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Design, analysis, parameter evaluation and testing of a laboratory-fabricated brush-less DC motor prototype

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Abstract

This paper presents detailed steps and procedures for the design of a 4-pole, 0.75-hp, 1500-r.p.m. surface-mounted permanent magnet brush-less DC (SPM-BLDC) motor. The motor has been fabricated at the works of a local manufacturer. The parameters of the machine have been analytically evaluated and subsequently compared to the experimentally determined values. Its practical performance on load has been experimentally evaluated in the laboratory and verified against analytical predictions too. Low-cost M45 electrical steel laminations, as used for commercial induction motors (IMs), have been used from considerations of cost and availability. This also enables direct comparison of important parameters (e.g. torque density, power density and efficiency) between the fabricated prototype and commercially available fractional-hp 3-phase and 1-phase IMs of similar rating. This study is significant since electrical motor manufacturers need not change their stator stamping production line for BLDC motor vis-a-vis IM in case of mass production. Such an approach is hardly reported in the available technical literature. Analytical methods adopted include both conventional hand calculations and finite-element analysis using commercially available software package(s). Excellent agreements between analytical and experimental values uphold the correctness of the design process, precision of fabrication and accuracy of experimental investigations.

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Abbreviations

\({{{\mathcal {P}}}}_0\) \(\triangleq \) :

rated output power of the motor, in hp.

\(S_{in}\triangleq \) :

input volt-ampere of the motor, in VA.

\(V_{dc}\) \(\triangleq \) :

DC input voltage, in V.

\(I_{dc}\) \(\triangleq \) :

DC input current, in A.

\({{\mathscr {N}}_r}\) \(\triangleq \) :

rated speed of the motor, in r.p.m.

\( {n_s}\) \(\triangleq \) :

synchronous speed of the motor, in r.p.s.

p \(\triangleq \) :

number of pole pairs.

f \(\triangleq \) :

electrical frequency, in Hz.

\(\eta \) \(\triangleq \) :

efficiency of the motor.

q \(\triangleq \) :

number of slots per pole per phase (SPP).

\({{\mathscr {D}}}\) \(\triangleq \) :

bore diameter of the motor, in mm.

\({{\mathscr {L}}}\) \(\triangleq \) :

stack length of the motor, in mm.

\(B_{av}\) \(\triangleq \) :

specific magnetic loading, in T.

\({\overline{ac}}\) \(\triangleq \) :

specific electrical loading, in A/m.

\(E_{b}\) \(\triangleq \) :

back emf (as seen from inverter DC side), in V.

\(E_{ph}\) \(\triangleq \) :

induced emf per phase (rms), in V.

\(I_{ph}\) \(\triangleq \) :

phase current (rms), in A.

\(k_w\) \(\triangleq \) :

winding factor.

\(k_d\) \(\triangleq \) :

distribution factor.

\(k_p\) \(\triangleq \) :

pitch factor.

\(k_{sk}\) \(\triangleq \) :

skew factor.

\(k_{cu}\) \(\triangleq \) :

copper fill factor of a slot.

\(N_{ph}\) \(\triangleq \) :

number of turns per phase.

\(N_{t}\) \(\triangleq \) :

number of turns per slot.

\(\ell _{mt}\) \(\triangleq \) :

length of mean turn, in mm.

\(l_g\) \(\triangleq \) :

effective air-gap length, in mm.

\(l_m\) \(\triangleq \) :

thickness of the magnet, in mm.

PC \(\triangleq \) :

permeance coefficient of magnet.

\(B_r\) \(\triangleq \) :

remanence flux density of magnet, in T.

\(H_c\) \(\triangleq \) :

coercivity of magnet, in kA/m.

\(R_{ph}\) \(\triangleq \) :

resistance per phase, in \(\Omega \).

\(L_d\) and \(L_q\) \(\triangleq \) :

d- and q-axis inductances, respectively, in mH.

\(X_d\) and \(X_q \triangleq \) :

d- and q-axis reactances, respectively, in \(\Omega \).

\(\theta _r\) \(\triangleq \) :

rotor position in electrical rads.

\({{\mathscr {T}}}_{shaft}\) \(\triangleq \) :

rated shaft torque, in N-m.

T \(\triangleq \) :

temperature of different parts of the motor, in \(^{\mathrm{o}}\hbox {C}\).

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Acknowledgements

The authors wish to thank the staff of M/S GE Motors Pvt. Ltd, Sheorapuli, in general, and Mr. Kausik Pyne, in particular, for the manufacturing support received in fabricating the BLDC motor. The authors also acknowledge the support received from the funding agencies like DeitY, CSIR (for manpower support). The moral support received from the research colleagues at the Advanced Power Electronics Laboratory, EE Department, and the authorities of IIEST, Shibpur, towards this work is also thankfully acknowledged.

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Correspondence to Pinaki Mukherjee.

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Mukherjee, P., Sengupta, M. Design, analysis, parameter evaluation and testing of a laboratory-fabricated brush-less DC motor prototype. Sādhanā 45, 247 (2020). https://doi.org/10.1007/s12046-020-01470-7

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