PEDS2009

Harmonic Restraint Technique of Stator Core Shape and Non Uniform Air-gaped
Universal Motors for Vacuum Cleaner

Yuta Niwa Yuji Akiyama Tomokazu Naruta

Dept. of Engineering Dept. of Engineering Dept. of Engineering
Kanagawa Institute of Technology Kanagawa Institute of Technology Kanagawa Institute of Technology
Kanagawa, Japan Kanagawa, Japan Kanagawa, Japan
Yuuta_Niwa@TOSEI.toshibatec.co.jp akiyama@ele.kanagawa-it.ac.jp naruta.t@nifty.com

Abstract— This paper focuses on the restraint method of the 3rd

harmonics current, in which close attention has been paid to the II. APPLICATION OF POWER SUPPLY HARMONIC CURRENT
iron core shape of the universal motor for power vacuum RESTRAINT STANDARD
cleaners. In this paper, the gap permeance, magnetic saturation
of an iron core, and the influence that a slot ripple has on A. IEC Standard (international standard) and a JIS
harmonic current were verified using FEM electromagnetism Standard (in Japan)
analysis. As the result, stator core shape proved quantitatively
The targeted testing machine is targeting the vacuum
that a restraint of harmonic current has an effect. The authors
think assert that a design manual should be adapted to create an
cleaner of input voltage AC200V and 1.5kW of input electric
international standard about a restraint of the harmonic current power in this paper. As for the international standard about the
of a universal motor. harmonic current restraint applicable to this apparatus,
IEC61000-3-2 and "the limit value over the apparatus (below
Keywords-Universal Motor; Harmonic Current; Core Shape; the input 16A) connected to a general low-voltage power
Vacuum Cleaner distribution system" correspond. However, the limit value
under the supply-voltage 220V is not prescribed by IEC61000-
I. INTRODUCTION 3-2.
Today, many electronic apparati are driven by an inverter to In Japan, two or more guidelines related with a harmonic
achieve high efficiency. As a result, under the influence of a current restraint were published. Then, JIS-C-61000-3-2
capacitor input type commutation circuit, a big current "Electromagnetic compatibility (EMC)-Part 3-2: Limits-Limits
distortion arose for the electric power system, and serious for harmonic current emissions (equipment input current ≦
problems, such as a transformer and a phase advance capacitor 20A per phase)" was enacted in 2003. This aims at consistency
by fire, have occurred big damage. The regulation of harmonic with an international standard in Japan where the electric
current restraint represents an international problem. power base differs from Europe.
In this paper, we explore the restraint technique of the
B. Application of IEC Standards
harmonic current of a universal motor. The harmonic restraint
technique described in this paper is didn’t use of neither a First, application of the harmonic restraint standard in this
reactor nor an active filter. We did study on the harmonic paper is defined. In this paper, since the target universal motor
restraint which paid its attention to the iron core shape of a assumes use with a vacuum cleaner, it applies the vacuum
universal motor. This is verifies quantitatively gap permeance, cleaner of IEC61000-3-2. A vacuum cleaner is classified into a
iron core saturation, and the influence of a slot and pole shape classification "Class A" of apparatus in this.
ripple. The harmonic current limit value of Class A is shown in
The result proved quantitatively that a harmonic restraint Table 1 here. In this paper, it is satisfied with a motor only, the
has an effect according to expansion of an air gap size on the substance of these harmonic current limit values, and aims at
pole edge, and the conditions of stator magnetic pole shape and showing the design manual which suppresses performance
the iron core quality of the material. Therefore, the authors reduction to the minimum. In addition, by the standard, which
assert the iron core design manual of the universal motor about apparatus with the regulating function of power consumption is
a harmonic restraint which carries out international standard described to set the degree of phase angle as 90±5 degrees.
conformity was able to be shown. In addition, the targeted However, in this time, the target is only the of sine wave drive.
model machines are input 1.5kw and a 33,000rpm high-speed
mass universal motor for cleaners.

