Pdt Wilson 94235 Cachan cedex, France
2
L2ES, Technical University of Belfort-Montbliard (UTBM)
13 rue Thierry Mieg, Btiment F, 90010 Belfort cedex, France
3
SATIE, UMR CNRS 8029, IUPGE Cergy, rue d'Eragny, Neuville sur Oise,
95031 Cergy Pontoise, France
E-mail: sami.hlioui@utbm.fr, hlioui@satie.ens-cachan.fr

Abstract-- A permanent magnets synchronous machine
electromagnetic design is presented in this paper. The
machine is characterised by a concentrated windings stator
and focusing principle ferrite permanent magnets rotor.
First, an analytic study is lead to determine the main
influent parameters. A finite element analysis is then
achieved in order to study more precisely the geometric
parameters impact on the magnetic performances.
Index terms-- Synchronous machine, permanent
magnets, design process, hybrid vehicle.
I INTRODUCTION
modelling methodology to represent the non-linear
magnetic behaviour in the induction machines. This
methodology is applied to induction machines, used as a
traction machine in a hybrid vehicle, to determine the
optimal operating points and efficiency mapping. The
mechanical performances that the electrical machines
must satisfy are shown on figure 1. The constant power
value of 15 kW after the base speed (2250 rpm)
corresponds to a steady operating mode. The power
characteristics of 30 kW and 33 kW correspond to
transitory operating points (respectively of 300 s and
30 s).

P ollution reduction is one of major challenges of

modern societies, as it will slow down climate
change. Transportation sector is the prime contributor to
greenhouse gazes emission [1]. Electric and hybrid
vehicles seem to be a relevant solution to this problem. In
such applications, the electric machine is a key
component of vehicles traction system; its design is an
important issue.In this paper, an electromagnetic design
process of a synchronous permanent magnet electrical
machine is presented. In fact, in order to satisfy a typical
hybrid traction specifications sheet, an analytical model
of the studied structure is used to perform the pre-design
process and to find the different dimensions and
parameters of the machine. Then, a numerical analysis
based on the finite elements method that take into
account saturation phenomena and leakage flux, is used
in order to study with more precision the impact of the
different dimensions on magnetic and mechanical
performances.
II CHOICE OF THE STRUCTURE
Electrical traction machines have to satisfy special
specifications, which can seem paradoxical: space saving,
high efficiency, high torque etc. Prior to the design
procedure, the choice of a specific structure is a crucial
issue. Many studies, where different electrical structures
have been used as traction machine, have been reported
in scientific and technical literature. In [2] authors
investigate the capabilities of the switched reluctance
motor (SRM) for electric vehicle and hybrid electric
vehicle applications. In [3] authors propose a new
Figure 1 Mechanical performances to de reached
The figure 2 shows the maximum volume dedicated
for the electrical machine (external diameter of 280 mm
and external axial length of 200 mm). Thus, a restricted
allocated volume matched to high mechanical
performances imposes, practically, the choice of the
permanent magnets synchronous machine. Many
structures of this machine exist and can be classified
depending on the position of permanent magnets and the
type of the stator windings. The chosen structure has
permanent magnets in the rotor in a focusing
configuration. Thanks to this configuration, ferrite
permanent magnets can be used and so reduces the total
price of the motor. [4], [5], [6] and [7] present studies
about the choice of the stator windings. Based on theses
studies, using concentrated stator winding seems to be a
good choice. Actually, with a very good winding factor
(60% versus 35% for the distributed winding) and shorter

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end winding, theses structures make possible to
maximize the ratio of the total torque by the total volume
and to minimize the total losses in the machine. So if one
cannot neglect the length of the end windings in front of
the active length, synchronous machines with concentric
winding have a better efficiency than those ones with
distributed winding.

Figure 5 Main dimensions of the rotor

Figure 2 Maximum allocated volume
III-1 EXCITATION FLUX AND
Thus, the studied structure was chosen and is
ELECTROMAGNETIC TORQUE
composed by a rotor with permanent magnets in focusing
EXPRESSIONS.
configuration and a stator with a concentric winding as
shown on figure 3. The presented analytical model takes into account
neither leakage flux nor saturation phenomena. The iron
sheets are considered as linear and have infinite
permeability characteristic. The expression of the
maximum excitation flux is given by formula (1).
Br eaim
vm = 2 pLa
3e fereaim (1)
+
lds haim
It can be seen that the maximum excitation flux
depends only of the dimensions of the permanent magnet
(its height haim et thickness eaim) and the width of the
Figure 3 The studied structure
stator teeth (lds). The expression of the hybrid
electromagnetic torque (the reluctant torque component is
III STUDY OF THE IMPACT OF THE
neglected) is given by formula (2).
DIMENSIONS ON THE PERFORMANCES OF
THE MACHINE C hm = 3 p v J s S cu (2)
Using a simplified analytical model, the impact of Where:
each parameter of this structure on its performances will
vm
be presented. Figure 4 and 5 show the main dimensions v =
of the structure. 2
(3)
Scu

=
kb
(
hds eep ) N (2R )
int s + hds + eep lds
2 e

The torque expression shows that the height of the

stators teeth hds is an influent dimension on the
electromagnetic torque value. The impact of this
dimension on the excitation flux and on the
electromagnetic torque will be presented with more
details in paragraph VI.

