Characteristics of PMSM with Sm<sub>2</sub>Fe<sub>17</sub>N<sub>3</sub>/Fe<sub>16</sub>N<sub>2</sub> Hybrid Bonded Magnets

This paper presents an investigation into the performance of a surface-mounted permanent magnet synchronous motor (PMSM) utilizing Sm2Fe17N3/Fe16N2 hybrid bonded magnets, developed as an alternative to traditional rare-earth-based magnets. The study aims to address the challenges associated with the high cost and supply chain vulnerabilities of rare-earth materials like neodymium and dysprosium. The motor's torque, efficiency, and losses under various loading conditions are evaluated by applying three-dimensional finite element method (3D-FEM) simulations and conducting experimental validation using a prototype motor. The experimental results closely align with the FEM simulations in terms of torque and efficiency, especially after a 40 mN·m load. However, discrepancies in iron losses are observed, with experimental values being approximately 2.5 W higher than FEM predictions. This variance is attributed to factors such as the rotor's overhang structure and the building factor of the motor core. Additionally, the study demonstrates that optimizing the magnet's properties could lead to a 32% increase in torque output. Future work will focus on improving magnet performance and refining FEM models for more practical applications.