“SIZING OF THE PERMAMENT MAGNET

MOTOR FOR FAN APPLICATIONS”

Minor Project Report

Submitted in Partial Fulfillment of the Requirements for

the Degree of
BACHELOR OF TECHNOLOGY

IN

ELECTRICAL ENGINEERING
By
ANUJ AGRAWAL (21BEE009)
ADITYA TODI (21BEE099)

Department of Electrical Engineering

Institute of Technology
NIRMA UNIVERSITY
Ahmedabad 382 481

September 2024

1|Institute of Technology, Nirma University, Ahmedabad

 ACKNOWLEDGEMENT

I must acknowledge the strength, energy and patience that almighty GOD bestowed upon me to start
& accomplish this work with the support of all concerned, a few of them I am trying to name
hereunder.

I would like to express my deep sense of gratitude to all faculties of Electrical Engineering
Department for their valuable guidance and motivation.

I would like to express my sincere respect and profound gratitude to Prof. (Dr.) S. C. Vora,
Professor & Head of Electrical Engineering Department for supporting and providing the
opportunity for the summer internship.

I would also like to thank all my friends who have helped me directly or indirectly for the
completion of my summer internship.

No words are adequate to express my indebtedness to my parents and for their blessings and
good wishes. To them I bow in the deepest reverence.

- Anuj Agrawal (21BEE009)

- Aditya Todi (21BEE099)

2|Institute of Technology, Nirma University, Ahmedabad

 LIST OF FIGURES
Figure No: Name of the Figure: Page No:
Fig. 1.1 BLDC Motor 9
Fig. 2.1 Bonded Magnet Rotors 13
Fig. 2.2 Interior permanent magnet (IPM) rotors 13
Fig. 2.3 Consequent Pole Rotors 14
Fig. 2.4 Surface-Mounted Permanent Magnet Rotors 14
Fig. 2.5 Salient-Pole Stator 14
Fig. 2.6 Slot less Stator 15

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 LIST OF TABLES
Table No: Name of the Table: Page No:
Table 1.1 Conventional vs BLDC Motors 9-10
Table 2.1 Comparison of Materials 17
Table 3.1 Defined Parameters 18
Table 3.2 Assumed Parameters 19
Table 3.3 Calculated Parameters 19

4|Institute of Technology, Nirma University, Ahmedabad

 LIST OF ACRONYMS
DC : Direct Current
AC : Alternating Current
PMBLD : Permanent Magnet Brushless DC Motor
C
SMPM : Surface Mounted Permanent Magnet
IPM : Interior Permanent Magnet
BLPM : Brushless Permanent Magnet
EPS : Electric Power Steering
HVAC : Heating Ventilation and Air-Conditioning

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 LIST OF NOMENCLATURE
𝑉𝑖
𝑉𝑜
: Input Voltage
: Output Voltage
ωm : Maximum Speed
Vn : Highest Permitted Supply Voltage
Pm : Mechanical Power Provided
Psh : Shaft Power
Bav : Specific Magnetic loading
Ac : Specific Electric loading
KTRV : Torque to volume ratio

6|Institute of Technology, Nirma University, Ahmedabad

 TABLE OF CONTENTS
ACKNOWLEDGEMENT 2
LIST OF FIGURES 3
LIST OF TABLES 4
LIST OF ACRONYMS 5
NOMENCLATURE/ABBREVIATIONS 6
TABLE OF CONTENTS 7

CHAPTER 1: INTRODUCTION 8
CHAPTER 2: LITERATURE REVIEW 13
CHAPTER 3: DESIGN CALCULATIONS 16
3.1 Main Dimensions 18
CHAPTER 4: CONCLUSION AND FUTURE SCOPE 20

REFERENCES 21

7|Institute of Technology, Nirma University, Ahmedabad

CHAPTER 1

INTRODUCTION

1.1 Overview of Fan Applications

The energy efficiency and affordability of ceiling fans make them a popular choice for air
circulation in homes, businesses, and industrial areas. Permanent magnet (PM) motors are
becoming more and more popular due to their increased efficiency, silent operation, and small
size. Traditionally, PM motors were driven by AC induction motors. The performance of a fan in
terms of air supply, speed, and energy consumption is directly impacted by the size of the motor,
which makes precise motor sizing essential.
In tropical and subtropical areas with warm climates, including as India, China, Brazil, and the
US, ceiling fans are commonly utilized. The amount of power used in homes is considerably
increased by these fans. In India, for example, ceiling fans were predicted to use 9% of
household power by 2020, up from 6% in 2000. This corresponds to an energy need that is equal
to the production of fifteen mid-sized power plants.
Currently, single-phase induction motors that use between 75 and 80 watts are the main source of
power for ceiling fans in India. On the other hand, up to 50% less energy can be used using more
energy-efficient alternatives such permanent magnet brushless DC (PM BLDC) motors. Despite
the development of single-phase PM BLDC motors using NdFeB (neodymium-iron-boron)
magnets, their cost and requirement for permanent magnets and an electronic controller limit
their use. The possibility of employing less expensive ferrite magnets rather than rare-earth
magnets like NdFeB to lower the price of PM BLDC motors for ceiling fans is investigated in
this research.

