A Project Report on

Comparative Investigation and Implementation of Propulsion Motor

for Electrified Transportation System

submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPUR,
ANANTAPURAMU

in partial fulfilment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY
in
ELECTRICAL AND ELECTRONICS ENGINEERING
by
SIRRI POORNA THEJA (18121A02F2)
PRABIN KAPURI (18121A02J2)
THATI SUMANTH (18121A02G1)
V. SURYA TEJA (18121A02H3)
V. PRAVEEN NAIK (18121A02G9)

Under the esteemed guidance of

Dr. S. PRABHU, ME, Ph.D.,
Associate Professor,
DEPARTMENT OF EEE.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

SREE VIDYANIKETHAN ENGINEERING COLLEGE
(An autonomous institution affiliated to JNTUA, Anantapuramu)
Sree Sainath Nagar, Tirupati – 517 102.

2021-2022
 SREE VIDYANIKETHAN ENGINEERING COLLEGE
(AUTONOMOUS)
Sree Sainath Nagar, A. Rangampet - 517 102

Department of Electrical and Electronics Engineering

VISION

To become the Nation’s premiere Centre of excellence in electrical engineering through

teaching, training, research and innovation to create competent engineering professionals
with values and ethics.
MISSION

➢ To foster intellectual curiosity, pursuit and dissemination of knowledge.

➢ To explore students’ potential through academic freedom and integrity.
➢ To promote technical mastery and nurture skilled professionals to face competition in
ever increasing complex world.

QUALITY POLICY

Sree Vidyanikethan Engineering College strives to establish a system of Quality Assurance

to continuously address, monitor and evaluate the quality of education offered to students,
thus promoting effective teaching processes for the benefit of students and making the
College a Centre of Excellence for Engineering and Technological studies.

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

VISION

To become the Nation’s premiere Centre of excellence in electrical engineering through

teaching, training, research and innovation to create competent engineering professionals
with values and ethics.
.
MISSION

➢ Department of Electrical Engineering strives to create human resources in Electrical

Engineering to contribute to the nation development and improve the quality of life.
➢ Imparting Knowledge through implementing modern curriculum, academic
flexibility and learner centric teaching methods in Electrical Engineering
➢ Inspiring students for aptitude to research and innovation by exposing them to
industry and societal needs to creating solutions for contemporary problems
➢ Honing technical and soft skills for enhanced learning outcomes and employability
of students with diverse background through comprehensive training
methodologies
➢ Inculcate values and ethics among students for a holistic engineering professional
practice.

I
 ➢ B. Tech. (Electrical and Electronics Engineering)
➢ Program Educational Objectives

After few years of graduation, the graduates of B. Tech (EEE) will be:
➢
PEO1. have enrolled in academic program in the disciplines of electrical engineering and
multidisciplinary areas.
PEO2. become entrepreneurs or be employed as productive and valued engineers in
reputed industries.
PEO3. engage in lifelong learning, career enhancement and adopt to changing professional
and societal needs.

➢ Program Outcomes
➢ On successful completion of the Program, the graduates of [Link]. (EEE) Program
will be able to:

PO1 Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and concepts of engineering to the solution of complex engineering
problems.
PO2 Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences and engineering sciences.
PO3 Design/development of solutions: Design solutions for complex engineering
problems and design system components or processes that meet the specified needs
with appropriate consideration for the public health and safety, and the cultural, societal,
and environmental considerations.
PO4 Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data,
and synthesis of the information to provide valid conclusions
PO5 Tools and Techniques: Create, select, and apply appropriate techniques, resources,
and modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.
PO6 Engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.
PO7 Environment and sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of and need for sustainable development.
PO8 Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.
PO9 Individual and Team work: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
PO10 Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend
and write effective reports and design documentation, make effective presentations, and
give and receive clear instructions.
PO11 Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a
member and leader in a team, to manage projects and in multidisciplinary environments
PO12 Life-long learning: Recognize the need for, and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
change.

II
 Program Specific Outcomes

On successful completion of the Program, the graduates of B. Tech. (EEE) will be able to

PSO1. Demonstrate knowledge of Electrical and Electronic circuits, Electrical Machines,

Power Systems, Control Systems, and Power Electronics for solving problems in
electrical and electronics engineering.
PSO2. Analyze, design, test and maintain electrical systems to meet the specific needs of
the industry and society.
PSO3. Conduct investigations to address complex engineering problems in the areas of
Electrical Machines, Power Systems, Control Systems and Power Electronics.
PSO4. Apply appropriate techniques, resources and modern tools to provide solutions for
problems related to electrical and electronics engineering.

III
 SREE VIDYANIKETHAN ENGINEERING COLLEGE
(An Autonomous institution affiliated to JNTUA, Anantapuramu)
Sree Sainath Nagar, Tirupati – 517 102
DEPARTMENT OF ELECTRICAL AND ELECTRONICS
ENGINEERING

Certificate
This is to certify that the project report entitled “COMPARATIVE
INVESTIGATION AND IMPLEMENTATION OF PROPULSION MOTOR
FOR ELECTRIFIED TRANSPORTATION SYSTEM” is the bona-fide work
done and submitted by
SIRRI POORNA THEJA (18121A02F2)
PRABIN KAPURI (18121A02J2)
THATI SUMANTH (18121A02G1)
V. SURYA TEJA (18121A02H3)
V. PRAVEEN NAIK (18121A02G9)

to department of EEE, Sree Vidyanikethan Engineering College, an

autonomous institution affiliated to Jawaharlal Nehru Technological
University Anantapur, Anantapuramu in partial fulfillment of the
requirements for award of degree of Bachelor of Technology in Electrical and
Electronics Engineering, is a bona-fide work submitted by them under my
supervision.

Guide: HOD:
Dr. S. Prabhu, ME., Ph. D., Dr. M. S. SUJATHA, M. Tech., Ph. D.
Associate Professor Professor
Department of EEE Department of EEE
Sree Vidyanikethan Engineering College Sree Vidyanikethan Engineering College
A. Rangampet. A. Rangampet.

EXAMINER – 1 EXAMINER - 2
IV
 DECLARATION

We hereby declare that the project report on “COMPARATIVE

INVESTIVATION AND IMPLEMENTATION OF PROPULSION MOTOR
FOR ELECTRIFIED TRANSPORTATION SYSTEM” has been submitted
by us under the guidance and supervision of Dr. S. PRABHU Associate
Professor, SREE VIDYANIKETHAN ENGINEERING COLLEGE
(Autonomous). This work / report has not been submitted either for the award
of any degree or any other similar title.

SIRRI POORNA THEJA 18121A02F2

PRABIN KAPURI 18121A02J2
THATI SUMANTH 18121A02G1
[Link] TEJA 18121A02H3
[Link] NAIK 18121A02G9

Place: Tirupati
Date:

V
 ACKNOWLEDGEMENTS

We are deeply indebted to our supervisor, Dr. S. PRABHU, M.E., Ph.D.,

Associate Professor, Department of Electrical and Electronics Engineering,
for his valuable guidance, constant encouragement and keen interest evinced
throughout the course of ourProject work.

We sincerely thank our Head of the Department, Dr. M. S. SUJATHA,Ph. D,

for hersupport and constructive suggestions at various levels of the work.

We express our gratitude to our principal Dr. B.M. SATISH, Ph. D and
the Management of SVEC for providing all kinds of support. We express
our heartfelt thanks to our all teachers in the department of Sree
Vidyanikethan Engineering College for their moral support and good
wishes.

Finally, we would like to express our sincere thanks to our parents, friends,
one and allthose who guided, motivated and helped us in completion of our
Project work.

SIRRI POORNA THEJA 18121A02F2

PRABIN KAPURI 18121A02J2
THATI SUMANTH 18121A02G1
[Link] TEJA 18121A02H3
[Link] NAIK 18121A02G9

VI
 ABSTRACT

This project deals with the design and investigations on various electric motors for

traction applications. The main aim of the project is to identify the inner rotor motor with

superior characteristics. The motor considered for analysis are Switched Reluctance

Motor (SRM), Synchronous Reluctance Motor (SyRM), Hybrid Motor and Brushless

DC Motor (BLDC) are investigated and compared with the parameters as torque ripple,

to find the behavior of the motor. The 2 kW, 48 V, 1500 RPM, three phase are the

specifications of the motors considered for analysis. The analysis is executed in the finite

element analysis environment by utilizing motorsolve package. SRM is investigated for

three phases, SyRM is analyzed for angled barrier, notched and angle barrier, round

barrier, notch and round barrier types, BLDC is examined for spoke, bread-loaf types.

By comparing all the types of motor, it is inferred that bread loaf with four non-embedded

magnet BLDC motor. The simulated results are validated with numerical equations. Then

a prototype implementation of conventional PMBLDC hub motor in the process of

converting exciting bike into electric vehicle is executed. The test findings of the electric

bike are investigated and reported.

Keywords: Brushless DC motor (BLDC), Switched reluctance motor (SRM),

Synchronous reluctance Motor (SyRM).

VII
 CONTENTS

S. No. Title Page No.

Abstract vii

List of Abbreviations x

List of Symbols xi

List of figures xii

List of Tables xviii

Chapter 1 Introduction 1-5

1.1 Introduction
1.2 Literature Survey

1.3 AIM of the Project

1.4 Contributions of the Thesis

1.5 Organizations of the Thesis

Chapter 2 Finite Element Modelling and Analysis of 6-18

Various Electric Traction Motor
1.1 Introduction

2.2 Comparative Investigation on BLDC propulsion

motors

Chapter 3 Electromagnet Analysis of Synchronous 19-43

VIII
 Reluctance Motor

Chapter 4 Electromagnetic Analysis of Switched 44-57

Reluctance Motor and Hybrid Motors

Chapter 5 Selection of Laminating Core Materials for 58-71

Bread Loaf with Four Non-Embedded
Magnets Per Pole

Chapter 6 Prototype Model and Hardware Testing 72-76

Results

Chapter 7 Conclusion and Future Scope 77

7.1 Conclusion

7.2 Future Scope

Chapter 8 Finance and Project management 78

Chapter 9 Time management and Societal impact 79

References 80-85

IX
 LIST OF ABBREVIATIONS

Abbreviation Description

BLDC : Brushless DC Motor

SyRM : Synchronous Reluctance Motor
SRM : Switch Reluctance Motor

X
 LIST OF SYMBOLS

Symbol Description
η : Efficiency
% : Percentage

XI
 LIST OF FIGURES
Title Page No.
Figure No.

Fig. 2.1 Different types of BLDC motors 9

Fig. 2.2 Model Diagram of Spoke type BLDC Motor. 11
Instantaneous fields of Spoke type BLDC Motor.
Fig. 2.3 11
Fig. 2.4 Torque waveform for Spoke type BLDC Motor. 11
Fig. 2.5 Force Fields of Spoke type BLDC Motor. 12
Fig. 2.6 Model Diagram of Bread loaf with two non-embedded 14
magnets per pole.
Fig. 2.7 Instantaneous fields of Bread loaf with two non-embedded 14
magnets per pole.
Fig. 2.8 Force Fields of Bread loaf with two non-embedded 14
magnets per pole.
Torque waveform for Bread loaf with two non-embedded
Fig. 2.9 15
magnets per pole.
Fig. 2.10 Model Diagram of Bread loaf with four non-embedded 17
magnets per pole.
Fig. 2.11 Instantaneous fields of Bread loaf with four non-embedded 17
magnets per pole.
Fig. 2.12 Torque waveform for Bread loaf with four non-embedded 17
magnets per pole.
Fig. 2.13 Force Fields of Bread loaf with four non-embedded 18
magnets per pole.
Fig. 3.1 Different types synchronous reluctance motors 20
Fig. 3.2 Model Diagram of SyRM with angled barrier (1Layer). 21
Fig. 3.3 Instantaneous fields of SyRM with angled barrier (1Layer). 21
Fig. 3.4 Torque waveform for SyRM with angled barrier (1Layer). 22
Fig. 3.5 Model Diagram of SyRM with angled barrier (2 Layer). 22
Fig. 3.6 Instantaneous fields of SyRM with angled barrier 22
(2Layer).

