Design, Optimization, and Indirect Field-Oriented Control of a Concentrated Wound DAB-Type High Speed IPMSM

The high-speed interior permanent magnet synchronous machines (HS-IPMSM) are widely adopted due to their high-performance capabilities. In this study, a concentrated wound double-tied arch bridge DAB-type HS-IPMSM comprising 4-poles and 24 slots is presented. The adopted winding configuration reduces the end winding length and copper losses, but at the cost of reduced flux linkage and average torque. The proposed design is optimized using the split ratio and a Genetic Algorithm (GA), following which an electromagnetic performance comparison is performed with the conventional distributed wound DAB-type IPMSM. Upon analysis, the cogging torque, copper losses, and overall machine weight are reduced by 57.17%, 69% and 17.14%, respectively, representing a significant improvement that directly enhances the overall efficiency of the optimized machine by 0.18%. The optimized design is further validated through the Maximum Mechanical Stress (MMS) test, confirming the MMS within the material’s safe limit. Subsequently, indirect Field-Oriented Control (FOC) incorporating Maximum Torque Per Ampere (MTPA) and field weakening control is employed as a full drive system to analyze machine performance under varying speed conditions. Finally, a comparative analysis is performed between the constant (lumped) motor parameters and the nonlinear lookup table (LUT) based motor parameters approach. The constant motor parameters approach is unable to fully utilize the motor capabilities due to the linear motor behavior. On the contrary, the LUTs base approach, considering nonlinearities of the motor, can utilize maximum motor performance across varying operating conditions, making it suitable for applications demanding high performance and a broad operational range.