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Analytical Model for Predicting Effects of Manufacturing Variations on Cogging Torque in Surface-Mounted Permanent Magnet Motors

In a mass production environment, due to the manufacturing tolerances, additional orders of cogging torque are created in addition to the fundamental components. The tolerances lead to asymmetry conditions both in the rotor as well as in the stator. Finite-element models can be used to analyze the cogging generated due to these asymmetries. However, it is extremely time consuming to study this uneven geometry numerically since periodicity and symmetry conditions cannot be used to reduce the model. Moreover, the experimental verification of all possible variations would be very challenging, as it would require part dimensioning, part sorting, a large quantity of motor builds, and finally testing of all samples. Therefore, in this paper, an analytical model is presented to study the effect of such imbalance on the cogging torque. The model is validated against finite-element models and also with experimental results.