XII
Fig. 3.7 Torque waveform for SyRM with angled barrier (2Layer). 23
Fig. 3.8 Model Diagram of SyRM with angled barrier (3 Layer). 23
Fig. 3.9 Instantaneous fields of SyRM with angled barrier (3Layer). 23
Fig. 3.10 Torque waveform for SyRM with angled barrier (3Layer). 24
Fig. 3.11 Model Diagram of SyRM with angled barrier (4 Layer). 24
Fig. 3.12 Instantaneous fields of SyRM with angled barrier(4Layer). 24
Fig. 3.13 Torque waveform for SyRM with angled barrier(4Layer). 25
Fig. 3.14 Model Diagram of SyRM with Notch and with angled 27
barrier (1 Layer).
Fig. 3.15 Instantaneous fields of SyRM with Notch and with angled 27
barrier (1 Layer).
Fig. 3.16 Torque waveform for SyRM with Notch and with angled 27
barrier (1 Layer).
Fig. 3.17 Model Diagram of SyRM with Notch and with angled 28
barrier (2 Layer).
Fig. 3.18 Instantaneous fields of SyRM with Notch and with angled 28
barrier (2 Layer).
Fig. 3.19 Torque waveform for SyRM with Notch and with angled 28
barrier (2 Layer).
Fig. 3.20 Model Diagram of SyRM with Notch and with angled 29
barrier (3 Layer).
Fig. 3.21 Instantaneous fields of SyRM with Notch and with angled 29
barrier (3 Layer).
Fig. 3.22 Torque waveform for SyRM with Notch and with angled 29
barrier (3 Layer).
Fig. 3.23 Model Diagram of SyRM with Notch and with angled 30
barrier (4 Layer).
Fig. 3.24 Instantaneous fields of SyRM with Notch and with angled 30
barrier (4 Layer).
Fig. 3.25 Torque waveform for SyRM with Notch and with angled 30
barrier (4 Layer).

XIII
Fig. 3.26 Model Diagram of SyRM with round barrier (1Layer) 32
Fig. 3.27 Instantaneous fields of SyRM with round barrier (1Layer) 32
Fig. 3.28 Torque waveform for SyRM with round barrier (1Layer) 33
Fig. 3.29 Model Diagram of SyRM with round barrier (2Layer) 33
Fig. 3.30 Instantaneous fields of SyRM with round barrier (2Layer) 33
Fig. 3.31 Torque waveform for SyRM with round barrier (2Layer) 34
Fig. 3.32 Model Diagram of SyRM with round barrier (3Layer) 34
Fig. 3.33 Instantaneous fields of SyRM with round barrier (3Layer) 34
Fig. 3.34 Torque waveform for SyRM with round barrier (3Layer) 35
Fig. 3.35 Model Diagram of SyRM with round barrier (4Layer) 35
Fig. 3.36 Instantaneous fields of SyRM with round barrier (4Layer) 35
Fig. 3.37 Torque waveform for SyRM with round barrier (4Layer) 36
Fig. 3.38 Model Diagram of SyRM with Notch and round barrier 38
(1Layer)
Fig. 3.39 Instantaneous fields of SyRM with Notch and round 38
barrier (1Layer)
Fig. 3.40 Torque waveform for SyRM with Notch and round barrier 38
(1Layer)
Fig. 3.41 Model Diagram of SyRM with Notch and round barrier 39
(2Layer)
Fig. 3.42 Instantaneous fields of SyRM with Notch and round 39
barrier (2Layer)
Fig. 3.43 Torque waveform for SyRM with Notch and round barrier 39
(3Layer)
Fig. 3.44 Model Diagram of SyRM with Notch and round barrier 40
(3Layer)
Fig. 3.45 Instantaneous fields of SyRM with Notch and round 40
barrier (3Layer)
Fig. 3.46 Torque waveform for SyRM with Notch and round barrier 40
(3Layer)
Fig. 3.47 Model Diagram of SyRM with Notch and round barrier 41
(4Layer)
Fig. 3.48 Instantaneous fields of SyRM with Notch and round 41
Barrier (4Layer)

XIV
Fig. 3.49 Torque waveform for SyRM with Notch and round barrier 41
(4Layer)
Fig. 4.1 Model Diagram of SRM 45
Fig. 4.2 Instantaneous fields of SRM 45
Fig. 4.3 Torque waveform for SRM 46
Fig. 4.4 Flux Linkages of Switched reluctance motor for different 46
rotor angles
Fig. 4.5 Inductance VS Rotor Angle characteristics of SRM 47
Fig. 4.6 The Hybrid Motor 1 with BLDC Stator and SRM Rotor 49
Fig. 4.7 The Hybrid Motor 2 with SRM Stator and BLDC Rotor 50
Fig. 4.8 Model Diagram of Hybrid motor with BLDC Stator and 52
SRM rotor
Fig. 4.9 Instantaneous fields of Hybrid motor with BLDC Stator 52
and SRM rotor
Fig. 4.10 Torque waveform for Hybrid motor with BLDC Stator and 52
SRM rotor
Fig. 4.11 Model Diagram of Hybrid motor with SRM Stator and 54
BLDC rotor
Fig. 4.12 Instantaneous fields of Hybrid motor with SRM Stator and 54
BLDC rotor
Fig. 4.13 Torque waveform for Hybrid motor with SRM Stator and 55
BLDC rotor
Fig. 4.14 Force fields of for Hybrid motor with SRM Stator and 55
BLDC rotor
Fig. 5.1 BH Curves of different materials for bread loaf with four 60
non-embedded magnets per pole
Fig. 5.2 Iron Loss Characteristics of different materials for bread 60
loaf with four non-embedded magnets per pole
Fig. 5.3 Model Diagram of Bread loaf with four non-embedded 61
magnets per pole made with 36F155
Fig. 5.4 Instantaneous Fields of Bread loaf with four non- 61
embedded magnets per pole made with 36F155
Fig. 5.5 Torque waveform for Bread loaf with four non-embedded 61
magnets per pole made with 36F155
Fig. 5.6 Force fields of Bread loaf with four non-embedded 62
magnets per pole made with 36F155

XV
Fig. 5.7 Model Diagram of Bread loaf with four non-embedded 62
magnets per pole made with 47F165
Fig. 5.8 Instantaneous Fields of Bread loaf with four non- 62
embedded magnets per pole made with 47F165
Fig. 5.9 Torque waveform for Bread loaf with four non-embedded 63
magnets per pole made with 47F165
Fig. 5.10 Force fields of Bread loaf with four non-embedded 63
magnets per pole made with 47F165
Fig. 5.11 Model Diagram of Bread loaf with four non-embedded 64
magnets per pole made with ARNON 7
Fig. 5.12 Instantaneous Fields of Bread loaf with four non- 64
embedded magnets per pole made with ARNON 7
Fig. 5.13 Torque waveform for Bread loaf with four non-embedded 65
magnets per pole made with ARNON 7
Fig. 5.14 Force fields of Bread loaf with four non-embedded 65
magnets per pole made with ARNON 7
Fig. 5.15 Model Diagram of Bread loaf with four non-embedded 66
magnets per pole made with M-27 24 Ga
Fig. 5.16 Instantaneous Fields of Bread loaf with four non- 66
embedded magnets per pole made with M-27 24 Ga
Fig. 5.17 Torque waveform for Bread loaf with four non-embedded 67
magnets per pole made with M-27 24 Ga
Fig. 5.18 Force fields of Bread loaf with four non-embedded 67
magnets per pole made with M-27 24 Ga
Fig. 5.19 Model Diagram of Bread loaf with four non-embedded 68
magnets per pole made with M-300 35A
Fig. 5.20 Instantaneous Fields of Bread loaf with four non- 68
embedded magnets per pole made with M-300 35A
Fig. 5.21 Torque waveform for Bread loaf with four non-embedded 68
magnets per pole made with M-300 35A
Fig. 5.22 Force fields of Bread loaf with four non-embedded 69
magnets per pole made with M-300 35A
Fig. 5.23 Model Diagram of Bread loaf with four non-embedded 69
magnets per pole made with M-420 50D
Fig. 5.24 Instantaneous Fields of Bread loaf with four non- 69
embedded magnets per pole made with M-420 50D
Fig. 5.25 Torque waveform for Bread loaf with four non-embedded 70

XVI
 magnets per pole made with M-420 50D
Fig. 5.26 Force fields of Bread loaf with four non-embedded 70
magnets per pole made with M-420 50D
Fig. 6.1 Side view of Prototype Model 72
Fig. 6.2 Rear View of Prototype Model 73
Fig. 6.3 Speed of the Vehicle 73
Fig. 6.4 Decibel under road condition 73
Fig. 6.5 Voltage VS Time Characteristics for different speeds with 74
single load
Fig. 6.6 Voltage VS Time Characteristics for different speeds with 74
two persons
Fig. 6.7 Speed VS Time Characteristics for different modes 75
Fig. 6.8 Decibel VS Speed Characteristics for different modes 75

XVII
 LIST OF TABLES

Table No. Title Page No.

Table 2.1 The required specifications for spoke type BLDC motor 9

Table 2.2 The specifications required for bread loaf with two non- 12
embedded magnets

Table 2.3 The specifications of bread loaf with four non embedded magnets 15
per pole BLDC motor

Table 2.4 The shows Comparison of Torque(N-m) 18

Table 3.1 The specifications of Synchronous reluctance motor (SyRM) with 20

angled barrier

Table 3.2 The specifications of Synchronous reluctance motor with notch 25

and angled barrier
Table 3.3 The specifications of Synchronous reluctance motor with round 31
barrier
Table 3.4 The specifications required for Synchronous reluctance motor 36
with notch and round barrier
Table 3.5 Comparison of torques for different SyRM Rotors. 42

Table 3.6 Comparison of torques between Bread loaf with four non- 43
embedded magnets per pole motor and SyRM with Notch and
Round barrier.

Table 4.1 The specifications required for Switched Reluctance Motor 44

Table 4.2 Comparison of torque values for bread loaf with four non- 48
embedded magnets per pole and SRM motor.

XVIII
Table 4.3 The specifications required for Hybrid Motor 1 50

Table 4.4 The specifications required for Hybrid Motor 2 53

Table 4.5 Comparison of torque values for Hybrid motors. 56

Table 4.6 Comparison of Brad loaf with four non-embedded magnets per 56
pole BLDC motor and SRM stator and BLDC rotor Hybrid motor

Table 5.1 The specifications required for Bread loaf with four non- 58
embedded magnets per pole BLDC motor

Table 5.2 Comparison of torque values for different materials. 71

XIX
 CHAPTER-1
INTRODUCTION

1.1 Introduction

An electric vehicle (EV) is one that runs on electricity rather than an internal-combustion
engine, which generates power by burning a mixture of fuel and gases. As a result, such a vehicle
is viewed as a potential replacement for current-generation automobiles in order to address issues
such as rising pollution, global warming, depleting natural resources, and so on. Though the
concept of electric vehicles has been around for a long time, it has gained a lot of attention in the
last decade due to rising carbon footprints and other environmental impacts of fuel-based vehicles.

Electric vehicles have minimal operating expenses since they have fewer moving parts to
maintain, and they are also very eco-friendly because they consume little or no fossil fuels (petrol
or diesel). While some EVs used lead acid or nickel metal hydride batteries, lithium-ion batteries
are currently the industry standard since they are more durable and have a low self-discharge rate
of only 5% per month. Despite their increased efficiency, these batteries still have issues with
thermal runaway.

Disadvantages of internal combustion engines

1. The available fuels are limited to high-quality gaseous and liquid fuels.
2. The fuel used, such as gasoline or diesel, is very expensive.
3. Engine emissions are generally high when compared to external combustion engines.
4. Unsuitable for large-scale power generation
5. Noise is produced by detonation of fuel in the case of reciprocating internal combustion.