1.2 Importance of Motor Sizing

The process of motor sizing is figuring out a motor's proper size, power, and performance
attributes to satisfy application-specific requirements. Oversized motors consume more energy
and are more expensive, whilst undersized motors may not have enough airflow and have a
shorter lifespan. A fan that is sized properly will run effectively, providing the necessary airflow
while using the least amount of energy.
1.3 Introduction to Permanent Magnet Motors

A brushless DC motor (also referred to as a BLDC) is a permanent magnet synchronous electric

motor that is powered by direct current (DC) electricity and achieves an electronically controlled
commutation system in place of a mechanically controlled one. Commutation is the process of
producing rotational torque in the motor by changing phase currents through it at the proper
times. The term "trapezoidal permanent magnet motor" is also used to describe BLDC motors.

8|Institute of Technology, Nirma University, Ahmedabad

 Fig. 1.1 BLDC Motor

Contrary to conventional brushed type DC motors, which use mechanical contact between the
brushes and the commutator on the rotor to create an electric path between a DC power source
and the rotor armature windings, BLDC motors use electrical commutation with permanent
magnet rotors and stator coil sequences. Current-carrying conductors are fixed while the
permanent magnet (or field poles) spins in this engine.

Transistors or silicon-controlled rectifiers electronically switch the armature coils at the proper
rotor position such that the armature field is in space quadrature with the rotor field poles. As a
result, the rotor rotates as a result of the force imposed on it. The most popular devices for
detecting the position of the rotor are rotary encoders or hall sensors, which are installed all
around the stator. When to switch the armature current is guided by the sensor's response on the
rotor position.

With this electronic commutation system, the commutator system and brushes in a DC motor are
eliminated, resulting in a more dependable and quieter operation. BLDC motors can operate at
high speeds since there are no brushes in them. BLDC motors generally have an efficiency of 85
to 90 percent, compared to 75 to 80 percent for brushed type DC motors. BLDC motors come in
a broad range of variations, with tiny power ranges, fractional horsepower, integral horsepower,
and huge power ranges among them.

1.4 Conventional vs BLDC Motors

FEATURES CONVENTIONAL DC MOTOR PMBLDC

Maintenance High Low

Speed/Torque Flat - Enables operation at all speeds Nonlinear - Lower torque at lower
Characteristics with rated load speeds

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 Commutation Mechanical contact between brushes Electronic switching using power
method and commutator semiconductor devices
ie, transistor, MOSFET
Rotor Inertia Low- Better dynamic characteristics High- Poor dynamic characteristics
Detecting Automatically detected by brushes Rotor position can be detected by
method using sensor i.e., Hall sensor,
optical sensor
Starting current Rated- No special circuit required Approximately up to seven times
of rated - Starter circuit rating
should be carefully selected.
Normally
uses a Star-Delta starter
Controllable Controlling speed is difficult Speed can be easily controlled so
that it is possible to have very high
speed
Control A controller is always required to No controller is required for speed;
Requirements keep the motor running. The same a controller is required only if
controller can be used for variable variable speed is desired
speed control

Table 1.1

1.4 Working of BLDC Motor

Stator: The stator is the stationary part of the motor that contains the windings. These
windings are made up of insulated copper wire and are arranged in a specific pattern. The
stator provides a magnetic field that interacts with the rotor to produce torque.

Rotor: The rotor is the rotating part of the motor that contains permanent magnets. The
magnets are arranged in a specific pattern, opposite to that of the stator. The interaction
between the magnetic fields of the stator and the rotor produces rotational movement.

Hall effect Sensor or Electronic controller: The Hall effect Sensor is the brain of the
motor. It is responsible for controlling the flow of current to the motor windings. The
controller also senses the position of the rotor and adjusts the current accordingly to ensure
smooth and efficient operation.

