FEM Based Design and Performance Analysis of 2-Poles Universal Motor
FEM Based Design and Performance Analysis of 2-Poles Universal Motor
Abstract
Among various special-purpose motors, the universal motor operates on both supplies, alternating current (AC) and
direct current (DC). In this paper, the design of special purpose 2 poles and 100-watt universal motor has been carried
out by ANSYS Maxwell software. The focus is on using the rotor pole embrace factor as a design variable; the analysis is
done with the help of the parametric approach based on several iterations. The different performance parameters have
been taken into account for design analyses like efficiency, torque, speed, and flux density of air gap of the respective
motor. Here, the flux pattern and characteristics of the motor with their respective curves was extracted. The
electromagnetic analysis of the proposed motor has been analyzed with the help of the finite element method (FEM).
Consequently, it is observed that the optimal model offers a significant enhancement in efficiency without bringing
additional losses to the motor.
Keywords
Universal motor, ANSYS maxwell, FEM, Parameters, Rotor pole embrace factor.
enhance efficiency with the selection of variable Nanhekhan et al. [12] developed the current sensing
parameters in the designing process. controller unit for vacuum cleaner application to
operate the motor. The advantage of the circuit is its
In this paper, a 2-poles universal motor with a 100- low cost and robust design. Moreover, the same
watt power rating is designed. While performing the circuit can be operated with AC grid. However, in
parametric analysis, the embrace factor of rotor pole this study Metal oxide semiconductor field effect
is considered a design variable to maximize motor transistor (MOSFET) design was used. Further, it
efficiency. Finite element-based electromagnetic can be replaced with insulated gate bipolar transistor
analysis has been performed using the ANSYS (IGBT) device for the energy-efficient circuit. Garg
Maxwell to increase the rated torque with the [13] presented a mathematical model of a universal
optimum efficiency of the proposed model. The motor based on AC and DC supplies which resulted
motor designed for optimal value of rotor pole in better motor performance on DC supply. The study
embrace factor, results in fewer losses and highest only focused on the electrical characteristics of
efficiency compared to other models. The transient mathematical modelling and did not opt for other
analysis along with the electrical analysis was also Multiphysics analyses.
done with the same tool on the optimal value of the
model. Umesh et al. [14] proposed design of universal motor
with rotor surface modification (RSM) to reduce
This paper has been divided into several sections. acoustic noises and improve the torque parameter
Section 1 illustrates introduction of the motor with with the FEM. The limitation of this work was not
various applications. Section 2 focuses on the employing the finite element adaptivity concept in
literature survey of the selected motor. Section 3 the design. Sharma and Manna [15] have presented
emphasis on methods and the mathematical the design of a universal motor for agro applications,
modelling of universal motor. Section 4 deals with resulting in efficiency improvement. The improved
the simulated results. Section 5 highlights the design was focused mainly on torque, efficiency, and
discussion of results with the limitations of the losses. The authors did not consider parameters like
present work and Section 6 manifest the conclusions brush angle, number of poles, number of rotor slots
of a proposed model of motor. etc. Qi et al. [16] proposed a deep slot universal
motor for powerful electric tools with an improved
2.Literature review commutation spark. However, the speed and
A comprehensive literature review has been efficiency of the motor get reduced with increasing
conducted to highlight similar applications proposed current.
and implemented during the time frames of ongoing
exploration. The researchers demonstrated their Nayak and Shivarudraswamy [17] presented a model
interest in the design and mathematical modelling of of a brushless direct current (BLDC) motor and
motors with various computational techniques. universal motor for grinder mixer application. The
authors only concentrated on the electrical analysis
Hsiao et al. [10] designed DC brush motor with an part of the motors and did not consider the crucial
optimized stator structure using finite element parameter of magnetic analysis. Nayak and
method (FEM) based Taguchi algorithm. This Shivarudraswamy [18] compared triode for AC
technique was beneficial to reduce the magnetic (TRIAC) based universal motor with a voltage
saturation and enhance the output power of the motor source inverter (VSI) to control the speed of the
for the respective application. However, it remains to BLDC motor. The design offered better performance
be discovered whether the hole's position, shape, and and was cost-effective compared to the conventional
size have a negative effect on the structural safety of design. However, the electrical circuitry of the design
the motor body. Kurihara and Koseki [11] designed a could not be fitted and compatible with all kinds of
new equivalent 4-pole universal motor with finite motor topologies.
