Hybrid-Magnet based Multilayer Interior Permanent Magnet Synchronous Motor for Low-Voltage Small Pallet Electric Truck Application

Interior permanent magnet synchronous motors (IPMSMs) are increasingly used in consumer electronics warehousing, where safe and efficient handling of fragile goods demands smooth torque, low vibration, and reliable performance. Conventional IPMSMs depend heavily on rare-earth magnets, raising cost and supply concerns. This paper proposes a reduced rare-earth hybrid-magnet multilayer IPMSM with structural enhancements tailored for a low-voltage (48 V), 1 kW pallet truck drive. A double-V flux barrier design increases saliency, widens the constant-power speed range (CPSR), and reduces core loss, while q-axis notches improve demagnetization resilience and extend the high-efficiency region. Fractional-slot windings (33/8) suppress cogging torque, enabling vibration-free lifting critical for consumer product safety. A magnetic equivalent circuit developed for hybrid based magnet rotor topology of IPMSM. The designed topology has 64% rare-earth reduction and 16% improved demagnetization margin. A fabricated prototype validates from FEA simulation, achieving 92.5% peak efficiency. The results demonstrate a cost-effective, safe motor solution for consumer electronics logistics and warehouse mobility.