Permanent Magnet Machine Design Boot Camp Internal PM, Surface PM, and Brushless DC

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Course Overview

Permanent magnet (PM) electrical machine design is one of the most important skill sets needed to stay competitive in the motors and generators industry. This intensive course covers the design of several types of PM machines, including internal PM, surface PM, and brushless DC machines. You will gain essential information on the various types of PM machines used in traction motors, industrial motors, aerospace motors, appliance motors, and generator designs.

Who Should Attend?

This course will benefit those whose work requires PM machine design knowledge, especially engineers involved in the design, specification, and integration of components and systems.

  • Electrical engineers 
  • Mechanical design engineers 
  • Project engineers, program managers 
  • Technical managers and supervisors 
  • System integrators

Course Outline

Introduction to PM Machine Design

  • Surface PM
  • Internal PM
  • Brushless DC
  • PM assisted

PM Machine Terminology and Important Definitions

PM and PM Machine Modeling

  • Review of Br, Hc, and energy density of magnet types
  • Equivalent circuits for PMs
  • PM machine modeling

PM Machine Power and Torque Equations

  • PM torque and reluctance torque components
  • Equivalent circuits
  • Vector diagrams

Permanent Magnet Fundamentals and Trends

  • Energy density, remnant flux, and coercive force
  • Temperature effect
  • Losses
  • Price trends
  • Pros and cons of each magnet type for machine design

Advances in Magnetic Materials Technology

Sizing Equations for PM machines

  • Electric loading
  • Magnetic loading
  • Shear stress

Surface PM Machines

  • Design and analysis

Brushless DC Machines

  • Design and analysis

Internal PM Machines

  • Design and analysis of interior PM machines
  • Flux weakening and fault-tolerant design of PM machines
  • Distributed vs. concentrated windings in PM machines
  • Computer-based design optimization of PM machines

Thermal Analysis – Cooling and Ventilation Systems

  • Conduction, convection, and radiation
  • FEA, CFD, lumped-parameters equivalent-networks
  • Fan ventilation, liquid cooling

Noise, Vibration, Structural Issues of PM Machines

Manufacturing of PM Machines

  • Laminations, cores, windings, frames, assemblies
  • Material and manufacturing tolerances

Finite Element Analysis of PM Machines

  • Fundamentals
  • Examples

Examples of PM Machines for Traction Drives

  • Tear down examples from Oak Ridge National Lab

Design Considerations for the Realization of PM Motors

PM Machine Design for Loss Minimization Control

PM Machine Design for Self-Sensing Control

PM Assisted Synchronous Machines

  • Design
  • Finite element
  • Optimization

Special Topics

  • Axial flux PM machines
  • PM flux switching machines


Timothy Burress

Tim Burress, Electric Machines Team Leader, Oak Ridge National Laboratory, Oak Ridge, Tennessee. Burress has led developments of motor controls and drives as well as comprehensive dynamometer evaluations for over 10 years. He also leads novel machine design projects for transportation applications.

Michael Harke

Michael received his BS, MS and Ph.D. in Mechanical Engineering from the University of Wisconsin – Madison in 1997, 1999 and 2006, respectively. His research focused on control theory, electric machines and power electronics. During his studies, he worked with numerous companies including Whirlpool, Ford Motor Company, Schneider Electric, International Rectifier and Hamilton Sundstrand.

In 2006, Michael joined Hamilton Sundstrand in the Applied Research Department where he worked on motor control and power electronics for aerospace applications including motor drives and actuators. Between 2010 and 2013 he was with Danfoss Power Electronics where he focused on industrial motor control. He has since returned to Hamilton Sundstrand, now known as UTC Aerospace Systems. He is also an Adjunct Professor at the University of Rome La Sapienza, teaching coursework on dynamic analysis and control of ac machines.

Michael is a member of the Institute of Electrical and Electronic Engineers where he serves as the Past Chair of the Industrial Drives Committee and society representative to the Sensors Council AdCom for the Industry Applications Society. He was the Technical Program co-Chair for the IEEE Energy Conversion Congress and Exposition 2013. He has published 25 papers in conferences and journals and has 8 patents.

Dan Ionel

Dan M. Ionel, PhD, FIEEE, is currently Chief Engineer for Regal Beloit Corp., and Visiting Professor at the University of Wisconsin in Milwaukee. After completing post-doctoral research in the SPEED Laboratory, University of Glasgow, UK, Dr. Ionel worked in industrial R&D for large corporations in the UK and the US, most recently as Chief Scientist for Vestas. His design experience covers a wide range of electric machines and drives for various applications with power ratings between 0.002 hp and 10,000 hp. Dr. Ionel published more than 100 technical papers, including two winners of Best Paper Awards from the IEEE Industry Applications Society Electric Machines Committee, and holds more than 30 patents. An IEEE Fellow, he is the Chair-Elect of the IEEE Power and Energy Society Electric Motor Sub-committee, Chair of the Milwaukee IEEE Power Electronics Chapter, and Editor-in-Chief of the Electric Power Components and Systems Journal.

Thomas Jahns

Thomas M. Jahns is a Professor with the Department of Electrical and Computer Engineering at the University of Wisconsin–Madison. Previously with GE Corporate R&D and Massachusetts Institute of Technology, Jahns has research interests in electric machines, drive system analysis and control, and power electronic modules.

Gianmario Pellegrino

Gianmario Pellegrino, an Associate Professor with the Politecnico di Torino, Italy. He has been a guest researcher at Aalborg University, Denmark, a visiting fellow at Nottingham University, UK, and an honorary fellow at the University of Wisconsin-Madison, USA. His research interests include the design of electrical machines and the control of electrical drives.

Aaron Williams

Aaron Williams is the Director of Engineering with Arnold Magnetic Technologies. He has 10 years experience in the magnetics and motors industry. He has a BS in Mechanical Engineering from the Rochester Institute of Technology and an MBA from the Simon School of Business at the University of Rochester. He is an active participant in the Motor and Motion Association (SMMA), Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC), and other industry related organizations.

Bulent Sarlioglu

Bulent Sarlioglu is a Jean van Bladel Associate Professor at University of Wisconsin–Madison, and Associate Director, Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC). Dr. Sarlioglu spent more than ten years at Honeywell International Inc.’s aerospace division, most recently as a staff system engineer, earning Honeywell’s technical achievement award in 2003 and an outstanding engineer award in 2011.  Dr. Sarlioglu contributed to multiple programs where high-speed electric machines and drives are used mainly for aerospace and ground vehicle applications. Dr. Sarlioglu is the inventor or co-inventor of 20 US patents and many other international patents. He published more than 200 journal and conference papers with his students. His research areas are motors and drives including high-speed electric machines, novel electric machines, and application of wide bandgap devices to power electronics to increase efficiency and power density. He received the NSF CAREER Award in 2016 and the 4th Grand Nagamori Award from Nagamori Foundation, Japan in 2019. Dr. Sarlioglu became IEEE IAS Distinguished Lecturer in 2018.  He was the technical program co-chair for ECCE 2019 and was the general chair for ITEC 2018.  He is serving as a special session co-chair for ECCE 2020.



Ian Brown

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Bulent Sarlioglu

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