element analysis (FEA) tool. This design provided
better output power and commutation than the Mercy et al. [19] presented the design of universal
existing design based on suitable pole arc coefficient. motor, which reflected a significant improvement in
However, the performance of the motor was analyzed efficiency and a reduction in heat losses. The thermal
on two parameters, i.e., rated speed and voltage. analysis was carried out and delivered better results
on DC supply than AC supply. Since the authors
performed the thermal analysis on the Multiphysics
1629
Sudhir Kumar Sharma and Manpreet Singh Manna
problem, less emphasis was paid on performance of parameters only but did not consider the variable or
electrical parameters. Gecer et al. [20] presented the external load.
design of switched reluctance motor (SRM), BLDC
motor, and induction motor (IM) with ANSYS The literature concludes that the universal motor is
Maxwell software for electric vehicle applications. designed only for small-scale industrial and domestic
The authors demonstrated that the SRM has high applications. Out of all the motors, the universal
torque performance at a high-power value and the motor, a special-purpose motor, is selected and
BLDC motor has better magnetic field density than designed with FEM to enhance the performance for
other motors. Natarajan et al. [21] proposed a various applications. FEM is an accurate and easy
universal motor controller with a pulse width technique for solving Multiphysics problems in large-
modulation (PWM) chopper for washing machine scale operations. It is observed that the universal
applications. However, an existing circuit can be motor is less efficient than other motors, and there is
employed with a solar photo voltaic system to reduce a scope for improvement of motor performance.
the power demand.
3.Methods
Benedik et al. [22] developed an approachable Initially, the field of electrical machine design used to
method to predict the life and failure reasons of the develop the magnetic circuit model of the machine
high-speed bearings used in the universal motor. for the analysis of the different parameters. However,
However, a single platform was used to analyze the the circuit technique was unable to analyze all the
issue, which could cause uncertainty in the designed parameters related to the electromagnetic domain of
motor. Araga et al. [23] discussed operating the machine, and it became necessary to use
characteristics of universal motor with experimental advanced techniques. Designing a motor before
equipment for AC and DC supplies. However, it was building saves the consumption of time and money.
observed that the obtained results were inconsistent, The use of computer technology, significantly reduce
which led to overheating during operation and the designer’s workload [29, 30]. Computational
mechanical vibrations. Girovsky and Kanuch [24] electromagnetic is being used more frequently due to
presented the effect of AC and DC supplies on the growing use of digital computers to solve
universal motor characteristics like speed, efficiency, electromagnetic difficulties. Therefore, problems can
torque, and electromagnetic radiation. The universal be solved using digitally enabled computers before
motor offered an increase in efficiency and torque for being carried out in the real world, saving time and
DC supply, and at AC supply, the universal motor money [31, 32]. In the midst of various numerical
has high electromagnetic field radiation. The authors methods, FEM is best suited for examining rotating
discussed the generalized modelling of the motor electrical machines because of its many advantages.
only and did not design the controller and other Simultaneously, the FEA tool could help designers
perspectives. and researchers in the realization of electromagnetic
calculations and simulating motor performance more
Li and Zhu [25] proposed a design strategy to precisely [33]. Numerical approaches can be used to
elucidate the effect of different design variables on solve real world electromagnetic problems. It may
the target using parametric analysis. A generalized take several attempts to incorporate parameter
system design solution has been discussed, but no in- changes into the machine's optimal design before the
depth study has been carried out. Liu et al. [26] and machine's performance is sufficient [34]. To perform
Tian et al. [27] presented the parametric analysis statics-magneto and electrostatic analysis with non-
technique that examined various issues, including linear materials, such as permanent magnets, steady-
thermodynamics, structural noise and vibration, state eddy currents, transient eddy currents, motional
thermal environment studies in buildings, and others. eddy currents, stress and thermal analysis, FEM-
Electromagnetic field analysis was carried out based tools have pre-processing and post-processing
laterally, which was responsible in determining other components. Analytical equations have been used to
stability factors on account of magnetic forces suggest numerous analytical models [35].