Working Principle of BLDC Motor: The working principle of BLDC motors is based on
the interaction between the magnetic fields of the stator and the rotor. The stator produces a

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 rotating magnetic field, which interacts with the permanent magnets on the rotor, producing a
torque that causes the rotor to rotate.

The Hall Effect Sensor plays a crucial role in the operation of the motor. It controls the flow
of current to the motor windings based on the position of the rotor. The controller senses the
position of the rotor using sensors or Hall effect devices mounted on the stator. These sensors
detect the position of the magnets on the rotor and send signals to the controller.
Based on the signals from the sensors, the controller adjusts the flow of current to the motor
windings to ensure that the magnetic fields of the stator and rotor are properly aligned. This
ensures that the motor operates efficiently and smoothly, without any loss of power or
vibration.

1.5 Advantages of BLDC Motor:

Higher efficiency: BLDC motors are more efficient than conventional DC motors due to the
absence of brushes. This results in less friction and lower power loss.

Higher power density: BLDC motors have a higher power density compared to conventional
DC motors. This means that they can produce more power in a smaller size.

Longer lifespan: The absence of brushes in BLDC motors results in less wear and tear,
making them more reliable and durable.

Low maintenance: BLDC motors require less maintenance compared to conventional DC

motors. This results in lower maintenance costs and longer service life.

1.6 Disadvantages of BLDC Motor:

High Cost: The high cost of BLDC motors is a significant drawback for various applications.
In the consumer electronics and automotive sector where cost efficiency is an important
factor, higher investment in BLDC motors may affect the price of the application and limit
the market share

Electronic Control System: The electromagnetic interference generated by electronic control

systems may interfere with electronic devices and cause operational risks. Compatibility
issues of this control system may hinder seamless integration and require additional resources
and efforts.

Limited High Speed and Torque: In electric vehicles and hybrid vehicles, where maintaining
performance at high speed is important, BLDC motors may not deliver sufficient torque and
impact the acceleration of the vehicle.
1.7 Application of BLDC Motor:

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 Brushless DC motors (BLDC) use for a wide variety of application requirements such as
 Computer hard drives and DVD/CD players
 Electric vehicles, hybrid vehicles, and electric bicycles
 Industrial robots, CNC machine tools, and simple belt driven systems
 Washing machines, compressors and dryers
 Fans, pumps and blowers.

1.8 Objectives

PM motors are seeing more and more use in ceiling fans as the market for energy-efficient
products grows. However, in order to optimize performance and economy, these motors'
optimum size is still essential. The purpose of this study is to:

1. Determine the important design factors for PM motors used in fan applications.
2. Examine how motor size affects performance.
3. Create a sizing technique depending on the demands of particular fans.
4. Compare the power and efficiency of the developed motors with those of commercial
solutions.

CHAPTER 2

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LITERATURE REVIEW

2.1.1 Variations in Rotor

The rotor, which houses permanent magnets and directly contributes to torque generation and
speed regulation, is the main component of BPMMs.

.
1. Bonded Magnet Rotors: This variant bonds magnets into a single component, which
minimizes manufacturing complexity at the expense of performance. This technique
works well for low-performance applications and small household devices.

Fig 1.1 Bonded Magnet

Rotors
2. Interior permanent magnet (IPM) rotors: Interior permanent magnet (IPM) rotors
benefit from flux concentration made possible by magnets embedded within the rotor,
which increases magnetic strength and motor performance. The IPM principle works well
in high-performance applications where lifespan and efficiency are crucial, such as
electric automobiles and high-speed industrial motors.

Fig 2.2 IPM

3. Consequent Pole Rotors This designRotors
basically reduces the number of magnets required
by switching between rotor back iron and magnetic poles. Even though this design is
cost-effective, it may result in reluctance torque, which would reduce the motor's
smoothness.

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 Fig 3.3 Consequent
Pole Rotors
4. Surface-Mounted Permanent Magnet Rotors: These rotors are frequently utilized and
have magnets fastened to them. This device is inexpensive and simple, but at high
spinning speeds, centrifugal forces might cause the magnets to break free. This design is
ideal for low-performance applications, such low-speed fans and basic domestic
appliances.

Fig 4.4 Variations of Surface-Mounted

2.1.2 Stator Variations

The stator, containing the motor windings and creating the magnetic field that interacts with the
rotor, comes in several designs:

1. Salient-Pole Stator: By grouping the windings around specific poles, this configuration
minimizes the motor's size and complexity, but at the expense of decreased torque.
Because of the imperfect magnetic coupling between the rotor and stator, this design is
less efficient.

Fig 2.5 Salient

Pole stator
2. Distributed Winding Stator: An even magnetic field is produced by spreading the
windings over several slots in this configuration. It may result in a higher cogging torque,
but it is more effective.