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C. Calculation of Harmonic Currents
The measurement apparatus of the harmonic current is
specified to IEC61000-3-2. In this paper, it is necessary to
evalutate the distortion of the waveform of the current obtained
by FEM analysis. Analysis value and an actual measurement
computed harmonic current with the discrete Fourier transform
(DFT) which shows the obtained current wave form in
equation (1) are used.

1 N −1 ⎛ 2π ⎞
ck = ⋅ ∑ xi ⋅ exp⎜ − j ki ⎟ , k = 0,", N − 1 (1)
N i =0 ⎝ N ⎠

III. SIMULATION OF THE HARMONIC CURRENT USING FEM

ELECTROMAGNETIC FIELD ANALYSIS

A. Outline of an Object Machine

The sectional view of the iron core of the universal motor Figure 1. Cross section of universal motor’s core.
used for this analysis is shown in Fig. 1. This design
dimensions and rating are shown in Table 1. The Slot
combinations are 22slot/2pole, and the total numbers of
commutator segments are 22 bars. Moreover, the armature TABLE I. MOTOR’S SPECIFICATION.
winding is lap winding. (Refer to Fig.2). Moreover, the spatial
relationship of Raiser and winding has placed the brush at the Input Voltage 200 V / 50 Hz
neutral point when a magnetic field system is the weakest Input Max Power 1,500 W
including armature reaction. Table 1 reveals that this motor is
Rotational Frequency / min. 33,000 r/min
considerably more high-powered than a Japanese standard
Field Winding φ0.5_106Turn / Pole
cleaner motor (inputs 900W and 100V) for home use. The
motor used in this experiment is a high-output cleaner of 200V Armature Winding φ0.4_30Turn / Slot
system, commonly used in Europe and the U.S.. These are Air Gap 0.5 mm
equivalent to a business-use cleaner in a Japanese market. In Core Thickness 21.0 mm
Japan, although there is no track record in 200V power supply; Iron Core Material Silicon Steel Plate (50A1300)
however, it is a standard system type in Europe and America.

Stator
Field Coil

Main Pole
Brush_A Brush_B Rotation
Commutator segment No.1～ 22
22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Tooth

Armature Coil : a-v

o p q r s t u v a b c d e f g h i j k l m n o

Figure 2. Figure of armature winding & brushes and pole’s arrangement.

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B. Analysis Method stator magnetic pole, and gap length. The problem of
This analysis simulation became the coupling analysis of commutation sparks or EMC is later explored in this analysis.
the iron core geometric model and external circuit which was It is asking for change of the leakage inductance of the coil in
taken in as a state variable. a slot by the position of the overlap condition of a slot and a
First, model is made with the finite element method in the magnetic pole, or armature winding are used linear analysis at
state element shown in Fig. 3, and considering the spatial the given degree of rotation angle θ of an armature. The
relationship of the space. Moreover, the external circuit shown simulation of the all of the 22 pieces of coil in a slot, shown in
in Fig. 4 is equivalent to the circuit composition of all universal Fig. 3 and Fig. 4, is carried out by forcing a rotation at a small
motors. The relations arrangement and number of rotations of angle ( ⊿ θ = 1 deg.) within every core. With the
an external circuit and an iron core geometric model have been conventional method, slot opening and magnetic pole shape
preestablished. Furthermore, the voltage equation by are taken in the shape of the state variable of a gap face by this
electromagnetism circuit combination (which added the
method to dealing with magnetic flux density as fixed. And,
conditions of equation (1)) has been formed. The details are
given below: since the simulation is carried out to revolving speed ω, most
important changing factors considered on a design have been
di ⎧RT ⎫ RT taken into account. And it is asking for magnetic flux density,
L + iR+ ⎨ b ⎬(I + i) − b (I − i) + ec = 0 (1) remains magnetic flux, or induction voltage in finite-element-
dt ⎩T − t ⎭ t
method by electromagnetic field analysis.
Here, it is R=Rc+R1 (Rc is coil resistance, Rl is resistance of In addition, FLUX-2D of this laboratory and the Grenoble
the lead which conducts a coil to a commutator bars.). T is the University (France) (CEDRAT) of the joint research point and
value which shaped brush width, and is divided by speed of Ver.7.6 are used for this analysis.
the commutator or the commutation cycle, and t is time
(second). ec represents the electromotive force "commutation
electromotive force" by a commutation.
Equation (1) is the first order differential equation, and L, R,
and T are circuit constants and time in this formula. Moreover,
t and i are variable constants, although it is not a variable: here, f
e g
the portions related to change of a state variable are the 3rd d n o p h
m q
term and the 4th term. That is, the contact resistance Rb of a c
l o
p q r
s r
i