applied on the motor. Sharma and Manna [28] Researchers report that FEM has been used for
simulated the universal motor with AC and DC various machines; the universal motor can also be
supplies to analyze the torque-speed features along employed with this method. There are three main
with motor proficiency. The authors analyzed the steps to perform FEA.
performance of the motor based on torque and speed The first step in FEM is pre-processing where entire
geometrical domain and variable-based elucidation
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International Journal of Advanced Technology and Engineering Exploration, Vol 9(96)
have been completed. The model domain is The equivalent circuit diagram of the universal motor
discretized into several finite elements and nodal is shown in Figure 2. The operating conditions, i.e.,
equations that correspond to them are developed. voltage and current equations of universal motor, are
Processing is the second stage, during which the similar to DC series motor. The generalized
actual analysis or solution is completed. The mathematical equations related to the universal motor
necessary analysis mode is configured based on the have been discussed in this section. The field current,
dynamic or static loading conditions and the material and armature current are equal to supply current as
specifications like linear or non-linear analysis, mentioned in Equation 1.
model analysis, and static analysis. Following the I = I f = Ia (1)
definition of the software type or the solution state,
this step concludes with the implementation of the
actual solution [36−39]. The final stage is post-
processing, wherein software comprises elegant
procedures for selecting, printing, charting, and
comparing the outcomes acquired at the processing
level with analytical data. Following that, a junction
error analysis is performed. The outcomes are
presented in graphical, visual, or spreadsheet form
[33, 39].
3.1Power loss
Efficiency is the ratio of output to input powers, it is
depend on different types of losses, such as copper
loss, iron loss, mechanical loss, and brush loss. The
mechanical loss and brush loss are depended on speed
of the motor.
3.1.1Copper loss
The copper loss occurred when current passes
through copper conductors. The armature and field
winding losses are two types of copper losses.
Copper loss of armature and field winding can be
determined in Equation 7 and Equation 8
respectively.
Parm._cu = Ia2 Ra (7)
Pfield_Cu = If2 Rf (8)
3.1.2Iron loss
The alternating magnetization of the magnet core
causes iron losses, which is the summation of
hysteresis and eddy current loss. The eddy current
loss (Pe) and hysteresis loss (Ph) can be calculated by
using Equation 9 and Equation 10 respectively.
Pe = ke B2 f2 v (9)
Ph = kh Bn f v (10)
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International Journal of Advanced Technology and Engineering Exploration, Vol 9(96)
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Sudhir Kumar Sharma and Manpreet Singh Manna
Figure 10 Air gap flux density vs. rotor pole embrace factor plot
Figure 9 shows that the rated speed is maximum at varies inversely proportional to rated torque to
0.5 and minimum at 0.85. The air gap flux density is maintain constant power output. But after because
minimum at value 0.85 and maximum at 0.5 as model achieves a saturation point, so the efficiency of
shown in Figure 10. It should be noted that the the model 8 starts decreasing.
designer carefully needs to decide the limits of the
solution range since the motor efficiency will fall Some important graphs are discussed below when the
below 70% for value 0.5 to 0.65. model simulation was executed in the RMxprt.
Critical performance data such as efficiency versus
5.Discussion speed, output torque versus speed, and output power
The comparative analysis of the results in tabular versus speed, can be quickly calculated at the optimal
form is shown in Table 3. It shows that the efficiency point 0.8 of the model. These various graphs of the
has improved from 65.3% to 72.03%, with minimum model's performance are shown in the Figure 11,
losses in value 0.8. The rated speed at this point is Figure 12 and Figure 13, respectively.
