Design of Intersect Consequent Pole Rotor for a Radial-Flux IPMSM to Reduce Rare-Earth Magnet Usage

Interior Permanent Magnet Synchronous Motors (IPMSMs) are widely used in the electrification sector; however, reliance on rare-earth magnets imposes constraints stemming from supply instability and mining-related environmental impacts, raising sustainability concerns. To address these issues, this study investigates an IPMSM employing a consequent pole (CP) structure, in which one permanent magnet pole is replaced by iron. Because flux asymmetry in CP IPMSMs can cause torque ripple and associated vibration and noise, we propose an Intersect Consequent Pole (ICP) rotor geometry and evaluate it against a conventional IPMSM under identical stator conditions. The proposed ICP topology reduces permanent magnet usage and provides a rare-earth-reduced design alternative that addresses the vibration/noise trade-off, with a particular focus on electric power steering (EPS) applications. Electromagnetic characteristics and performance were analyzed using finite element analysis (FEA) and verified via FEA-based comparisons.