Design of a PM-Assisted Synchronous Reluctance Motor Utilizing Additive Manufacturing of Magnetic Materials

This paper presents a novel design for Permanent Magnet (PM) assisted Synchronous Reluctance (SynR) motors, where the rotor consists of alternate layers of PM and Soft Magnetic Composite (SMC) deposited on the rotor shaft using additive manufacturing. The proposed design eliminates the need for the bridges and/or center-posts. These features are essential for the rotor mechanical integrity in laminated SynR motors, but provide a path for performance-limiting leakage flux. Consequently, their elimination in the proposed design led to a superior torque, power and power factor compared to conventional SynR and PM-assisted SynR motors.