n 16 17 18 19
brush is expressed in the shape of a temporal response. In this k b m
14
15 20
Rotation 21
t
u
s
j

analysis, it is considered as change of brush part resistance of j a

Brush_B →
l 13
12 No.
Commutator 1
22 v t k
← Brush_A
k Segment No. a
the external circuit shown in Fig. 4 means contact of the brush v i
j
11
Armature
10 a- v Coil No. 3
2
b
l u
9 4
h
contact resistance. The contact surface product of a brush and u
g
i
h
8
7 6
g
5 c
e
d
a
m
v
f
a commutator bar carries out modeling as brush contact t
f b
n

s e d c o
surface product change, which shows signs that it changes by r q p

the rotation angle θ in Fig. 5 (a). If this contact surface product

is treated in the form of a differential equation as a temporal
response by rotation angle degree θ=ωt of an armature, it will
change, as shown in Fig. 5 (b). In addition, contact resistance
changes with the reciprocal of this contact surface product.
L of equation (1) is the inductance of a commutation coil, Figure 3. Figure of armature winding, brush, pole’s arrangement
and is computed in finite-element-method, magnetic field
analysis from the shape and material characteristics of an iron
Brush 【Voltage Source】
core, or the number of turns of winding. In addition, the n=22 Magunitude of the variation
: AC220 Volt
normal magnetization curve is used for the nonlinear of the
Field Coil Voltage Source Field Coil

Frequency : 50Hertz
Armature Coil
【Brush】
iron core to simplify our analysis. Moreover, the induced ON state resistance
: 0.2 or 11 Ohm
voltage generated in a commutation coil becomes a relation of OFF state resistance
: 1,000,000 Ohm
Brush opening angle
equation (2). Usually, there are two types divided, roughly : 16 Degree
V

Commutator segment angular position

into the speed electromotive force of the 1st terms, and the : 16.363636× segment No. Degree
Commutator segment opening angle
: 14.2 Degree
transformer electromotive force of the 2nd terms: 【Field Coil】
Number of turns : 106

⎛ dφ di ⎞
D.C. resistance : 0.84 Ohm/ Pole
di
e = −L =− ⎜ + ⎟
【Armature Coil】
(2) Commutator Segment
Number of turns : 15

dt ⎝ dθ dt ⎠
D.C. resistance : 0.13 Ohm/ Slot
n=22

This first term changes with magnetic resistance that

change of a air gap parmiance; harmonic current and Figure 4. External Circuit figure for universal motor simulation
commutation sparks are influenced by slot shape, shape of a

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θ bru Brush opening angle
Commutator segment 3

Harmonic Current [A]

Brush
θ pos angular position
θbru + θ bar (x) (y)
versus brush position Limits for (x) : Simulated results
θbru − θ bar 2.5
1 Class A equipment
G= (y) : Measured results
Ron 2
Commutator
θ bar segment opening
1.5
angle
1
Commutator segment Roff − θ pos − θ pos + 360 θ
1
0
Slide contact line
0.5
(a) Contact condition of (b) Modelling figure of 0
modelling figure Contact area & resistance 3 5 7 9
Harmonic Order