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 Fig 2.6 Slotless

3. Slotless Stator: The stator's cogging torque is completely eliminated by this design,
improving its quiet and smooth operation. However, this design's greater air gap
reluctance makes heat dissipation challenging.

4. Slotted Stator: Most PM BLDC motors have slotted stators because they have a stronger
magnetic contact with the rotor. However, especially at low speeds, cogging torque—
which slotted stators naturally produce—may cause vibrations and noise.

5. Shoes and Teeth: The chapter introduces the concept of adding shoes and teeth to slotted
stator designs in order to reduce cogging torque and improve motor performance.

Shoes refer to the extensions placed on the stator teeth that increase the effective air gap
area and create a smoother route for magnetic flux. By aiding in the more uniform
distribution of magnetic flux over the air gap, shoes lessen cogging torque. Shoes can,
however, increase slot leakage inductance, which can lower motor efficiency to some
extent. For this reason, this design has to be carefully adjusted.

Teeth: In a slotted stator, the magnetic teeth positioned between the slots play a crucial
role in shaping the air gap flux. They interact with the rotor magnets to generate torque.
The distribution and type of teeth can be adjusted to help reduce flux pulsations and
further streamline the motor's operation.
Shoes and teeth are common parts of high-end ceiling fans, where quiet operation and
minimum noise levels are critical requirements, and high-performance industrial motors,
where smooth torque output is required.

2.1.3 Design Equations

The design equations cover both radial flux and dual axial flux topologies, emphasizing
that motor design is an iterative process involving numerous trade-offs.
Radial Flux Motor Design
The equations for radial flux motors focus on calculating the critical dimensions and
parameters:
 Fixed Parameters: The starting point for any design involves fixing known values such
as power, speed, number of phases, and magnet poles

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  Key Geometrical Parameters: The equations define relationships between the various
motor radii, air gap length, and the slot dimensions
 Torque and Back EMF: The torque and back electromotive force (EMF) produced by
the motor are calculated during the design phase based on the interactions between the
magnetic fields and the slot winding arrangements.
For instance, torque plays a crucial role in industrial conveyor motors, and the torque
equations offer the basis for motor size optimization. Ensuring appropriate torque output
while keeping the motor's size within application restrictions is ensured by the necessary
slot and winding design.

Dual Axial Flux Motor Design

The dual axial flux design equations are also included, however they are less prevalent.
This design's two air gaps add complexity, necessitating the use of more sophisticated
magnetic circuit models. Instead of being created over a single radius, torque is produced
across a continuum.
These formulas aid designers in understanding how air gap length, magnet size, and
stator winding arrangement affect the efficiency and power output of motors used in flat
disc motors for drones.
Iterative Process and Design Trade-Offs
The chapter emphasizes how iterative motor design is. It is necessary for designers to
regularly review and modify their decisions on variables such as magnet length, air gap,
and slot size. They balance trade-offs between manufacturing costs, torque production,
efficiency, and heat dissipation using these formulae.
From a practical standpoint, these equations help in fine-tuning the design of an electric
bike motor. You might maximize the bike's motor's speed and power while adhering to
weight and budgetary restrictions by doing several iterations with various parameter
configurations.

2.2.1 Magnet Properties and Cost: There are two primary types of magnets used in the study

 Neodymium-Iron-Boron (NdFeB) Magnets:

The maximum energy density may be found in these magnets.
There are two types of NdFeB: bonded and sintered. The sintered form has greater energy
densities.
 Bonded NdFeB:
it is more practicable for consumer items than sintered NdFeB magnets, which are far
more expensive.
These have a lower energy density than NdFeB magnets, but they are significantly less
expensive.
Despite requiring a greater number of magnets to get the necessary air gap flux density,
ferrite motors offer a financial benefit because of their much cheaper cost.

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 The document lists magnet parameters that illustrate the trade-off between cost and
performance, including maximal energy product (BHmax), coercive force (Hc), and
remanent flux density (Br). While ferrite magnets are 8–12 times less expensive than
NdFeB magnets, they have the lowest performance attributes.