Advantages of Electric Vehicles

1. Feasible Alternate
2. No Fuel
3. Low Maintenance
4. Environment Friendly
5. Safety First
6. Designed for The Future

1
1.2 Literature Survey

S. B. Santra et al. (2022), A 300 W, BLDC motor is investigated with selective harmonic
elimination PWM method to reduce the losses at various load and speed conditions. The common
mode noise developed in BLDC motor is due to PWM technique, capacitances and rate of change
of voltages. This elaborates the reduction of noise caused due to PWM technique by adopting
silicon carbide (SiC)-based inverters on the BLDC drives systems. Further, CM noise filter design
is demonstrated. The torque performance and the motor efficiency of a sensor less BLDC motor
depends on accurate commutation. A closed loop correction method named floating phase back
electromotive force (EMF) integration is used to eliminate the commutation error. But the
inaccurate calculation of integral calculation leads to reduction of correction accuracy. So, a
hardware configuration is designed to convert the back-EMF integral into a filtered analog voltage.
So, that the commutation is achieved by closed loop control, particularly in high-speed range.

S. Singh et al. (2022), The common mode noise developed in BLDC motor is due to PWM
technique, capacitances and rate of change of voltages. This elaborates the reduction of noise
caused due to PWM technique by adopting silicon carbide (SiC)-based inverters on the BLDC
drives systems. Further, CM noise filter design is demonstrated.

H. Jin et al. (2022), The torque performance and the motor efficiency of a sensor less BLDC
motor depends on accurate commutation. A closed loop correction method named floating phase
back electromotive force (EMF) integration is used to eliminate the commutation error. But the
inaccurate calculation of integral calculation leads to reduction of correction accuracy. So, a
hardware configuration is designed to convert the back-EMF integral into a filtered analog voltage.
So, that the commutation is achieved by closed loop control, particularly in high-speed range.

Y. Lee et al. (2022), The BLDC motor create a two degree of freedom (2-DOF)
transformation of the wheel. This mechanism (2-DOF) is obtained by a 7-bar linkage with six
rotational joints and one prismatic joint. This will make the motor to climb up and down the stair
case. This will be used in applications such as wheelchairs and baby carriages that can move up,
down and sidewise. The driving mode of the motor has influence on motor losses such as iron loss,
copper loss, and converter loss. The loss characteristics of doubly salient brushless motor
(DSBLM) with rectangular wire armature winding driven by Brushless DC(BLDC) and Brushless
AC(BLAC) are compared by considering the magnetic flux density waveforms and influence of
pulse width modulation (PWM) on motor losses. In addition, with converter losses. In the end it
was found that the BLAC driving mode, a DSBLM with rectangular wire armature winding has
better loss characteristics.

J. Zhang et al. (2022), The driving mode of the motor has influence on motor losses such

2
as iron loss, copper loss, and converter loss. The loss characteristics of doubly salient brushless
motor (DSBLM) with rectangular wire armature winding driven by Brushless DC(BLDC) and
Brushless AC(BLAC) are compared by considering the magnetic flux density waveforms and
influence of pulse width modulation (PWM) on motor losses. In addition, with converter losses.
In the end it was found that the BLAC driving mode, a DSBLM with rectangular wire armature
winding has better loss characteristics.

SMDS Spoke-Type BLDC Motor for PV Bore-Well S. Sashidhar and B. G. Fernandes

(2014). Now-a-days electric vehicles (EVs) are increasing more to reduce oil dependence as well
as to lessen noise and pollution. The key features to technology success are efficient power
electronics-based energy conversion and electric machines, together with high power and high
energy density storage devices. Concerning electric machines, the following requirements are
crucial when dealing with EV: high torque and power density, wide speed range, high efficiency
over wide torque and speed ranges, high reliability and robustness, among others. Rise in cost of
rare earth metals that used in PMBLDC motors are more burden to rural people and it also have
the low reminisce flux density and are brittle. So, reduce that topology we have to use a new “semi-
modular dual-stack” ST BLDC motor which it has a less flux leakages in PV system.

C. -L. Jeong et al. (2021), A new application to improve quality of a spoke-type brushless
direct current (BLDC) motor using ferrite permanent magnets (Fe-PMs) through demagnetization
method is used for prototype design and output characteristics. H. -W. Kim et al. (2013), We
propose a method for optimize the (cogging and ripple) torque to develop a SPOKE-type BLDC
motor by ferrite magnets other than rare earth metals. At last, we compare and analyze simulation
results and experimental results to get required torque.

M. R. Mohammad et al. (2013), A innovative design of a SPOKE-type PMBLDC motor

via pushing magnet for air gap flux density and analysis the results experimentally. This analysis
works for both motor rotor and magnetized permanent magnets.

1.3 AIM of The Project

The main aim of this work is to adapt the design procedure reported earlier for electric
bike to conventional petrol bike. The objectives of this research are summarized as follows:

i. To design 2 kw, 48 v, 1500 rpm, 12.7 Nm BLDC electric motor using electromagnet FEA
tools.
ii. To design 2 kw, 48 v, 1500 rpm, 12.7 Nm SyRM electric motor using electromagnet FEA
tools.
iii. To design 2 kw, 48 v, 1500 rpm, 12.7 Nm SRM electric motor using electromagnet FEA
tools.
iv. To design a Hybrid motor (i.e., Stator of SRM and Rotor of BLDC and Vice-Versa) using

3
 FEA tools.
v. Selection of laminating core materials, to identify the superior behavior of the motor
vi. To convert conventional bike to electric vehicle by adopting existing PMBLDC Hub
motor.

1.4 Contribution of The Thesis

The thesis has been organized into six chapters as discussed below. These chapters describe
the introduction, literature survey, investigations undertaken, and results obtained through
fabrication and testing of a 2KW, 12.7 Nm PMBLDC Hub prototype, followed by conclusions.

i. To design high energy efficient motor for traction application using existing conventional
bike.
ii. To convert conventional petrol bike to electric bike using PMBLDC Hub motor.

1.5 Organization of The Thesis

The thesis has been organized into seven chapters as discussed below. These chapters
describe the introduction, literature survey, investigations undertaken, and results obtained through
fabrication and testing of a 2 KW, 60V, 12.7 Nm PMBLDC Hub motor prototype, followed by
conclusions.

Chapter 1 gives introduction about the analysis of different electric motors with advantage
over. conventional vehicles. The literature review concerning the different type of electric motors
in general, the application of various electric motors in EVs in particular has been presented, with
a concluding remark on the and AIM for this project work. The objectives of the work have also
been briefed.

Chapter 2 bounces comparative investigation on BLDC propulsion motors. Two-

dimensional FEA is used to verify the design procedure of the BLDC. Using a commercial finite
element analysis software package, the flux linkages and the inductances of the phase windings,
the torque developed by the BLDC for various rotor positions are determined. Through 2D
transient simulation, excitation current at different loads is obtained.

Chapter 3 springs electromagnetic analysis of synchronous reluctance motor for the

application of traction and comparing it with the BLDC motor in the field of magnetic field
distribution, force field, ripple, torque characteristics and efficiency.

Chapter 4 elasticities electromagnetic analysis of switch reluctance motor and hybrid

motor and comparing the torque characteristic, ripple, force field, instantaneous magnetic fields

4
and efficiency.

Chapter 5 stretches selection of laminating core materials for bread loaf with four non-
embedded magnets per pole and also comparing the superior materials with the highly
efficient motor of Chapter 2, Chapter 3 and, Chapter 4 in field of instantaneous magnetic
field, ripple, torque characteristic, force fields and efficiency.

Chapter 6 springs prototype model and hardware testing results in fields of speed and
sound of the PMBLDC hub motor with the existing conventional petrol bike and electric bike.

Chapter 7 delivers the conclusion and future scope of the electric bike with the
replacement of the conventional petrol bike with the electric bike.

5
 CHAPTER-2
FINITE ELEMENT MODELLING AND ANALYSIS OF VARIOUS
ELECTRIC TRACTION MOTOR

2.1 Introduction
The mathematical model of brush less DC motor, synchronous reluctance motor, switched
reluctance motor and hybrid motor with SRM stator and BLDC motor and vice versa are used for
optimum values of Flux linkages and flux distribution on the motor. By using the mathematical
modelling, the torque values, flux density, speed, Accurate voltage of the respective motors can
be found out effectively.

The mathematical modelling for brush less DC motor, synchronous reluctance motor,
switched reluctance motor and hybrid motor with SRM stator and BLDC motor and vice versa are
mentioned below.

Flux Density,
B = H (1)
As shown earlier,
F = R (2)
Torque,
T = kD 2 L (3)
Reluctance,
1 l
R= = (4)
P A
Power,
Pe = ke h2 f 2 B 2 (5)
Flux,
Ni
= (6)
R
Flux Density,
Bm = Br +  R o H m (7)
Flux of permanent magnets,
 = Bm Am = Br Am +  R o Am H m (8)
Flux Linkage of coil,
N2
= i (9)
R

6
Induced Voltage,
d ( Li ) di dL
e= = L +i (10)
dt dt dt
Accurate Torque,
1 dL 1 2 dR d
T = i2 −  + Ni (11)
2 d 2 d d
Inductance for air gap,
2o Lst Rro 2
Lg = N (12)
lm
g+
 R C
Motor Constant K,
2 NBg Lst Rro I 2 NBg Lst Rro Bg Rro
Km = = = Vwb (13)
2
I (2 Rslot ) 2  Lst N / Awb 
Cogging Torque,
1 dR
Tcog = −  2 (14)
2 d
Torque Ripple,
T −T
Tripple = max min (15)
Tavg
360
stepangle, = (16)
Q  Nr
Speed,
P *60
N= (17)
2*  * T
Area of the stator,
D 
As =  − g  L s (18)
2 
Flux in the stator,
 = Bs * As (19)
Area of the rotor,
Ar = (( D / 2) * L *  r (20)
Flux density in the rotor,
Br = ( Bs * As ) / AT (21)
Area of the Yoke,
Ay = Ar / 2.1 (22)

7
Flux in the yoke,
y = sc =  / 2 (23)
Flux density in the yoke,
By =  y / Ay (24)
Assume,
Asc = As (25)
Area of the air gap,
 D g    + s  −6
Ag =  −   r  *75*10 (26)
 2 2  2 
Air gap flux density,
AB
BG = s s (27)
Ag
Air gap field intensity,
Bg
Hg = (28)
0
Height of the stator core,
A
hsc = sc (29)
L
Height of the stator pole,
D D A
hs = − g − sh − sc (30)
2 2 L
Height of the rotor Pole,
D D
hr = o − C − (31)
2 2
Length of the flux path in Yoke,
D C
ly =  *  o −  (32)
 2 2
The length of the flux path in stator core,
D g h D 
lsc =  *  − + s + sh  (33)
4 2 2 4 
The length of the flux path in rotor,
C
lr = hr + (34)
2

2.2 Comparative Investigation on BLDC propulsion motors

Electric vehicles (EVs) are becoming increasingly essential to reduce oil dependence as
well as to lessen noise and pollution. The key features to technology success are efficient power

8
electronics-based energy conversion and electric machines, together with high power and high
energy density storage devices.

BLDC

Spoke type Bread loaf type

With two non With four non

embedded magnets embedded magnets

Fig 2.1 Different types of BLDC motors

The Specifications of the spoke type BLDC motor are mentioned below and these values
are more or less same for all the BLDC motors mentioned in the flow.