III-2 IMPACT OF THE DIMENSIONS

OF THE PERMANENT MAGNET

In order to study the impact of the dimensions of the

permanent magnet, the dimensions of the stator are fixed.
Naturally, increasing the height or the thickness of the
permanent magnet will improve the electromechanical
Figure 4 Main dimensions of the stator

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performances of the machine. Thats why the aim is to
optimise the volume of the permanent magnet Vaim. For a
given volume of the permanent magnet
( Vaim = eaim haim La with La the active length of the
structure), the thickness that maximises the excitation
flux (thus the electromagnetic torque) is to be
determined. Formula (4) gives the optimal permanent
magnet thickness.
3e ferVaim
eaimopt =
La l ds
Figure 6 shows comparison between the analytical
model and 2D finite elements analysis results. A good
agreement has been found with a relative error of about
10%. The optimal thickness of the permanent magnet can
not be simulated with finite elements analysis. In fact, it
matches with a zero shafts radius (Figure 7).
Figure 6 The excitation flux versus the thickness of permanent
magnets
Figure 7 Minimum radius of the shaft versus the thickness of
permanent magnets
For a given minimal radius of the shaft (it can be
imposed by the specifications sheet), the minimal
thickness of the permanent magnet is given by the
formula (5)
Vaim
eaim min =
( )
Rextr Rarb min e pr La
(5)
It can be seen that this thickness is always greater
than the optimal thickness.
Figure 8 shows the variation of the excitation flux
versus mechanical position. For a given permanent
magnets volume, increasing its thickness makes the
excitation flux decreases but do not increases its
harmonic contents.
(4)
Figure 8 The excitation flux versus mechanical position
Figure 9 presents the variation of the electromagnetic
torque versus current density for different thickness of
the permanent magnet. It can be seen that for low current
densities (less than 5A/mm) the highest torque values
are obtained for the lowest thickness of the permanent
magnet. However, for current densities that exceeds
5A/mm, the highest torque values are obtained for the
highest thickness of the permanent magnet.
Figure 9 The electromagnetic torque versus the current density
III-3 IMPACT OF THE DIMENSIONS OF
THE TEETHS OF THE STATOR
The teeth of the stator present mainly two dimensions
which are the height and the width. Each of theses
parameters will be studied in order to find their impact on
the performances of the structure.
Most probably, increasing the width of the stators
teeth increases the excitation flux value and reduces its
harmonic components as shown on figure 10. However,
increasing this dimension decreases the place allowed for
the stator winding. Thus an optimal stators teeth winding
is to find. This optimal dimension is given by the formula
(6).
Figure 11 shows the comparison between the results
obtained by the finite elements analysis and the analytical
model. It can be seen (Finite element analysis curve) that
for a stators teeth width greater than 20 mm the
excitation flux does no longer increases. It is caused by
the important increase of the leakage flux.
In order to confirm the existence of this optimum, the
analytical variation of the torque versus the stators teeth
width for a given current density (1A/mm) is shown on
figure 12.
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Figure 10 The excitation flux versus mechanical position
Figure 11 The excitation flux versus the width of stators teeth
Figure 12 The electromagnetic torque versus the width of the
stators teeth
Figure 13 shows the variation of the torque versus the
current density for different stators teeth width. For low
current densities (less than 5A/mm) the best width of
stators teeth is equal to 15 mm. However, for higher
current densities values, and because of the saturation
phenomena, greater stators teeth width must be chosen.
Thus the actual optimal stators teeth width will be
always greater than the analytical optimal value (because
of the saturation phenomena which had been neglected in
the analytical model).
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Figure 13 The electromagnetic torque versus current density
The study of the impact of the height of the stators
teeth seems to be more complicated. In fact, if the radius
of the shaft (Rarb) and the external radius of the machine
(Rexts) are fixed, increasing the height of the stators teeth
makes the height of the permanent magnet (haim)
decreases. Figure 14 that shows the variation of the
excitation flux versus the height of the stators teeth
calculated by both the finite elements analysis and the
analytical model.
Figure 14 The excitation flux versus the height of the stators teeth
However increasing this dimension makes the space
allocated to the stator winding greater. The variation of
the electromagnetic torque versus the height of the
stators teeth is shown on figure 15 and shows that an
optimal value of this dimension exists and must be
determined. Using the analytical model, the optimal
value of the stators teeth height can be found and is
given by formula (7).
As mentioned before, the analytical model does not
take into account the saturation phenomena. In order to
complete this study, many finite elements analysis was
undertaken and figure 17 shows the variation of the
electromagnetic torque versus the current density for
different heights of the stators teeth. It can be seen that
for low current densities values (less than 5A/mm) the
highest are the stators teeth, the greatest is the
electromagnetic torque value. Nevertheless, for high
current densities values (more than 5A/mm) this finding
is not really correct (as shown on figure 17).
 achieve the required specifications. The final structure is
represented on figures 3, 4 and 5. One can notice that for
the required electromechanical torque level, the optimal
thickness of the permanent magnets and the optimal
width of the stator teeth are relatively broad (respectively
16 mm and 22 mm), the optimal height of the stators
teeth is rather small (24 mm), as predicted previously
when the analytical study and the finite elements analysis
were combined

