Design Considerations on E-core for Modular and Scalable Permanent Magnet Synchronous Machine

In electrical machines, the modularity by making the stator in multiple parts brings many advantages. The ability to create machines of different power using the same E-cores,to be scalable, is very important in terms of production and transportation costs. In this study, E-core design for a modular and scalable PMSG is discussed. E-core dimensions are determined by considering magnetic and electrical loading, magnetic coupling, torque ripple, cogging torque, voltage harmonics, etc. apart from enabling the creation of different slot/pole combinations. Core and magnet sizes are determined analytically and FEM analysis of two selected models have been performed. Prototypes of machines with slot/pole combinations of 24/22 and 48/46 and rated power of 2.5kW and 5kW respectively have been manufactured with the same E-cores.