Table 2.1 Specifications for spoke type BLDC motor

Specifications Values

Supply voltage 48 V

Rated Current 40 A

Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 1.5 mm

9
 Stack height 150 mm

No of poles 4

No of phases 3

No of Slots 15

Rotor Inner Diameter 20 mm

Rotor outer Diameter 82 mm

Bridge Thickness 4.3 mm

Mid Core Thickness 0.0811 mm

Slit inset depth 18.7 mm

Slit Length 0.0408 mm

Slit Width 0

Magnet outer gap width 1.02 mm

Magnet Thickness 8.35 mm

Magnet Width 25.4 mm

Coil Placement Method Over-Under

Slot Liner Thickness 0.28 mm

Coil Separator Thickness 0.28 mm

Slot Wedge Thickness 0.56 mm

Wire Size Method Coil fill factor

Coil Fill Factor 40

Number of Strands in hand 1

Automatic Layout 86.9% (1 -4 -12 -13 15)

No of Turns 20

10
Fig 2.2 Model Diagram of spoke type Fig2.3 Instantaneous Fields of spoke type
BLDC motor BLDC motor

Fig 2.4 Torque waveform for spoke type BLDC motor

11
 Fig 2.5 Force Fields for spoke type BLDC motor

From figure 2.2 it is observed that the magnets in the rotor are embedded inside the rotor
and that’s why it is called Spoke type Brush less DC motor with embedded magnets. Figure 2.3
depicts the Instantaneous fields distributed in the spoke type BLDC motor with maximum flux
density of 2.39 Tesla. Figure 2.4 infers the Torque waveform produced by the spoke type BLDC
motor with maximum, minimum and average Torque values of 13.647 Nm,10.675 Nm, 12.082
Nm.
Therefore, the torque ripple can be calculated with the formula,
T −T
Tripple = max min (34.1)
Tavg
The value of torque ripple after substituting the above-mentioned values we get torque ripple as
0.47. From figure 2.5 it is inferred that the force fields are produced in the motor with maximum
flux density of around 0.994 Tesla.

Table 2.2 Specifications required for bread loaf with two non-embedded magnets
Specifications Values

Supply voltage 48 V

Rated Current 40 A

12
 Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 1.5 mm

Stack height 150 mm

No of poles 4

No of phases 3

No of Slots 15

Rotor Inner Diameter 20 mm

Rotor outer Diameter 82 mm

Sleeve Thickness 0 mm

Magnet Angle 60 degrees

Magnet inset depth 0 mm

Magnet Thickness 8.37 mm

Segment Gap Width 0.837 mm

Magnet tip radius 0 mm

Number of parallel paths 1

Diode voltage drop 0.6

Coil Placement Method Over-Under

Slot Liner Thickness 0.28 mm

Coil Separator Thickness 0.28 mm

Slot Wedge Thickness 0.56 mm

Wire Size Method Coil fill factor

Coil Fill Factor 40

Number of Strands in hand 1

Automatic Layout 86.9% (1 -4 -12 -13 15)

13
 Fig 2.6 Model Diagram of Bread loaf Fig 2.7 Instantaneous fields of Bread
two non-embedded magnets per pole loaf two non-embedded magnets per
pole
Figure 2.6 depicts the model diagram of Bread loaf with two non-embedded magnets per
pole. The magnets are present outside the rotor; therefore, the magnets are non-embedded and each
magnet is split in to two equal halves as shown in figure 2.6. Here red colour indicates north pole
and blue colour indicates south pole. From figure 2.7 it is observed that the instantaneous fields
distributed in the bread loaf with two non-embedded magnets per pole BLDC motor with
maximum flux density of 1.33 Tesla.

Fig 2.8 Torque Waveform of Bread loaf two non-embedded magnets per pole

14
 Fig 2.9 Force Fields of Bread loaf two non-embedded magnets per pole

From figure 2.8 it is inferred that the Torque waveform produced by the bread loaf with two
non-embedded magnets per pole BLDC motor with maximum, minimum and average Torque
values of 12.493 Nm,10.493 Nm, 11.514 Nm. Therefore, the torque ripple can be calculated with
the formula, (34.1) and the value of torque ripple after substituting the above-mentioned values we
get torque ripple as 0. [Link] figure 2.9 it is inferred that the force fields are produced in the
motor with maximum flux density of around 0.204 Tesla.

Table 2.3 Specifications of bread loaf with four non-embedded magnets per pole BLDC
motor
Specifications Values

Supply voltage 48 V

Rated Current 40 A

Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 1.5 mm

Stack height 150 mm

No of poles 4

No of phases 3

15
 No of Slots 15

Rotor Inner Diameter 20 mm

Rotor outer Diameter 82 mm

Sleeve Thickness 0 mm

Magnet Angle 60 degree

Magnet inset depth 0 mm

Segment Gap Width 0.837 mm

Magnet tip radius 0 mm
Number of parallel paths 1
Diode voltage drop 0.6
Coil Placement Method Over-Under
Slot Liner Thickness 0.28 mm
Coil Separator Thickness 0.28 mm
Slot Wedge Thickness 0.56 mm
Wire Size Method Coil fill factor
Coil Fill Factor 40
Number of Strands in hand 1
Automatic Layout 86.9% (1 -4 -12 -13 15)
No of Turns 9

16
 Fig 2.10 Model Diagram of Bread loaf Fig 2.11 Instantaneous fields of Bread loaf four
four non-embedded magnets per pole non embedded magnets per pole

Figure 2.10 depicts the model diagram of Bread loaf with four non embedded magnets per
pole. The magnets are present outside the rotor; therefore, the magnets are non-embedded and each
magnet is split in to four equal halves as shown in figure 2.10. Here red colour indicates north pole
and blue colour indicates south pole. From figure 2.11 it is observed that the Instantaneous fields
distributed in the bread loaf with four non embedded magnets per pole BLDC motor with
maximum flux density of 1.34 Tesla.

Fig 2.12 Torque Waveform of Bread loaf four non embedded magnets per pole

17
 Fig 2.13 Force Fields of Bread loaf four non embedded magnets per pole
From figure 2.12 it is inferred that the Torque waveform produced by the bread loaf with
four non embedded magnets per pole BLDC motor with maximum, minimum and average Torque
values of 13.482 Nm,11.210 Nm, 13.389 Nm. Therefore, the torque ripple can be calculated with
the formula, (34.1) and the value of torque ripple after substituting the above-mentioned values we
get torque ripple as 0.183. From figure 2.13 it is inferred that the force fields are produced in the
motor with maximum flux density of around 0.201 Tesla.

Table 2.4 Comparison of Torque(N-m)

Parameters Spoke type with Bread-loaf with Bread-loaf with

embedded magnets (Nm) two non-embedded four non-embedded
magnets per pole magnets per pole
(Nm) (Nm)

Average Torque 12.77489 11.51991 13.39713

Torque Ripple 0.2378 0.1721 0.1763

Cogging Torque 0.0002 0.022 0.055

Inference:
In this chapter different types of BLDC motors are compared and among them BLDC motor
with bread loaf with four non-embedded magnets is having high average torque and minimum
torque ripple.

18
 CHAPTER-3
ELECTROMAGNETIC ANALYSIS OF SYNCHRONOUS RELUCTANCE
MOTOR

3.1 Introduction
Now-a-days electric vehicles (EVs) are increasing more to reduce oil dependence as well
as to lessen noise and pollution. The key features to technology success are efficient power
electronics-based energy conversion and electric machines, together with high power and high
energy density storage devices. Concerning electric machines, the following requirements are
crucial when dealing with EV: high torque and power density, wide speed range, high efficiency
over wide torque and speed ranges, high reliability and robustness, among others.

Advantages:
1. It operates at a constant speed (i.e., synchronous speed) from no-load to full-load.

2. Power factor of a synchronous motor can be easily controlled by changing the excitation
of the motor.

3. For low speed (< 300 RPM) applications, synchronous motors are more economical than
induction motors.

4. The synchronous motors have high starting torque as compared to induction motors.

5. A single synchronous motor can be used for driving the load as well as correcting the power
factor of the plant.

Disadvantages:

1. Synchronous motors are not self-starting.

2. Synchronous motors require DC excitation at the rotor.
3. The construction of a synchronous motor is more complicated than induction motors.
4. Synchronous motors are costlier than induction motors.

The advanced angle is nothing but the angle between stator and the rotor rotating angles
and it is same (40 Deg) for all the Synchronous reluctance motors mentioned below.

19
 SyRM

Angled Notch and Round Notch and

barrier Angled barrier Round
barrier barrier

1 layer 1 layer 1 layer

1 layer
2 layer 2 layer 2 layer
2 layer
3 layer 3 layer 3 layer
3 layer
4 layer 4 layer 4 layer
4 layer

Fig 3.1 Different types synchronous reluctance motors

Table 3.1 Specifications of Synchronous reluctance motor (SyRM) with angled barrier

Specifications Values

Supply voltage 48 V
Rated Current 41.9A
Rated Speed 1500 rpm
Stator Outer Diameter 100 mm
Air Gap Thickness 0.5 mm
Stack height 180 mm
No of poles 4
No of phases 3
No of Slots 12
Rotor Inner Diameter 8.89mm

20
 Rotor outer Diameter 54.4 mm
Inner slot depth 12.5 mm
Inner Slot Width 1 4.44
Outer slot orientation 45
Slot thickness 1 1.67 mm

Bridge thickness 1 1.11 mm

Core bulge thickness 0 mm

Core flat width 0 mm

Post width 1 0.556 mm

Coil Placement Method Over-Under

Slot Liner Thickness 0.222 mm

Coil Separator Thickness 0.222 mm

Slot Wedge Thickness 0.444 mm

Wire Size Method Coil fill factor

Coil Fill Factor 40

Number of Strands in hand 1

Automatic Layout 86.6% (1 2 7 8)

No of Turns 18

Fig 3.2 Model diagram of SyRM with Fig 3.3 Instantaneous fields of SyRM with
angled barrier (1layer) angled barrier (1layer)
21
 Fig 3.4 Torque waveform of SyRM with angled barrier (1 layer)

From figure 3.2 it is observed that the rotor is having one angled barrier. Figure 3.3 depicts
the Instantaneous fields distributed in the Synchronous Reluctance motor with one angled barrier
with maximum flux density of 2.17 Tesla. Figure 3.4 infers the Torque waveform produced by the
Synchronous Reluctance motor with one angled barrier with maximum, minimum and average
Torque values of 22.84 Nm,1.426 Nm, 11.831 Nm. Therefore, the torque ripple can be calculated
with the formula, (34.1) and the value of torque ripple after substituting the above-mentioned
values we get torque ripple as 1.81.

Fig 3.5 Model diagram of SyRM with Fig 3.6 Instantaneous fields of SyRM with
angled barrier (2layer) angled barrier (2layer)

22
 Fig 3.7 Torque waveform of SyRM with angled barrier (2layer)

From figure 3.5 it is observed that the rotor is having two angled barriers. Figure 3.6 depicts
the Instantaneous fields distributed in the Synchronous Reluctance motor with two angled barriers
with maximum flux density of 2.19 Tesla. Figure 3.7 infers the Torque waveform produced by the
Synchronous Reluctance motor with two angled barriers with maximum, minimum and average
Torque values of 16.221 Nm,8.909 Nm, 12.285 Nm. Therefore, the torque ripple can be calculated
with the formula, (34.1) and the value of torque ripple after substituting the above-mentioned
values we get torque ripple as 0.595.

Fig 3.8 Model diagram of SyRM with Fig 3.9 Instantaneous fields of SyRM with
angled barrier (3layer) angled barrier (3layer)

23
 Fig 3.10 Torque waveform of SyRM with angled barrier (3layer)

From figure 3.8 it is observed that the rotor is having three angled barriers. Figure 3.9
depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with three angled
barriers with maximum flux density of 2.14 Tesla. Figure 3.10 infers the Torque waveform
produced by the Synchronous Reluctance motor with three angled barriers with maximum,
minimum and average Torque values of 18.424 Nm,10.136 Nm, 13.968 Nm. Therefore, the torque
ripple can be calculated with the formula, (34.1) and the value of torque ripple after substituting
the above-mentioned values we get torque ripple as 0.593.

