Optimized Rotor Shape for Reducing Torque Ripple and Electromagnetic Noise

This article proposes a rotor design method suitable for double-layer interior permanent magnet synchronous motor (DIPMSM), which can reduce electromagnetic torque ripple and at the same time reduce the electromagnetic noise of the motor. In previous studies, the inverse cosine function (ICF) was used to modify the rotor shape for making the air-gap flux density distribution sinusoidal under no-load conditions, which can reduce the torque ripple. However, conventional ICF can only be used in a single-layer interior rotor structure. Consequently, this article proposes a piecewise inverse cosine function (PICF) based on ICF, which can be applied to DIPMSM. To verify the improvement of the proposed method in the electromagnetic and noise aspects of the motor, the electromagnetic model and a noise prediction model of the 36-slot/8-pole motor are established by the finite element method. The PICF model is compared with the prototype in the aspects of electromagnetic performance and noise. The torque ripple is reduced by 54.16%, from ±2.4 to ±1.1 N m, and the electromagnetic noise is reduced by about 4.9 dB. Finally, the accuracy of the noise prediction model is verified by the noise test of the prototype.