Design and Validation of SPMSM with Step-Skew Rotor for EPS System Using Cycloid Curve

This study considers a robust design methodology to reduce cogging torque in the EPS (Electric Power Steering) of an automotive system. Cogging torque reduction is the key design factor to improve steering feeling and drive stability in an EPS system. For this reason, an SPMSM (Surface Permanent Magnet Synchronous Motor) has been widely applied to drive a motor in an EPS system. Furthermore, two design methods, which are a magnet shape and step-skew design for rotor assembly, have been mainly used to reduce cogging torque in an SPMSM. In this paper, an SPMSM is selected as the drive motor and a robust design methodology is proposed to reduce cogging torque in an EPS system. Firstly, a cycloid curve is used for the magnet shape to reduce cogging torque. An evaluation index δq is also used to compare this with a conventional magnet shape design. Secondly, based on the results of the magnet shape design with the cycloid curve, a step-skew design for rotor assembly is also applied to reduce cogging torque. In order to validate the effectiveness of the robust design for the cycloid curve and conventional magnet shape with rotor step-skew, the results from FEM (Finite Element Method) analysis and prototype tests are compared. The cycloid curve magnet shape model with rotor step-skew was verified to reduce the cogging torque and enhance the robustness for cogging torque variation through the analysis and protype test results. The verified results for the proposed model will be extended to meet the required cogging torque variation for the various applications driven by SPMSM with the robust design model.