Novel Design of Permanent Magnet-Assisted Synchronous Reluctance Motor Using Metal Additive Manufacturing Technology

This paper presents an advanced design and investigation of a Permanent Magnet Assisted Synchronous Reluctance Motor (PM-Assisted-SynRM). This unique design incorporates a two-level permanent magnet flux barrier to secure the permanent magnet, accompanied by an additional third-level flux barrier, aiming to achieve a sinusoidal air-gap flux density. The main innovation involves introducing a higher number of stator slots to enhance output power density. These stator slots are designed to house rectangular copper windings, thereby increasing the slot fill factor. The consideration of a single turn in each slot is explored to minimize dv/dt interference and enable the utilization of higher frequency power electronics drives. The challenges in manufacturing complex geometry stator and rotor laminations are addressed through the application of metal additive manufacturing technology. The efficacy of the proposed model is evaluated by validating its characteristics, including output torque, torque ripple, radial air-gap flux density, cogging torque, static torque, and back-EMFs, through finite element analysis (FEA).