Figure 5. Modelling figure’s of brush and commutater bar’s change of Figure 7. Frequency analysis result of harmonics current
contact resistance

IV. THE RESTRAINT TECHNIQUE OF HARMONIC CURRENT

A. Air-gap Size
C. Steady Operation Analysis and Harmonic Current
The analysis figure model which made the air gap size and
Analysis of the Universal Motor the parameter is shown in Fig. 8(a). This is a common
In order to conduct harmonic current analysis, it is technique used in Europe to suppress a steep current distortion
necessary to compute input distortion correctly. In this paper, by taking a large gap on the pole edge size, and satisfies an IEC
analysis model which took into consideration strictly the standard. However, generating torque becomes problematic.
various factors in the operational status of a universal motor Harmonic current came to be shown in Fig. 8(b), and when the
was conducted. The power supply voltage of the universal air gap size was 1.0mm or more, that result a EMC’s standard
motor is rotating at 33,000rpm, the actual measurement of value could be satisfied was obtained.
current, and an analyzed value are shown in Fig. 6. When
compared with measured and in this harmonics componential
analysis, it was well in agreement. (a) 0.5 mm
(b) 1.0 mm
(c) 1.5 mm
300 15
Voltage
200 10
Current
Current [A]
Voltage [V]

100 5

0 0
65
°
-100 -5
10msec
-200 -10

-300 -15 (a) Shape of analysis model

(a) Measured results
3
300 15
Harmonic Current [A]

(a) (b) (c) Limits for Air Gap Width

2.5
Voltage Class A equipment (a) : 0.5mm
200 10 2 (b) : 1.0mm
Current (c) : 1.5mm
Current [A]

1.5
Voltage [V]

100 5
1
0 0
0.5
-100 -5 0
10msec 3 5 7 9
-200 -10 Harmonic Order

-300 -15 (b) Analysis result of harmonic current

(b) Simulated results
Figure 8. Change of the harmonic current at the time of changing the length
of an air gap
Figure 6. Voltage and current waveform (control angle = 0 deg.)

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B. Non-linear Air Gap Shapes
The model which changed the stator pole shape of the air
gap part ion to Fig. 9(a), and compared it with it is shown. The (d) 1.0 mm
analyzed result of harmonic current was shown in Fig. 9(b),
and the difference was insubstantial. The harmonic current (e) 2.0 mm
resulting from a slot ripple reflects a very high frequency. (f) 3.0 mm
Therefore, it does not influence in the number region of low
frequency waves. Our team hypothesizes that the harmonics of
a lower degree will not be greatly affected. Moreover, in the
separate torque analysis conducted by our team, the mitigation
effect of the torque ripple which aligned with Rota Tooth’s
cycle was accepted. From this result, the non-linear gap shape
of a stator pole can be expected cause reduction of a torque 65
° Airgap
ripple.
0.5mm

(a’ ) non uniform (a) Shape of analysis model

airgap
(0.5mm～ 1.4mm)
(a) uniform airgap 3
(d) (e) (f)

Harmonic Current [A]

(0.5 mm) Limits for Stator Teeth Width
2.5
Class A equipment
(d) : 1.0mm
2
(e) : 2.0mm
1.5 (f) : 3.0mm
1
0.5
0
65 3 5 7 9
° Harmonic Order
(b) Analysis result of harmonic current

Figure 10. Change of the harmonic current at the time of changing the stator
pole tip’s thickness
(a) Shape of analysis model

3
D. Influence by Iron Core Material
(a) (a') The influence on the harmonic current at the time of
Harmonic Current [A]

2.5
Limits for Air Gap Form
Class A equipment (a) : Non Uniform Gap changing iron core material into 50A1300 from the silicon steel
2 (a') : Uniform Gap plate 50A800 was also considered in our research. In addition,
1.5
the analysis models are gap shape such as 0.5mm of air gaps,
1 and 1.5mm of stator chips. By the harmonic current that result
0.5 in this analysis is shown in Fig. 11. It is more possible by using
0 the iron core material of high Bmax iron core, then to raise a
3 5 7 9 torque characteristic than this result. As expected, this has an
Harmonic Order effect of a restraint of harmonic current. Our results show that
iron core material and quality has a drastic impact on harmonic
(b) Analysis result of harmonic current current, and should be considered along with cost.

