Line start radial flux permanent magnet synchronous motor design and prototype manufacturing

In this thesis, the design of IE4 Super Premium Efficiency class Line Start Radial Flux Synchronous Motor has been designed according to IEC-60034-30-2:2014 standard. In the design process, the IE2 High Efficiency class asynchronous motor, which is already offered to the industrial market, has been remodeled by adding a permanent magnet to the rotor. In the modeling process, a new rotor topology with two different slot types and surface permanent magnets is proposed. Analytical methods were used to design a motor in the proposed topology. Geometric optimization has been done by using Genetic Algorithm in the obtained design. In order to reduce torque ripples, which is an important problem in motors with permanent magnets, a skewing stator structure is used in the design. In the determination of the motor performance, a validated, finite element analysis software was used. In order to verify the obtained data, the prototype production of the final motor design with rotor structure has been made in the proposed topology. As a result, a new Radial Flux Synchronous Motor has been designed and designed to replace asynchronous motors available in pumps and fans such as pump and fan, which can work with higher efficiency and power factor by connecting directly to line and with the same asynchronous motor body structure in the same power as the completed thesis study. In addition, it has become possible to use the innovative rotor design obtained as a result of not changing the body structure of the existing IE2 motor to make the low power standard asynchronous motors with the same power more efficient.