The efficiency of permanent-magnet (PM) synchronous machines with outer rotor and concentrated windings is investigated as a function of the mass of magnets used, keeping the power, volume, and mechanical air-gap thickness constant. In order to be useful for electric vehicle motors and wind turbine generators, the efficiency is computed in wide speed and torque ranges, including overload. For a given type and amount of magnets, the geometry of the machine and the efficiency map are computed by analytical models and finite-element models, taken into account the iron loss, copper loss, magnet loss, and pulsewidth-modulation loss. The models are validated by experiments. Furthermore, the demagnetization risk and torque ripple are studied as functions of the mass of magnets in the machine. The effect of the mass of magnets is investigated for several soft magnetic materials, for several combinations of number of poles and number of stator slots, and for both rare earth (NdFeB) magnets and ferrite magnets. It is observed that the amount of PM material can vary in a wide range with a minor influence on the efficiency, torque density, and torque ripple and with a limited demagnetization risk.
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