Figure 15 The electromagnetic torque versus the height of the

stators teeth

In order to go forward in this study, the optimisation

criterion is to be changed, and the ratio of winding losses
by electromagnetic torque was chosen and the parameter
to be optimized is the radio of the internal radius of the
stator Rints by the external radius of the machine Rexts as
shown on figure 16. The winding losses are calculated by
formulas 8
Pj = 3 p cu J s2 l cu S cu Figure 17 The electromagnetic torque versus current density

( ) ( ( ))
With cu Tc = a 1 + T Tc Ta , In addition, External dimensions are less that those

(T ) = 17,8.10 .m ,
imposed by the specifications sheet (132 mm for the
9
a = cu a external radius and 80 mm for the axial length).This was
(8)
made possible due to the use of permanent magnets in the
T = 3,81.10 3 K 1 and machine. Figures 18 and 19 show the performances of the
2 h final structure. It can be seen that the required torque
l cu = 2 La + Rint s + ds levels are reached with quietly high current densities that
Ne 2
are still acceptable. The machine is cooled by water.
Figure 19 shows the characteristic torque-speed obtained
by classical analytical models [9].

Figure 16 Minimisation of the ratio of winding losses by the

electromagnetic torque

Obviously, increasing the ratio between the internal Figure 18 The electromagnetic torque versus current density
radius of the stator and the external radius of the machine
makes the height of the teeth of the stator decrease. That
way it can be easily predicted that, when the saturation
phenomena will be taken into account, the best ratio
between the winding losses and the electromagnetic
torque will be greater than the one calculated by the
analytical model.

IV OPTIMAL DESIGN OF THE STRUCTURE

For the given specifications sheet (presented on figure
1 and 2), a parametric study (scan of all possible
dimensions of the magnets and the stator teeth and taking
as beginning dimensions those given by the analytical
model) made it possible to find the best structure that Figure 19 The electromagnetic torque versus the mechanical speed

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 It can be seen that the final machine achieves the
required maximum speed.
V CONCLUSION
I n order to achieve an optimal design of the structure
presented in this paper, it was necessary to study the
impact of the different dimensions on the electromagnetic
and mechanical performances. The presented structure in
this paper has permanent magnets in focusing
configuration in the rotor and a concentric winding in the
stator. The study was focused on the dimension of the
permanent magnets (its thickness and its height) and the
width and the height of stators teeth.
On the basis of the conducted study, the following
conclusions have been drawn:
1) For a given volume of the permanent magnet and
a given torque to reach, an optimal thickness of the
permanent magnet that allows to minimizing the
current density exists. This dimension was estimated
by using a linear analytical model. However, because
of the saturation phenomena, the actual optimal
thickness is greater than the analytical value.
2) The existence of an optimal width and an optimal
height of the stators teeth were proved and the
optimal dimension was calculated by the analytical
linear model and verified by finite elements analysis.
The actual optimal width of stators teeth is greater
than the analytical value and the actual optimal
height of stators teeth value is less than the one
obtained by the analytical model. It is mainly due to
the saturation phenomena.
The analytical model was combined to a 2D finite
elements analysis and made possible to optimise the ratio
of the winding losses by the electromagnetic torque for
the base point and to use as well as possible the given
volume of permanent magnets. Thus, an optimal machine
was dimensioned
In order to use the finite elements analysis only to
validate the final structure, a more complete model needs
+ h ds + e ep
h aim e aim 2 R int
s
l dsopt = 3 e fer 1+
e aim 3 N e h aim e fer
2 2
Ne R Rexts R2 N N
hdsopt = Rexts l ds arb + arb e l ds Rexts + e l ds
3 3 3 3 3 9
to be developed. It must take into account all leakage
fluxes and the saturation phenomena. This final model
will be combined to an optimisation algorithm such as
the genetic algorithm. Thus, it will be possible to obtain,
at once, the optimal machine for a given specifications
sheet.
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1
(6)
N
e l ds Rarb (7)
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