Figure 9. Change of the harmonic current at the time of changing the length 3
Harmonic Current [A]

of unequal Air gap (g) (h) Limits for Core Material

2.5
Class A equipment (g) : 50A800
2 (h) : 50A1300
C. Stator Teece face Geometry 1.5
The analysis model figure which made thickness of the 1
stator pole the parameter is shown in Fig. 10(a). This figure 0.5
considers the influence on the harmonics of the magnetic
0
saturation phenomenon at the tip of a stator pole. A large pole 3 5 7 9
angle is seen here, as well as the magnetic saturation at the pole
Harmonic Order
tips, suggesting a reduction of the harmonic current. However,
since the magnetic saturation phenomenon at the tip of a stator Figure 11. Change of the harmonic current at the time of changing the core
chip indicates an improvement of a commutation phenomenon materials
has an effect, caution and further research are required.

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V. CONCLUSIONS REFERENCES
In this paper, we consider the influence of the core shape [1] Yuji Akiyama, Toshiyasu Takura, Yuta Niwa : “A study about Core
and iron core material upon the harmonic current. The shape Design of 200V Lines for Vacuum Cleaner Universal Motor”, The
paper of Technical Meeting on Rotating Machinery, IEE Japan,
valuation basis was based on the IEC standard. No.RM03-137, pp.7-12 (2003) (in Japanese)
The evaluation technique was examined using FEM [2] S.Suzuki, K.Kurihara, H.Nase, K.Takahashi : “RF Noise Associated
electromagnetism analysis. Our strict analysis utilized various with Time Varying Arc Current across Brush and Commutator in
Universal Motors”, T.IEE Japan, Vol.118-D, No.6, pp.773-779 (1998)
functions, such as brush contact resistance which changes with (in Japanese)
rotation, in FEM electromagnetic analyzed by FLUX-2D○R . We [3] H.Koharagi, K.Tahara, Y.Ishii, S.Suzuki : “Application and Evaluation
also took into account variated state functions, such as brush of Commutation Performance with an Exceptional Armature Winding
contact resistance commutation phenomena and used iron core, Form for Small Universal Motors”, T.IEE Japan, Vol.115-D, No.4,
etc. As a result, the power supply current distortion wave form pp.488-494 (1995) (in Japanese)
was able to obtain the waveform was very similar to an actual [4] Yuta Niwa, Mithuhito Kawamura, Yuji Akiyama : “Request of
technological points for vacuum cleaner motor in 200V system”, The
measurement. paper of Technical Meeting on Rotating Machinery, IEE Japan,
In this paper, our team was able to show quantitatively that No.RM04-168, pp.45-50 (2004) (in Japanese)
a restraint of harmonic current has an effect under the influence [5] R. Richter : Elektrische Maschinen Ⅴ (1950)
real iron core shape and the quality of the materials. Although [6] IEC 61000-3-2, Electromagnetic compatibility (EMC) Part 3-2: Limits
for harmonic current emissions (equipment input current ≦ 16A per
it corresponds by addition of a reactor, etc. conventionally in phase)
many cases, naturally there is a problem of increased cost.
Therefore, current harmonics are controlled by the design of
iron core shape. The balance of a restraint of operation
characteristics and harmonic current should be maintained. By
using the methods mentioned above, we assert that iron core
shape and performance (considering cost optimization) should
be implemented into the design process.

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