Material Br Hc Bhmax
Ceramic 1 2200 1900 1.1
Ceramic 2 3950 2400 3.6
SmCo 18 8600 7200 18
SmCo 26 10500 9200 26
NdFeB 35 12300 11300 35
NdFeB 42 13050 12500 41
Table 2.1 comparison of

2.2.2. Torque-Speed Characteristics

When building a motor, the torque-speed relationship of the fan blades is essential. While
the power needed to drive the blades is proportionate to the cube of the speed, the torque
needed is roughly proportional to the square of the speed.
A ceiling fan driven by an induction motor and operating at 370 RPM was examined in
order to determine the motor parameters. By monitoring power consumption at different
speeds and progressively lowering the input voltage, the torque-speed characteristics
were ascertained. To confirm these findings, the motor was subsequently disconnected
from the fan blades and put through a dynamometer test. These tests yielded an output
power of 22 W and a torque of 0.567 N-m at 370 RPM.

CHAPTER 3

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DESIGN CALCULATIONS

In this chapter the various parameters of the PMBLDC motors are being calculated
like stator outer diameter, inner diameter, rotor outer diameter, inner diameter,
torque of PMBLDC Motor for an application of Fan applications. These
parameters are hence optimized to reduce the losses and hence optimize the
efficiency of the motor for optimal output of approximately. The designing of the
motor and their optimization are depicted as follows.

3.1 Main Dimensions:

Poles 16
Voltage 170 v
Power output 22 W
Speed 370 v
Torque 0.567 N-m
Efficiency 75%
Power Input 29 W
Phase Voltage 210 v

Table 3.1: Defined Values

Bg 0.6 T
SR 0.5

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 KTRV 25
AR 0.35
Space Factor 0.4
Current Density 0.6 A/mm2

Table 3.2: Assumed Parameters

𝜔 38.80 rad/sec
Stack Length 28.07 mm
Dso 80.2 mm
Dr0 40.1 mm
Ac 20,833.33 A/mm2
Iph 0.0920 A
Zph 14.25 ohm
Tph 7.128 N-m

Table 3.3: Calculated Parameters

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CHAPTER 4
CONCLUSION AND FUTURE SCOPE

CONCLUSION:
The emerging significance of Permanent Magnet Brushless DC (PM BLDC) motors as energy-
efficient substitutes for conventional induction motors in ceiling fan applications is brought to
light by this study. A viable way to achieve energy efficiency at a lower cost is to investigate
more affordable options, such as switching to ferrite magnets from rare-earth NdFeB magnets. It
is evident from a thorough examination of the various rotor and stator designs, motor size
factors, and performance vs cost trade-offs that optimizing motor design is essential to lowering
energy consumption and preserving or boosting ceiling fan performance.

The link between motor performance and fan blade speed is well illustrated by the measurement
of torque-speed characteristics in ceiling fans, which highlights the significance of accurate
motor sizing. This study offers insight into the design parameters that affect motor efficiency,
cost, and overall performance, which is a critical first step toward the development of more
reasonably priced and energy-efficient ceiling fan motors.

Further work might entail testing motors with different magnet materials and improving the
design equations to better account for particular ceiling fan applications. The ultimate objective
is to strike a balance between price, performance, and efficiency in order to increase the market's
accessibility to energy-efficient fans.

FUTURE SCOPE:
Future work will involve refining the calculations of stator and rotor dimensions and further
optimizing the performance of the BLDC motor. Using advanced tools like MotorSolve, detailed
simulations will allow for precise dimensioning, enabling better torque, efficiency, and overall
motor performance. These simulations will guide the development of physical prototypes, which
can be tested to validate and improve upon the current design.
Further research can focus on enhancing motor efficiency by optimizing winding patterns and
improving magnetic circuit designs. Additionally, exploring the effects of varying key
parameters, such as split ratio and space factor, can lead to a more efficient and cost-effective
BLDC motor tailored specifically for fan applications.

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REFERENCES
[1] D. C. Hanselman, Brushless Permanent-Magnet Motor Design, 1st ed. New York, NY, USA:
McGraw-Hill, 1994, Ch. 5, pp. 103–123.

[2] D. C. Hanselman, Brushless Permanent-Magnet Motor Design, 1st ed. New York, NY, USA:
McGraw-Hill, 1994, Ch. 6, pp. 125–150.

[3] A. Saxena, "Performance and cost comparison of PM BLDC motors for ceiling fan," 2014
IEEE International Conference on Power Electronics, Drives and Energy Systems (PEDES),
Mumbai, India, 2014, pp. 1-5, doi:10.1109/PEDES.2014.7041981.

[4] Renesas Electronics, "Brushless DC Motor Basics," Renesas, [Online]. Available:

https://www.renesas.com/us/en/support/engineer-school/brushless-dc-motor-01-overview.

[5] "Magnet Materials - Types of Magnet Materials," MagnetShop.com.

https://www.magnetshop.com/resources/magnet-materials.html

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