Design and Development of Reconfigurable PMSM for Stator Winding Turn Variation Investigation

Abstract

Permanent Magnet Synchronous Motors (PMSMs) play a central role in modern industries due to their high efficiency and torque density; however, experimental platforms that allow controlled variation of key electromagnetic parameters—particularly stator winding turns—are limited. This paper presents the design, development, and experimental validation of an electromagnetic module based on a laboratory-scale permanent magnet synchronous motor developed to investigate the influence of stator winding variation on torque characteristics. The research integrates analytical design, finite-element simulation, and controlled laboratory experimentation. A permanent magnet synchronous motor prototype was designed from first principles, covering magnetic loading, induced EMF, conductor sizing and winding distribution. A multitap stator winding arrangement was implemented, enabling the effective number of turns to be varied between 40 and 60 without physical rewinding. Finite-element model was developed using ANSYS to predict electromagnetic torque behavior, while experimental tests were conducted using an inverter-fed drive system. Simulation results revealed a non-monotonic torque response, with torque peaking at intermediate winding configurations, 23.29 Nm at 45 turns, before decreasing at higher turn counts, indicating the influence of electrical and magnetic constraints captured within the numerical model. In contrast, experimental measurements showed a stronger torque dependence on winding configuration, with torque increasing from 22.81 Nm at 40 turns to a maximum of 28.94 Nm at 55 turns, followed by a slight reduction to 27.27 Nm at 60 turns. The results confirm that stator winding variation is a dominant but multi-dimensional design parameter in permanent magnet synchronous motor torque performance and that optimal torque occurs within a finite winding range rather than through indefinite turn increase. The developed electromagnetic module serves as a flexible experimental platform for parametric studies in electric machine design, optimization and education.