In this paper an investigation into an alternative topology for reluctance synchronous machine rotor flux barriers is presented. The investigated topology employs a high number of flux barrier variables with an alternative asymmetric rotor structure. The focus in the paper is on maximising average torque and minimising torque ripple, using finite element-based design optimisation, in order to study the possibility of achieving acceptably low torque ripple. A subsequent investigation into the effect of rotor skew on the proposed optimised design to reduce torque ripple even further is also conducted, as well as the manufacturing and testing of the proposed flux barrier prototype.
I. INTRODUCTIONWith the increasing emphasis on efficiency and cost reduction, the interest in reluctance synchronous machines (RSMs) has grown during the past decade. This interest is driven by not only the robustness, efficiency and simplicity of RSMs, but also by the fact that the cost of rareearth magnets is increasing and their market stability is decreasing.The main focus of most RSM design optimisation, depending on application, is on maximising average torque (T A ), within the limits of an allowable volume, and minimising torque ripple (T R ). The latter is conventionally achieved by rotor skewing and stator cording in order to reduce the air-gap harmonics that produce a high T R . In this paper, the possibility of both maximising T A and minimising T R without implementing rotor skew techniques to achieve acceptable T R values is investigated. A further investigation into the effect of rotor skew on the proposed topology to reduce T R values even further is also presented.A large part of the design of RSMs is focused on the rotor creation, and more specifically the type of flux barrier topology and its creation procedure. With the latter in mind, two creation techniques are summarised by Vagati [1], the first of which implements generalised lumped-parameter modelling of the rotor magnetic circuit and the second, a numeric design optimisation of a rotor flux barrier structure.The second procedure is implemented in this research. This procedure is based on a predetermined basic barrier structure with a fixed number of variable parameters, such as barrier tip angle and barrier width. These parameters are numerically optimised by implementing a finite element method (FE) package that calculates each iteration's relevant machine performance parameters, for example torque and torque ripple. Examples of this design procedure can be found in [2]-[5]. The advantage of this approach is that the optimisation inherently takes complex phenomena, such as torque harmonics and cross saturation, into account.In RSM design, three basic rotor topologies have emerged with combinations and small variations between specific