Fig 3.11 Model diagram of SyRM with Fig 3.12 Instantaneous fields of SyRM
angled barrier (4layer) with angled barrier (4layer)

24
 Fig 3.13 Torque waveform of SyRM with angled barrier (4layer)

From figure 3.11 it is observed that the rotor is having four angled barriers. Figure 3.12
depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with four angled
barriers with maximum flux density of 2.13 Tesla. Figure 3.13 infers the Torque waveform
produced by the Synchronous Reluctance motor with four angled barriers with maximum,
minimum and average Torque values of 24.299 Nm,1.449 Nm, 11.827 Nm. Therefore, the torque
ripple can be calculated with the formula, (34.1) and the value of torque ripple after substituting
the above-mentioned values we get torque ripple as 1.931.

Table 3.2 Specifications of Synchronous reluctance motor with notch and angled barrier

Specifications Values

Supply voltage 48 V

Rated Current 41.9A

Rated Speed 1500 rpm

Stator Outer Diameter 100 mm

Air Gap Thickness 0.5 mm

Stack height 150 mm

No of poles 4

25
 No of phases 3

No of Slots 12

Rotor Inner Diameter 8.89mm

Rotor outer Diameter 54.4 mm

Inner slot depth 10.1 mm

Inner Slot Width 1 4.44

Outer slot orientation 45

Slot thickness 1,2 1.67 mm

Bridge thickness 1,2 1.11 mm

Core bulge thickness 0 mm

Core flat width 0 mm

Post width 1,2 0.556 mm

Coil Placement Method Over-Under

Slot Liner Thickness 0.222 mm

Coil Separator Thickness 0.222 mm

Slot Wedge Thickness 0.444 mm

Wire Size Method Coil fill factor

Coil Fill Factor 40

Number of Strands in hand 1

Automatic Layout 86.6% (1 2 7 8)

No of Turns 18

26
 Fig 3.14 Model diagram of SyRM with Fig 3.15 Instantaneous fields of SyRM with
notch and angled barrier (1layer) notch and angled barrier (1layer)

Fig 3.16 Torque waveform of SyRM with notch and angled barrier (1 layer)

From figure 3.14 it is observed that the rotor is having one angled barrier with notch. Figure
3.15 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with one
angled barrier with notch having maximum flux density of 2.19 Tesla. Figure 3.16 infers the
Torque waveform produced by the Synchronous Reluctance motor with one angled barrier with
notch having maximum, minimum and average Torque values of 17.377 Nm,5.361 Nm, 13.055
Nm. Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 0.92.

27
Fig 3.17 Model diagram of SyRM with Fig 3.18 Instantaneous fields of SyRM with
notch and angled barrier (2layer) notch and angled barrier (2layer)

Fig 3.19 Torque waveform of SyRM with notch and angled barrier (2layer)

28
 From figure 3.17 it is observed that the rotor is having two angled barriers with notch.
Figure 3.18 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with
two angled barriers with notch having maximum flux density of 2.19 Tesla. Figure 3.19 infers the
Torque waveform produced by the Synchronous Reluctance motor with two angled barriers with
notch having maximum, minimum and average Torque values of 21.110 Nm,6.821 Nm, 12.481
Nm. Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 1.144.

Fig 3.20 Model diagram of SyRM with notch Fig 3.21 Instantaneous fields of SyRM with
and angled barrier (3layer) notch and angled barrier (3layer)

Fig 3.22 Torque waveform of SyRM with notch and angled barrier (3layer)

29
 From figure 3.20 it is observed that the rotor is having three angled barriers with notch.
Figure 3.21 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with
three angled barriers with notch having maximum flux density of 2.08 Tesla. Figure 3.22 infers
the Torque waveform produced by the Synchronous Reluctance motor with three angled barriers
with notch having maximum, minimum and average Torque values of 24.770 Nm,1.671 Nm,
13.702 Nm. Therefore, the torque ripple can be calculated with the formula, (34.1) and the value
of torque ripple after substituting the above-mentioned values we get torque ripple as 1.685.

Fig 3.23 Model diagram of SyRM with notch Fig 3.24 Instantaneous fields of SyRM with
and angled barrier (4layers) notch and angled barrier (4layers)

Fig 3.25 Torque waveform of SyRM with notch and angled barrier (4layers)

30
 From figure 3.23 it is observed that the rotor is having four angled barriers with notch.
Figure 3.24 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with
four angled barriers with notch having maximum flux density of 2.21 Tesla. Figure 3.25 infers the
Torque waveform produced by the Synchronous Reluctance motor with four angled barriers with
notch having maximum, minimum and average Torque values of 16.076 Nm,4.618 Nm, 11.594
Nm. Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 0.987.

Table 3.3 Specifications of Synchronous reluctance motor with round barrier

Specifications Values

Supply voltage 48 V

Rated Current 41.9A

Rated Speed 1500 rpm

Stator Outer Diameter 100 mm

Air Gap Thickness 0.5 mm

Stack height 250 mm

No of poles 4

No of phases 3

No of Slots 12

Rotor Inner Diameter 8.89mm

Rotor outer Diameter 54.4 mm

Inner slot depth 9.66 mm

Inner Slot Width 1 4.44 mm

Outer slot orientation 45

Slot thickness 1,2,3 1.67 mm

Bridge thickness 1,2,3 1.11 mm

Core bulge thickness 0 mm

Core flat width 0 mm

31
 Post width 1,2,3 0.556 mm

Coil Placement Method Over-Under

Slot Liner Thickness 0.222 mm

Coil Separator Thickness 0.222 mm

Slot Wedge Thickness 0.444 mm

Wire Size Method Coil fill factor

Coil Fill Factor 40

Number of Strands in hand 1

Automatic Layout 86.6% (1 2 7 8)

No of Turns 18

Fig 3.26 Model diagram of SyRM with Fig 3.27 Instantaneous fields of SyRM
round barrier (1layer) round barrier (1layer)

32
 Fig 3.28 Torque waveform of SyRM with round barrier (1layer)

From figure 3.26 it is observed that the rotor is having one round barrier. Figure 3.27 depicts
the Instantaneous fields distributed in the Synchronous Reluctance motor with one round barrier
with maximum flux density of 2.11 Tesla. Figure 3.28 infers the Torque waveform produced by
the Synchronous Reluctance motor with one round barrier with maximum, minimum and average
Torque values of 14.698 Nm,7.970 Nm, 11.069 Nm. Therefore, the torque ripple can be calculated
with the formula, (34.1) and the value of torque ripple after substituting the above-mentioned
values we get torque ripple as 0.607.

Fig 3.29 Model diagram of SyRM with Fig 3.30 Instantaneous fields of SyRM
round barrier (2layer) round barrier (2layer)

33
 Fig 3.31 Torque waveform of SyRM with round barrier (2layer)

From figure 3.29 it is observed that the rotor is having two round barriers. Figure 3.30
depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with two round
barriers with maximum flux density of 2.11 Tesla. Figure 3.31 infers the Torque waveform
produced by the Synchronous Reluctance motor with two round barriers with maximum, minimum
and average Torque values of 17.907 Nm,7.684 Nm, 12.117 Nm. Therefore, the torque ripple can
be calculated with the formula, (34.1) and the value of torque ripple after substituting the above-
mentioned values we get torque ripple as 0.843.

Fig 3.32 Model diagram of SyRM with

round barrier (3layer) Fig 3.33 Instantaneous fields of SyRM
round barrier (3layer)

34
 Fig 3.34 Torque waveform of SyRM with round barrier (3layer)

From figure 3.32 it is observed that the rotor is having three round barriers. Figure 3.33
depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with three round
barriers with maximum flux density of 2.09 Tesla. Figure 3.34 infers the Torque waveform
produced by the Synchronous Reluctance motor with three round barriers with maximum,
minimum and average Torque values of 17.596 Nm,7.082 Nm, 11.439 Nm. Therefore, the torque
ripple can be calculated with the formula, (34.1) and the value of torque ripple after substituting
the above-mentioned values we get torque ripple as 0.918.

Fig 3.35 Model diagram of SyRM with

round barrier (4layer) Fig 3.36 Instantaneous fields of SyRM
round barrier (4layer)

35
 Fig 3.37 Torque waveform of SyRM with round barrier (4layers)

From figure 3.35 it is observed that the rotor is having four round barriers. Figure 3.36
depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with four round
barriers with maximum flux density of 2.09 Tesla. Figure 3.37 infers the Torque waveform
produced by the Synchronous Reluctance motor with four round barriers with maximum,
minimum and average Torque values of 17.277 Nm,7.298 Nm, 11.842 Nm. Therefore, the torque
ripple can be calculated with the formula, (34.1) and the value of torque ripple after substituting
the above-mentioned values we get torque ripple as 0.842.

Table 3.4 Specifications required for Synchronous reluctance motor with notch and round
barrier
Specifications Values

Supply voltage 48 V

Rated Current 41.9A

Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 0.5 mm

Stack height 200 mm

36
 No of poles 4

No of phases 3

No of Slots 12

Rotor Inner Diameter 13.3 mm

Rotor outer Diameter 81.7 mm

Inner slot depth 8.66 mm

Inner Slot Width 1 6.67 mm

Outer slot orientation 45

Slot thickness 1,2,3,4 2.5 mm

Bridge thickness 1,2,3,4 1.67 mm

Core bulge thickness 0 mm

Core flat width 0 mm

Post width 1,2,3,4 0.833 mm

Coil Placement Method Over-Under

Slot Liner Thickness 0.333 mm

Coil Separator Thickness 0.333 mm

Slot Wedge Thickness 0.667 mm

Wire Size Method Coil fill factor

Coil Fill Factor 40

Number of Strands in hand 1

Automatic Layout 86.6% (1 -3 7 -9)

No of Turns 18

37
 Fig 3.38 Model diagram of SyRM with Fig 3.39 Instantaneous fields of SyRM
notch and round barrier (1layer) with notch and round barrier (1layer)

Fig 3.40 Torque waveform of SyRM with notch and round barrier (1layers)

From figure 3.38 it is observed that the rotor is having one round barrier with notch. Figure
3.39 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with one
round barrier with notch having maximum flux density of 2.22 Tesla. Figure 3.40 infers the Torque
waveform produced by the Synchronous Reluctance motor with one round barriers with notch
having maximum, minimum and average Torque values of 16.179 Nm,9.787 Nm, 13.321 Nm.

38
Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 0.497.

Fig 3.41 Model diagram of SyRM with Fig 3.42 Instantaneous fields of SyRM
notch and round barrier (2layer) with notch and round barrier (2layer)

Fig 3.43 Torque waveform of SyRM with notch and round barrier (2layers)

39
 From figure 3.41 it is observed that the rotor is having two round barriers with notch. Figure
3.42 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with two
round barriers with notch having maximum flux density of 2.19 Tesla. Figure 3.43 infers the
Torque waveform produced by the Synchronous Reluctance motor with two round barriers with
notch having maximum, minimum and average Torque values of 20.155 Nm,1.952 Nm, 12.422
Nm. Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 1.494.

Fig 3.44 Model diagram of SyRM with

Fig 3.45 Instantaneous fields of SyRM
notch and round barrier (3layer)
with notch and round barrier (3layer)

Fig 3.46 Torque waveform of SyRM with notch and round barrier (3layers)

40
 From figure 3.44 it is observed that the rotor is having three round barriers with notch.
Figure 3.45 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with
three round barriers with notch having maximum flux density of 2.17 Tesla. Figure 3.46 infers the
Torque waveform produced by the Synchronous Reluctance motor with three round barriers with
notch having maximum, minimum and average Torque values of 14.914 Nm,8.248 Nm, 11.769
Nm. Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 0.566.