1434.7 rpm with rated torque of 0.063 Nm and air
gap density of 0.21675 T. As pole arc increases, the The variation of the performance data is seen with the
surface area of pole increases, this implies increment variation of the speed. Figure 11 shows the efficiency
in pole embrace value, which affects the air gap flux of the motor decreases after rated speed and increases
density in decreasing manner. The decrement of air before rated speed. Figure 12 shows that output
gap flux density requires low current. This low torque is inversely proportional to varying with
current is responsible for less losses, affecting respect to speed. Figure 13 shows output power with
efficiency in an increasing manner. The rated speed respect to speed graph.
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Sudhir Kumar Sharma and Manpreet Singh Manna
ANSOFT
70.00 Curve Info
Efficiency
60.00
50.00
40.00
(%)
30.00
20.00
10.00
0.00
0.00 10000.00 20000.00 30000.00 40000.00 50000.00 60000.00
n (rpm)
Figure 11 Efficiency versus speed curve
ANSOFT
0.35 Curve Info
Output Torque
0.30
0.25
0.20
(N.m)
0.15
0.10
0.05
0.00
0.00 10000.00 20000.00 30000.00 40000.00 50000.00 60000.00
n (rpm)
Figure 12 Output torque versus speed curve
ANSOFT
120.00 Curve Info
Output Power
100.00
80.00
(W)
60.00
40.00
20.00
0.00
0.00 10000.00 20000.00 30000.00 40000.00 50000.00 60000.00
n (rpm)
Figure 13 Output power versus speed curve
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International Journal of Advanced Technology and Engineering Exploration, Vol 9(96)
The motor design created on RMxprt is transformed and stator of the motor at specific time of rotor
into Maxwell two dimensional (2D). At output power position. The magnetic field vector potential of the 2-
and rated speed, the optimal model design generated poles universal motor is shown in Figure 16. The
for the optimal embrace factor value derived from the flux density lines start from the north pole moving
optimization is subjected to 2D transient FEM towards the south pole of the motor having high
evaluations. The electromagnetic analysis is done density in the boundary at the motor pole. As a result,
with the help of Maxwell 2D. The magnetic flux the motor size is limited, and it is also ensured that
density distribution at a specific time of rotor position the motor does not function at a flux density close to
is shown in Figure 14. The magnetic field density of saturation. These criteria are necessary for thoroughly
the motor is approximately achieved and it can be examining ideal motor design characteristics. Figure
interpreted that the distribution is varied at various 17 shows the variation of induced rms current in a
positions of the motor. The magnetic field lines are winding of motor with respect to time. A complete
shown in Figure 15 at specific boundaries of rotor list of abbreviations is shown in Appendix I.
The main drawback is that the design rating of losses when the operating supply is AC as it has high
universal motor cannot go beyond 1kW with 2 or 4 reactance losses. As compared to other special
pole only. Its size is compact and used for small purpose motors, this particular motor has low
operations. The motor cannot run without load, and efficiency.
the starting speed is very high. This motor has high
1.00
0.50
Current(Coil0) [A]
0.00
-0.50
-1.00
-1.50
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00
Time [ms]
the motor is also realized with their directions and automotive engine start applications. In student
patterns. Further, we can select more than one conference on electric machines and systems 2019
variable to enhance the motor's performance and (pp. 1-5). IEEE.
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equivalent 4-pole universal motor. In international
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International Journal of Advanced Technology and Engineering Exploration, Vol 9(96)
Appendix I
S. No. Abbreviation Description
1 AC Alternating Current
2 BLDC Brushless Direct Current
3 DC Direct Current
4 FEA Finite Element Analysis
5 FEM Finite Element Method
6 IGBT Insulated Gate Bipolar Transistor
7 IM Induction Motor
8 LIM Linear Induction Motor
9 MOSFET Metal Oxide Semiconductor Field
Effect Transistor
10 PWM Pulse Width Modulation
11 RSM Rotor Surface Modification
12 SRM Switched Reluctance Motor
13 TRIAC Triode For Alternating Current
14 VSI Voltage Source Inverter
15 2D Two Dimensional
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