Series Production Challenges of High-Efficient Flux Barrier Permanent Magnet Machines (FB-PMSM)

This paper describes the series production challenges of high-efficient Flux Barrier technology used in permanent magnet synchronous machines. Within the paper the Flux Barrier technology is described and how it can be used in a beneficial way concerning efficiency or torque increase as well as cost saving element. Furthermore, challenges and beneficial effects are influenced within production. This effects are mentioned, underpinned with “lessons learned” from the first productions of Flux Barrier machines. The experiences of three different motor designs are described: a small fan motor, a medium power e-bike motor and a high torque steering drive. A consideration of cooling within Flux barriers is also mentioned in paper. Included are the measured facts about the sensitivity analysis and the prototype measurements with the comparison with the original machines as well as the summary and perspective of future work.