Permanent magnet synchronous machine using ferrite vs rare earth magnets : how do they compare?

Abstract: Permanent magnet synchronous machines (PMSM are considered as viable options for automotive and traction applications. Rare earth magnets such as Neodymium Iron Boron (NdFeB is the most common choice in the PMSM for electric vehicles to achieve high power density machines. However, rare earth magnets are problematic from ethical and sustainability perspectives. From these perspectives, there are better magnet alternatives, such as ferrites. Ferrite magnets are well known for lower environmental impact, abundance and low cost. Due to a lower residual flux density of a ferrite magnet than that of a rare earth magnet, a larger amount of ferrite magnets are needed to achieve the same performance. This master thesis is aimed to compare a PMSM using NdFeB magnets with a PMSM using ferrite magnets in terms of different parameters such as torque production, power factor, drive cycle efficiency, losses mapping, cost, and environmental impact. The machines are designed based on the Volvo XC40 vehicle requirements. In order to compare both the machines, ferrite based machine with different types of rotor structures such as arc and spoke type configurations are designed in Ansys Maxwell and compared with the reference PMSM holding NdFeB magnet. The demagnetisation study was performed on the ferrite magnets at lower temperature in order to investigate the feasibility of the design. In order to reduce the risk of demagnetisation, a parametric analysis of the rotor structure has been conducted. Furthermore, the mechanical integrity was investigated at top speed.