Analysis of vibration and acoustic noise in permanent magnet motors

The drive motor is a frequent source of vibration and acoustic noise in many precision spindle motors. One of the electromagnetic sources of vibration in permanent magnet motors is the torque ripple, consisting of the reluctance torque and electromagnetic torque fluctuation. This type of vibration is becoming more serious with the advent of new high-grade magnets with increased flux density. Acoustic noise of electromagnetic origin is difficult to predict and its exact mechanism is unclear. The mechanism of noise generation should be revealed to design a quieter motor which is the modern customer's demand.;For motor operation at low speeds and loads, torque ripple due to the reluctance torque is often a source of vibration and control difficulty. The reluctance torque in a motor was calculated from the flux density by a finite element method and the Maxwell stress method. Effects of design parameters, such as stator slot width, permanent slot width, airgap length and magnetization direction, were investigated. Magnet pole shaping, by gradually decreasing the magnet thickness toward edges, yields a sinusoidal shape of the reluctance torque with reduced harmonics, thus reducing the vibration. This dissertation also presents two motor design techniques: stator tooth notching and rotor pole skewing with magnet pole shaping, and the effect of each method on the output torque. The analysis shows that the reluctance torque can be nearly eliminated by the suggested designs, with minimal sacrifice of the output torque.;In permanent magnet DC motors, the most popular design type is the trapezoidal back electro-motive force (BEMF), for switched DC controllers. It is demonstrated that the output torque profile of one phase energized is qualitatively equivalent to the BEMF profile for motors with reduced reluctance torque. It implies that design of BEMF profile is possible by magnetic modeling of a motor, without expensive and time-consuming experiments for different designs. The effect of various design parameters on the output torque and torque ripple are discussed. Design parameters include winding patterns, magnetization direction, magnet arc length, number of segments in poles and magnet pole shaping. New designs of trapezoidal BEMF motors are proposed to reduce the electromagnetic torque ripple. Magnet stepping and magnet edge shaping with reduced arc length, significantly reduce torque ripple, with minimal sacrifice of the maximum output torque.;Acoustic noise of electromagnetic origin is investigated using a magnetic frame which emulates a DC motor. The driving electromagnetic force is calculated using finite element analysis and the resulting vibration and acoustic noise is measured. Acoustic noise of purely electromagnetic origin was also tested with a DC brushless motor to confirm the results of the magnetic frame. The mechanism of noise generation in a DC motor is a quasi-static response of a stator not only at the fundamental frequency but also at higher harmonic frequencies of alternating switched DC, which is a current characteristic of a DC motor. Noise generation is significantly aggravated when some of those harmonics are close to the resonant frequencies of the stator. Therefore, acoustic noise is highly dependent upon the excitation current shape, as higher harmonics may match with resonant frequencies of the stator.