Fig 3.47 Model diagram of SyRM with notch Fig 3.48 Instantaneous fields of SyRM with
and round barrier (4layer) notch and round barrier (4layer)

Fig 3.49 Torque waveform of SyRM with notch and round barrier (4layers)

41
 From figure 3.47 it is observed that the rotor is having four round barriers with notch.
Figure 3.48 depicts the Instantaneous fields distributed in the Synchronous Reluctance motor with
four round barriers with notch having maximum flux density of 2.16 Tesla. Figure 3.49 infers the
Torque waveform produced by the Synchronous Reluctance motor with four round barriers with
notch having maximum, minimum and average Torque values of 16.422 Nm,8.477 Nm, 12.135
Nm. Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 0.656.

Table 3.5 Comparison of torques for different Synchronous reluctance motors

PARAMETERS LAYERS MAXIMUM MINIMUM AVERAGE TORQUE

TORQUE TORQUE TORQUE RIPPLE
(N-m) (N-m) (N-m)

ROTOR
TYPES
ROUND 1 14.698 7.970 11.069 0.607
BARRIER
2 17.907 7.684 12.117 0.843

3 17.596 7.082 11.439 0.918

4 17.277 7.298 11.842 0.842

NOTCH AND 1 16.179 9.787 13.321 0.497
ROUND
BARRIER 2 20.155 1.952 12.422 1.494

3 14.914 8.248 11.769 0.566

4 16.422 8.477 12.135 0.656

From table 3.5 it is observed that Synchronous reluctance motor with notch and round
barrier rotor specifically layer 1 is having maximum value of average torque and the torque ripple
for the motor is very less when compared to other Synchronous reluctance motors. Therefore,
Synchronous reluctance motor with notch and round barrier layer 1 is found to be best among the
Synchronous reluctance motors.

42
 Table 3.6 Comparison of torques between Bread loaf with four non-embedded magnets
motor and Synchronous reluctance motor with notch and round barrier(1Layer)

PARAMETERS MAXIMUM MINIMUM AVERAGE TORQUE

TORQUE TORQUE TORQUE RIPPLE
(N-m) (N-m) (N-m)

ROTOR
TYPES
BREAD LOAF WITH 13.482 11.210 13.389 0.183
4 NON-EMBEDDED
MAGNETS

NOTCH AND 16.179 9.787 13.321 0.497

ROUND BARRIER (1
LAYER)

Inference:

From table 3.6 it is observed that both BLDC motor with bread loaf with four non-
embedded magnets per pole and Synchronous reluctance motor with notch and round barrier layer
1 are compared in terms of torque values. Finally in this chapter Bread loaf with four non-
embedded magnets per pole motor is found to be best when compared different types of
Synchronous reluctance motors as it is having maximum value of average torque and minimum
value of torque ripple.

43
 CHAPTER 4

ELECTROMAGNETIC ANALYSIS OF SWITCHED RELUCTANCE

MOTOR AND HYBRID MOTORS

4.1 Introduction to Switched Reluctance Motor (SRM):

Recently, switched reluctance motors (SRMs) are attracting more and more interest in
some variable speed drive applications, since they have several advantageous characteristics such
as rugged construction, low production cost, high starting torque, high fault-tolerance capability
and wide speed range. All these merits made SRMs are suitable for many industrial applications
such as aircraft starter/generator, electric vehicles (EVs) and wind power generation. However,
they also suffer from some disadvantages, such as low torque/power density, low efficiency, high
torque ripple and acoustic noise when compared to permanent magnet (PM) machines.

Table 4.1 Specifications required for Switched Reluctance Motor

Specifications Values

Supply voltage 48 V

Rated Current 40 A

Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 0.5 mm

Stack height 50 mm

No of poles 8

No of phases 3

No of Stator poles 6

Rotor Inner Diameter 30 mm

Rotor outer Diameter 81.7 mm

Core Thickness 13 mm

Bifurcation radius 0 mm

Rotor pole angle 30°

44
 Tooth angle 90°

Pole bottom radius 0 mm

Pole tip radius 0 mm

Coil angle 82.7°

Coil bottom width 11.8 mm

Coil length 19.4 mm

Bifurcation radius 0 mm

Slot depth 21 mm

Stator pole angle 30.9°

Tooth angle 89.9°

Bottom fillet radius 2.22 mm

Tooth tang radius 0 mm

Layout method Automatic

No of Turns 60

Fig 4.1 Model diagram of Switched reluctance Fig 4.2 Instantaneous fields of Switched
motor reluctance motor

45
 Fig 4.3 Torque waveform of Switched reluctance motor

Fig 4.4 Flux linkages of switched reluctance motor for different rotor angles

46
 Fig 4.5 Inductance vs Rotor angle characteristics of switched reluctance motor

Figure 4.1 indicates the model diagram of switched reluctance motor and from figure 4.2
the instantaneous fields distributed in the Switched Reluctance Motor with maximum flux density
of 2.07 Tesla. Figure 4.3 infers the Torque waveform produced by the Switched Reluctance motor
with maximum, minimum and average Torque values of 13.482 Nm,11.210 Nm, 13.389 Nm.
Therefore, the torque ripple can be calculated with the formula, (34.1) and the value of torque
ripple after substituting the above-mentioned values we get torque ripple as 0. [Link] figure 4.4
it is understood that the flux linkages vary for different rotor angles. Figure 4.5 indicates that how
the inductance in the switched reluctance motor varies with Rotor angle for different current
values.

47
Table 4.2 Comparison of torque values for bread loaf with four non-embedded magnets per
pole and SRM motor
PARAMETERS MAXIMUM MINIMUM AVERAGE TORQUE
TORQUE TORQUE TORQUE RIPPLE
(N-m) (N-m) (N-m)

MOTOR
TYPE

BREADLOAF WITH 4 13.482 11.210 13.389 0.183

NON-EMBEDDED
MAGNETS

SWITCHED
RELUCTANCE 13.28 10.512 11.00 0.253
MOTOR

In table 5.1, switched reluctance motor is compared with bread loaf with four non-
embedded magnets per pole and it is found that bread loaf with four non-embedded magnets per
pole motor is having maximum value of average torque and minimum value of torque ripple when
compared to switched reluctance motor.

4.2 Introduction to Hybrid motors:

Now-a-days electric vehicles (EVs) are increasing more to reduce oil dependence as well
as to lessen noise and pollution. The key features to technology success are efficient power
electronics-based energy conversion and electric machines, together with high power and high
energy density storage devices. Concerning electric machines, the following requirements are
crucial when dealing with EV: high torque and power density, wide speed range, high efficiency
over wide torque and speed ranges, high reliability and robustness, among others.

48
BLDC SRM

ROTOR
ROTOR
STATOR

HYBRID MOTOR 1

Fig 4.6 Hybrid Motor 1 with BLDC Stator and SRM Rotor

49
BLDC
SRM

ROTOR
STATOR

HYBRID MOTOR 2

Fig 4.7 Hybrid Motor 2 with SRM Stator and BLDC Rotor

Table 4.3 Specifications required for Hybrid Motor 1

Specifications Values

Supply voltage 48 V

Rated Current 41.6A

Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 0.3mm

Stack height 150 mm

No of poles (Stator, rotor) 18,12

50
 No of phases 3

Core Thickness 15.645568 mm

Rotor Inner Diameter 20 mm

Rotor outer Diameter 82 mm

Rotor Pole Angle 12.196042 degree

Tooth Angle 96.897859 degree

Pole bottom radius 0 mm

Pole tip radius 0 mm

No of parallel paths 1

Wire size method Rectangular

Strand width 1.32 mm

Strand height 1.32 mm

No of strands in hand 1

Wire insulation thickness 0 mm

Layout method Automatic

No of turns 10

Bifurcation radius 0

Coil core transparency 50

Friction Loss 0

Windage loss 0

Stray loss factor 0

51
Fig 4.8 Model diagram of Hybrid motor 1 with Fig 4.9 Instantaneous fields of Hybrid
BLDC Stator and SRM Rotor motor 1 with BLDC Stator and SRM
Rotor

Fig 4.10 Torque waveform of Hybrid motor 1 with BLDC Stator and SRM Rotor

52
 Figure 4.8 indicates the model diagram of Hybrid Motor 1 with BLDC stator and SRM
rotor and from figure 4.9 the instantaneous fields distributed in the Hybrid Motor 1 with BLDC
stator and SRM rotor with maximum flux density of 1.06 Tesla. Figure 4.10 infers the Torque
waveform produced by the Hybrid Motor 1 with BLDC stator and SRM rotor with maximum,
minimum and average Torque values of 11.356 Nm,5.8692 Nm, 8.3246 Nm. Therefore, the torque
ripple can be calculated with the formula, (34.1) and the value of torque ripple after substituting
the above-mentioned values we get torque ripple as 0.65.

Table 4.4 Specifications required for Hybrid motor 2

Specifications Values

Supply voltage 48 V

Rated Current 41.6A

Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 0.3 mm

Stack height 200 mm

No of poles 4

No of phases 3

No of slots 12

Rotor Inner Diameter 40 mm

Rotor outer Diameter 82 mm

Bridge thickness 0.519 mm

Mid-core hub thickness 1.46 mm

Slit inset depth 3.62 mm

Slit length 12.7 mm

Slit width 10.4 mm
Magnet outer gap width 2.19 mm
Magnet thickness 17.4 mm

53
 Magnet width 1.32 mm
No of strands in hand 15.5 mm
Coil placement method Side by side
Slot liner thickness 0.333 mm
Coil separator thickness 0.333 mm
Slot wedge thickness 0 mm
Layout method Automatic
Winding type Lap
Automatic layout 86.6% (1 -3 7 -9)
No of turns 11

Fig 4.11 Model diagram of Hybrid motor 2 Fig 4.12 Instantaneous fields of Hybrid
with SRM Stator and BLDC Rotor motor 2 with SRM Stator and BLDC
Rotor

54
Fig 4.13 Torque waveform of Hybrid motor 2 with SRM Stator and BLDC Rotor

Fig 4.14 Force Fields for Hybrid motor 2 with SRM Stator and BLDC Rotor

55
 Figure 4.11 indicates the model diagram of Hybrid Motor 2 with SRM stator and BLDC
rotor and from figure 4.12 the instantaneous fields distributed in the Hybrid Motor 2 with SRM
stator and BLDC rotor with maximum flux density of 2.54 Tesla. Figure 4.13 infers the Torque
waveform produced by the Hybrid Motor 2 with SRM stator and BLDC rotor with maximum,
minimum and average Torque values of 24.542 Nm,0.2827 Nm, 12.481 Nm. Therefore, the torque
ripple can be calculated with the formula, (34.1) and the value of torque ripple after substituting
the above-mentioned values we get torque ripple as 1.943. Figure 4.14 shows the Force fields
produced in the Hybrid Motor 2 with SRM stator and BLDC rotor with maximum flux density of
0.28 Tesla.

Table 4.5 Comparison of torque values for Hybrid motors

PARAMETERS MAXIMUM MINIMUM AVERAGE TORQUE

TORQUE TORQUE TORQUE RIPPLE
MOTOR (N-m) (N-m) (N-m)
TYPES
BLDC Stator and 11.356 5.8692 8.3246 0.65
SRM rotor Hybrid
motor

SRM Stator and 24.542 0.2827 12.481 1.943

BLDC rotor Hybrid
motor

56
 Table 4.6 Comparison of Bread loaf with four non-embedded magnets per pole BLDC
motor and SRM stator and BLDC rotor hybrid motor

PARAMETERS MAXIMUM MINIMUM AVERAGE TORQUE

TORQUE TORQUE TORQUE RIPPLE
MOTOR (N-m) (N-m) (N-m)
TYPES

SRM Stator and BLDC 24.542 0.2827 12.481 1.943

rotor Hybrid motor

BREAD LOAF WITH 4 13.482 11.210 13.389 0.183

NON-EMBEDDED
MAGNETS

From the above table it is observed that SRM stator and BLDC rotor Hybrid motor is
having maximum value of average torque and minimum value of torque ripple. Therefore, now
this motor is being compared with bread loaf with four non-embedded magnets per pole.

