Integrated high-speed PMSM drive with IMS PCB-technology for mobile applications

The design of a permanent magnet synchronous machine with an integrated control and power circuit for sensored field oriented controlled (FOC) operation at a high power density is presented in this paper. To cool down the switching power transistors inside the machine, a single sided insulated metal substrate (IMS) PCB is used for thermal coupling of the power components with the housing of the PMSM by mounting them onto the motor end shield. The most common application field for IMS PCB-technology is the lighting industry with their power LEDs [1]. The utilization in a compact PMSM drive system is a novelty. For the angle and current measuring, the FOC-algorithm calculation and the excitation of the power transistors, a piggyback control PCB is also integrated. The system size and the voltage level are based on application standards for handheld power tools. The paper introduces the machine and PCB design of this new compound system and investigates power limitations and curve progressions such as speed, power and efficiency over torque. Also research on thermal distributions of the drive system are considered.