Inference:

In this chapter it is observed that bread loaf with four non-embedded magnets per pole
motor is found to be having maximum value of average torque and minimum value of torque ripple
when compared to SRM stator and BLDC rotor Hybrid motor. Therefore, now the electromagnetic
analysis of bread loaf with four non-embedded magnets per pole BLDC motor with different rotor
materials are studied and characteristics of the motor are obtained successfully

57
 CHAPTER 5
SELECTION OF LAMINATING CORE MATERIAL FOR BREAD LOAF
WITH FOUR NON-EMBEDDED MAGNETS PER POLE BLDC MOTOR

5.1 Introduction:
On comparing the spoke type BLDC motor, Bread loaf BLDC motors, Synchronous
reluctance motors of all the above-mentioned types, switched reluctance motor and Hybrid motors
with BLDC Stator and SRM rotor and vice versa it is found with Bread loaf with four non-
embedded magnets is found to best when compared to all the above-mentioned motors in terms of
maximum value of Average torque and minimum value of torque ripple values.
Therefore, bread loaf with four non-embedded magnets per pole Brush less DC motor is
analysed with different laminating core materials. They are 36F155,46F165, M-27 24 Ga, ARNON
7, M-300 35A, M-420 50D.

Table 5.1 Specifications required for Bread loaf with four non-embedded magnets per pole
BLDC motor

Specifications Values

Supply voltage 48 V

Rated Current 40 A

Rated Speed 1500 rpm

Stator Outer Diameter 150 mm

Air Gap Thickness 1.5 mm

Stack height 150 mm

No of poles 4

No of phases 3

No of Slots 15

Rotor Inner Diameter 20 mm

Rotor outer Diameter 82 mm

58
 Sleeve Thickness 0 mm

Magnet Angle 60 degrees

Magnet inset depth 0 mm

Magnet Thickness 8.37 mm

Segment Gap Width 0.837 mm

Magnet tip radius 0 mm

Number of parallel paths 1

Diode voltage drop 0.6

Coil Placement Method Over-Under

Slot Liner Thickness 0.28 mm

Coil Separator Thickness 0.28 mm

Slot Wedge Thickness 0.56 mm

Wire Size Method Coil fill factor

Coil Fill Factor 40

Number of Strands in hand 1

Automatic Layout 86.9% (1 -4 -12 -13 15)

No of Turns 9

59
 Fig 5.1 BH Curves of different materials for bread loaf with
four non-embedded magnets per pole BLDC motor

Fig 5.2 Iron Loss characteristics of different materials for bread loaf
with four non-embedded magnets per pole BLDC motor

60
 From figures 5.1 and 5.2 it is observed that bread loaf with four non-embedded magnets per
pole BLDC motor made with 36F155 material is maximum value of BH curve and minimum value
of Iron losses characteristics when compared to other materials.

Fig 5.3 Model diagram of bread loaf Fig 5.4 Instantaneous fields of bread loaf
with four non-embedded magnets per with four non-embedded magnets per
pole made with 36F155 material pole made with 36F155 material

Figure 5.3 depicts the model diagram of Bread loaf with four non-embedded magnets per
pole made with 36F155 material. The magnets are present outside the rotor; therefore, the magnets
are non-embedded and each magnet is split in to four equal halves as shown in figure 5.3. Here
red colour indicates north pole and blue colour indicates south pole. From figure 5.4 it is observed
that the Instantaneous fields distributed in the bread loaf with four non-embedded magnets per
pole BLDC motor(36F155) with maximum flux density of 1.34 Tesla.

Fig 5.5 Torque waveform of bread loaf with four non-embedded magnets per pole made
with 36F155 material

61
 Fig 5.6 Force fields of bread loaf with four non-embedded magnets per pole made with
36F155 material

From figure 5.5, it is inferred that the Torque waveform produced by the bread loaf with
four non-embedded magnets per pole BLDC motor(36F155) with maximum, minimum and
average Torque values of 13.484 Nm,11.260 Nm, 12.398 Nm. Therefore, the torque ripple can be
calculated with the formula, (34.1) and the value of torque ripple after substituting the above-
mentioned values we get torque ripple as 0.179. From figure 5.6 it is inferred that the force fields
are produced in the motor with maximum flux density of around 0.201 Tesla.

Fig 5.7 Model diagram of bread loaf Fig 5.8 Instantaneous fields of bread loaf
with four non-embedded magnets per with four non-embedded magnets per
pole made with 46F165 material pole made with 46F165 material

62
 Figure 5.7 depicts the model diagram of Bread loaf with four non-embedded magnets per
pole made with 46F165 material. The magnets are present outside the rotor; therefore, the magnets
are non-embedded and each magnet is split in to four equal halves as shown in figure 5.7. Here
red colour indicates north pole and blue colour indicates south pole. From figure 5.8 it is observed
that the Instantaneous fields distributed in the bread loaf with four non-embedded magnets per
pole BLDC motor(46F165) with maximum flux density of 1.34 Tesla.

Fig 5.9 Torque waveform of bread loaf with four non-embedded magnets per pole made
with 46F165 material

Fig 5.10 Force fields of bread loaf with four non-embedded magnets per pole made with
46F165 material

63
 From figure 5.9, it is inferred that the Torque waveform produced by the bread loaf with
four non-embedded magnets per pole BLDC motor(46F165) with maximum, minimum and
average Torque values of 13.483 Nm,11.211 Nm, 12.397 Nm. Therefore, the torque ripple can be
calculated with the formula, (34.1) and the value of torque ripple after substituting the above-
mentioned values we get torque ripple as 0.183. From figure 5.10 it is inferred that the force fields
are produced in the motor with maximum flux density of around 0.201 Tesla.

Fig 5.11 Model diagram of bread loaf Fig 5.12 Instantaneous fields of bread
with four non-embedded magnets per loaf with four non-embedded magnets
pole made with ARNON7 material per pole made with ARNON7 material

Figure 5.11 depicts the model diagram of Bread loaf with four non-embedded magnets per
pole made with ARNON7 material. The magnets are present outside the rotor; therefore, the
magnets are non-embedded and each magnet is split in to four equal halves as shown in figure
5.11. Here red colour indicates north pole and blue colour indicates south pole. From figure 5.12
it is observed that the Instantaneous fields distributed in the bread loaf with four non-embedded
magnets per pole BLDC motor (ARNON7) with maximum flux density of 1.34 Tesla.

64
Fig 5.13 Torque waveform of bread loaf with four non-embedded magnets per pole made
with ARNON7 material

Fig 5.14 Force fields of bread loaf with four non-embedded magnets per pole made with
ARNON7 material

65
 From figure 5.13, it is inferred that the Torque waveform produced by the bread loaf with
four non-embedded magnets per pole BLDC motor (ARNON7) with maximum, minimum and
average Torque values of 13.482 Nm,11.210 Nm, 12.397 Nm. Therefore, the torque ripple can be
calculated with the formula, (34.1) and the value of torque ripple after substituting the above-
mentioned values we get torque ripple as 0.183. From figure 5.14 it is inferred that the force fields
are produced in the motor with maximum flux density of around 0.201 Tesla.

Fig 5.15 Model diagram of bread loaf Fig 5.16 Instantaneous fields of bread
with four non-embedded magnets per loaf with four non-embedded magnets
pole made with M-27 24 Ga material per pole made with M-27 24Ga material

Figure 5.15 depicts the model diagram of Bread loaf with four non-embedded magnets per
pole made with M-27 24Ga material. The magnets are present outside the rotor; therefore, the
magnets are non-embedded and each magnet is split in to four equal halves as shown in figure
5.15. Here red colour indicates north pole and blue colour indicates south pole. From figure 5.16
it is observed that the Instantaneous fields distributed in the bread loaf with four non-embedded
magnets per pole BLDC motor (M-27 24Ga) with maximum flux density of 1.34 Tesla.

66
 Fig 5.17 Torque waveform of bread loaf with four non-embedded magnets per pole made
with M-27 24 Ga material

Fig 5.18 Force fields of bread loaf with four non-embedded magnets per pole made with M-
27 24Ga material
From figure 5.17, it is inferred that the Torque waveform produced by the bread loaf with
four non-embedded magnets per pole BLDC motor (M-27 24Ga) with maximum, minimum and
average Torque values of 13.482 Nm,11.210 Nm, 12.397 Nm. Therefore, the torque ripple can be
calculated with the formula, (34.1) and the value of torque ripple after substituting the above-
mentioned values we get torque ripple as 0.183. From figure 5.18 it is inferred that the force fields
are produced in the motor with maximum flux density of around 0.201 Tesla.

67
 Fig 5.20 Instantaneous fields of bread
Fig 5.19 Model diagram of bread loaf loaf with four non-embedded magnets
with four non-embedded magnets per per pole made with M-300 35A material
pole made with M-300 35A material

Figure 5.19 depicts the model diagram of Bread loaf with four non-embedded magnets per
pole made with M-300 35A material. The magnets are present outside the rotor; therefore, the
magnets are non-embedded and each magnet is split in to four equal halves as shown in figure
5.19. Here red colour indicates north pole and blue colour indicates south pole. From figure 5.20
it is observed that the Instantaneous fields distributed in the bread loaf with four non-embedded
magnets per pole BLDC motor (M-300 35A) with maximum flux density of 1.34 Tesla.

Fig 5.21 Torque waveform of bread loaf with four non-embedded magnets
per pole made with M-300 35A material

68
Fig 5.22 Force fields of bread loaf with four non-embedded magnets per pole made with M-
300 35A material

From figure 5.21, it is inferred that the Torque waveform produced by the bread loaf with
four non-embedded magnets per pole BLDC motor (M-300 35A) with maximum, minimum and
average Torque values of 13.483 Nm,11.211 Nm, 12.398 Nm. Therefore, the torque ripple can be
calculated with the formula, (34.1) and the value of torque ripple after substituting the above-
mentioned values we get torque ripple as 0.183. From figure 5.18 it is inferred that the force fields
are produced in the motor with maximum flux density of around 0.201 Tesla.

Fig 5.23 Model diagram of bread loaf Fig 5.24 Instantaneous fields of bread loaf
with four non-embedded magnets per with four non-embedded magnets per pole
pole made with M-420 50D material made with M-420 50D material

69
 Figure 5.23 depicts the model diagram of Bread loaf with four non-embedded magnets per
pole made with M-420 50D material. The magnets are present outside the rotor; therefore, the
magnets are non-embedded and each magnet is split in to four equal halves as shown in figure
5.23. Here red colour indicates north pole and blue colour indicates south pole. From figure 5.24
it is observed that the Instantaneous fields distributed in the bread loaf with four non-embedded
magnets per pole BLDC motor (M-420 50D) with maximum flux density of 1.34 Tesla.

Fig 5.25 Torque waveform of bread loaf with four non-embedded magnets per pole made
with M-420 50D material

Fig 5.26 Force fields of bread loaf with four non-embedded magnets per pole made with M-
420 50D material

70
 From figure 5.25, it is inferred that the Torque waveform produced by the bread loaf with
four non-embedded magnets per pole BLDC motor (M-420 50D) with maximum, minimum and
average Torque values of 13.484 Nm,11.212 Nm, 12.399 Nm. Therefore, the torque ripple can be
calculated with the formula, (34.1) and the value of torque ripple after substituting the above-
mentioned values we get torque ripple as 0.183. From figure 5.26 it is inferred that the force fields
are produced in the motor with maximum flux density of around 0.201 Tesla.

Table 5.2 Comparison of torque values for different materials

PARAMETERS MAXIMUM MINIMUM AVG. TORQUE
TORQUE TORQUE TORQUE RIPPLE
(N-m) (N-m) (N-m)

MATERIALS
36F155 13.484 11.260 12.398 0.179

46F165 13.483 11.211 12.397 0.183

ARNON7 13.482 11.210 12.397 0.183

M-27 24Ga 13.482 11.210 12.397 0.183

M300 35A 13.483 11.211 12.398 0.183

M420-50D 13.484 11.212 12.399 0.183

Inference:
In this chapter it is observed that bread loaf with four non-embedded magnets per pole
BLDC motor made with 36F155 material is having maximum value of average torque and
minimum value of torque ripple when compared to other materials. Also, 36F155 material is
having maximum value of B-H curve characteristics and minimum value of Iron loss
characteristics.

71
 CHAPTER 6

PROTOTYPE MODEL AND HARDWARE TESTING RESULTS

6.1 Introduction

The conventional petrol bike is converted in to electric bike by installing 2 KW ,60V, 1500
RPM permanent magnet brush less DC (PMBLDC) Hub motor. In Permanent magnet brush less
DC (PMBLDC) Hub motor, the rotor is present outside and the stator is present inside the motor.
Therefore, there is no requirement of Chain system in the electric Vehicle. The battery capacity
required for this prototype is 24 AH Lithium ferrous phosphate battery. The Prototype model and
the hardware testing results were deliberated in this chapter. The back view and side view of the
prototype is also mentioned in this chapter. The figures and the experimental results are explained
below in detail.

Fig 6.1 Side view of prototype model

72
 Fig 6.2 Rear view of prototype model

EXPERIMENTAL FINDINGS:

Fig 6.3 The speed of the vehicle Fig 6.4 The decibel under road condition

73
 Figure 6.3 indicates the speed of the vehicle while conducting the sound testing of the
vehicle. The maximum, minimum and average values sound in decibel are 77.9 dB, 32dB and 57.5
db. The sound of the vehicle in decibels depends on the speed of the vehicle, load and the road
conditions.

Fig 6.5 Voltage vs time characteristics for different speeds with single load

Fig 6.6 Voltage vs time characteristics for different speeds with two persons

74
 Figure 6.5 represents the voltage vs time characteristics of the vehicle for single load and
at different speed conditions as 20 Kmph, 30 Kmph, 40 Kmph. Similarly figure 6.6 represents the
voltage vs time characteristics of the vehicle for two persons at different speed conditions. From
the above two figures it is inferred that Voltage consumption is high at lower speed when compared
to higher speed.

Fig 6.7 Speed vs time characteristics for different modes

Fig 6.8 Decibel vs speed characteristics for different modes

75
Inference:

Figure 6.7 describes the speed of the vehicles for different time periods under different
speed modes like mode 1, mode 2, mode 3. From figure 6.7 it is inferred that speed of the vehicle
is more when the vehicle is in mode 3. Therefore, the vehicle pickups the speed very fast when
compared to other modes.

Figure 6.8 represents the decibel vs speed characteristics of the vehicle in different
modes. Mode1, mode 2 and mode three are forward modes and the last one is the reverse mode.
From figure 6.8 it is inferred that the sound of the vehicle in decibels depends on speed of the
vehicle and the relation is inversely proportional.

76
 CHAPTER 7
CONCLUSION AND FUTURE SCOPE

7.1 Conclusion
On comparing the Spoke type BLDC motor, Bread loaf with two non-embedded magnets
per pole BLDC motor, Bread loaf with four non embedded magnets per pole BLDC motor it is
found that bread loaf with four non embedded magnets per pole BLDC motor is found to best
motor as it is having maximum value of average torque and minimum value of torque ripple.

By analysing the Synchronous reluctance motor with angled barrier, notch and angled
barrier, round barrier, notch and round barrier for four layers it is inferred that notch and round
barrier is having maximum value of average torque and minimum value of torque ripple. Now it
is then compared with bread loaf with four non embedded magnets per pole and it is found that
bread loaf with four non embedded magnets is found to be having optimum values of torque.

The Switched reluctance motor is analysed and compared with bread loaf with four non
embedded magnets per pole BLDC motor then it is found that bread loaf is giving better results in
terms of torque values. Later the hybrid motor with SRM stator and BLDC rotor and vice versa
are analysed and they are compared with brad loaf with four non embedded magnets per pole
BLDC motor. It is found that Bread loaf giving better results in terms of torque values with less
ripple content.

Therefore, bread loaf with four non embedded magnets is found to be best among the rotor
types as its torque is maximum. For rotor materials we found 36F155 has optimum values of
torque. Therefore, BLDC Motor with Bread loaf four non embedded magnets is suitable for better
performance of the electric motor.

7.2 Future Scope

This project can be further extended as follows,

1. Electromagnetic analysis can be further executed to obtain the required torqued in hybrid
motor1.
2. The mechanical analysis as vibration and thermal analysis can be carried out to study the
behavior of the motor.
3. The control technique as hysteresis, current control, ANN can be implemented to machine
drive systems.

77
 CHAPTER 8
FINANCE AND PROJECT MANAGEMENT

8.1 EXPERIMENTAL HARDWARE

The Experimental hardware setup which are required for project are mentioned in below
table 8.1.

Table 8.1: Equipment required for hardware setup and Price of each
Name of the equipment No of Units Ratings Price (Rs.)
Permanent Magnet Brushless DC Hub 1 2 KW, 60 V, 15,000
Motor 1500 rpm
Battery 1 60V, 24Ah 30,000
Charger 1 230V/60V 10,000
Miscellaneous cost N.A. N.A. 5,000
Total 60,000

8.2 SOFTWARE
The software used for this project are Simcenter Motorsolve and MATLAB with
additional Toolboxes.

78
 CHAPTER 9
TIME MANAGEMENT AND SOCIETAL IMPACT

Time Management:

Work Done February March April May

Literature Survey

Electromagnetic analysis of
BLDC motors
Electromagnetic analysis of
SyRM motors
Electromagnetic analysis of
SRM and Hybrid motors
Hardware Testing

Societal Impact:
Because of their low costs, high efficiency and ability to operate in harsh environments so
brushless DC motor is suitable for electric vehicle application and helps to reduce pollution by using
electric vehicles instead of conventional vehicles

79
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85
 SREE VIDYANIKETHAN ENGINEERING COLLEGE
(AUTONOMOUS)
Sree Sainath Nagar, A. Rangampet - 517 102

Department of Electrical and Electronics Engineering

PROJECT TITLE:

Comparative Investigation and Implementation of Propulsion Motor for

Electrified Transportation System

ABSTRACT:

This project deals with the design and investigations on various electric
motors for traction applications. The main aim of the project is to identify
the inner rotor motor with superior characteristics. The motor considered for
analysis are Switched Reluctance Motor (SRM), Synchronous Reluctance
Motor (SyRM), Hybrid Motor and Brushless DC Motor (BLDC) are
investigated and compared with the parameters as torque ripple, to find the
behavior of the motor. The 2 kW, 48 V, 1500 RPM, three phase are the
specifications of the motors considered for analysis. The analysis is executed
in the finite element analysis environment by utilizing motorsolve package.
SRM is investigated for three phases, SyRM is analyzed for angled barrier,
notched and angle barrier, round barrier, notch and round barrier types,
BLDC is examined for spoke, bread-loaf types. By comparing all the types of
motor, it is inferred that bread loaf with four non-embedded magnet BLDC
motor. The simulated results are validated with numerical equations. Then
a prototype implementation of conventional PMBLDC hub motor in the
process of converting exciting bike into electric vehicle is executed. The test
findings of the electric bike are investigated and reported.
PROJECT BATCH:

SIRRI POORNA THEJA 18121A02F2

PRABIN KAPURI 18121A02J2
THATI SUMANTH 18121A02G1
[Link] TEJA 18121A02H3
[Link] NAIK 18121A02G9

GUIDE:
Dr. S. PRABHU, ME, Ph.D., Associate Professor, Department of EEE.

86
CO - POs Mapping table:

Course Program Outcomes

Outcomes
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12
CO1. knowledge on
√
the project topic.
CO2. analytical
ability exercised in √
the project work.
CO3. design skills
applied on the √
project topic.
CO4. ability to
investigate and
solve complex
engineering √
problems faced
during the project
work.
CO5. ability to
apply tools and
techniques to
complex
engineering √
activities with an
understanding of
limitations in the
project work.
CO6. ability to
provide solutions as
per societal needs
with consideration
√
to health, safety,
legal and cultural
issues considered
in the project work.
[Link]
of the impact of the
professional
engineering
solutions in
environmental √
context and need
for sustainable
development
experienced during
the project work.

87
CO8. ability to
apply ethics and
norms of the
√
engineering
practice as applied
in the project work.
CO9. ability to
function effectively
as an individual as √
experienced during
the project work.
CO10. ability to
present views
cogently and √
precisely on the
project work.
CO11. project
management skills
√
as applied in the
project work.
CO12. ability to
engage in life-long
leaning as √
experience during
the project work

Signature of the Guide

88
 SREE VIDYANIKETHAN ENGINEERING COLLEGE
(AUTONOMOUS)
Sree Sainath Nagar, A. Rangampet - 517 102

Department of Electrical and Electronics Engineering

PROJECT TITLE:
Comparative Investigation and Implementation of Propulsion Motor for
Electrified Transportation System.

PROJECT BATCH List:

SIRRI POORNA THEJA 18121A02F2
PRABIN KAPURI 18121A02J2
THATI SUMANTH 18121A02G1
[Link] TEJA 18121A02H3
[Link] NAIK 18121A02G9

GUIDE:
Dr. S. PRABHU, ME, Ph.D., Associate Professor, Department of EEE.

POs Attained:

Program Specific
Project Program Outcomes
Outcomes
title
PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2 PSO3 PSO4
Comparative
Investigation
and
Implementati
on of
Propulsion
Motor for √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √
Electrified
Transportatio
n System.

Signature of the Guide

89
 BIODATA

NAME : SIRRI POORNA THEJA

ROLL NO. : 18121A02F2
AADHAAR
: 337076823938
NUMBER
FATHER NAME : S MUDDU
DATE OF BIRTH : 04/08/2000
NATIONALITY : INDIAN

CONTACT DETAILS

CONTACT NO. : +919618067975

EMAIL : Poornasirri9372@[Link]
CONTACT 14-102/1-1, Gowri Nagar, Renigunta,
:
ADDRESS Chittoor, 517520

NAME : PRABIN KAPURI

ROLL NO. : 18125A02J2
AADHAAR 611406794211
:
NUMBER
FATHER NAME : MAHESH SHAH
DATE OF BIRTH : 07/12/1999
NATIONALITY : NEPALESE

CONTACT DETAILS

CONTACT NO. : 8235721650

EMAIL : Kapuriprabin69@[Link]
MITHELESHWAR, MAUWAHI-01,
CONTACT
: JANAKPURDHAM, DHANUSHA,
ADDRESS
NEPAL

90
 NAME : Sumanth Thati
ROLL NO. : 18125A02G1
AADHAAR 828383245537
:
NUMBER
FATHER NAME : Thati Ravi
DATE OF BIRTH : 10/06/2000
NATIONALITY : INDIAN

CONTACT DETAILS

CONTACT NO. : 9550303969

EMAIL : sumanththati6@[Link]
CONTACT 000, Paramatamma Street, Vindhuru,
:
ADDRESS Gudur (Mandal), 524101.

NAME : V SURYA TEJA

ROLL NO. : 18125A02H3
AADHAAR 978653830891
:
NUMBER
FATHER NAME : V CHANDRA SEKHAR
DATE OF BIRTH : 01/01/2001
NATIONALITY : INDIAN

CONTACT DETAILS

CONTACT NO. : 9866720095

EMAIL : vamanagirisuryateja@[Link]
CONTACT 18-1-2-4-7, Lakshmi Nagar,
:
ADDRESS Pattikonda, Kurnool, 518380.

91
 NAME : V Praveen Naik
ROLL NO. : 18125A02G9
AADHAAR 659964398454
:
NUMBER
FATHER NAME : V Shankar Naik
DATE OF BIRTH : 5/5/2001
NATIONALITY : INDIAN

CONTACT DETAILS

CONTACT NO. : 9666915528

EMAIL : vpraveennaik842@[Link]
CONTACT 4/50 Ananthapur (D), Ananthapur (M),
:
ADDRESS NN Kunta (V) ,515003

92