Effect of Hall Errors on Electromagnetic Vibration and Noise of Integer-Slot Inset Permanent Magnet Synchronous Motors

effect of Hall errors on electromagnetic vibration and noise of integer-slot inset permanent magnet synchronous motors (PMSMs) is investigated in this article. First, the rotor position estimation error caused by Hall errors is introduced. Then, the influence of Hall errors on phase current is theoretically deduced and verified through simulation and experimental data. The results show that Hall errors not only affect the amplitude of the fundamental current but also introduce (6k +/- 1)th and (6k +/- 3)th current harmonics. Subsequently, the spatiotemporal distribution characteristics of the electromagnetic force are analyzed and validated via an electromagnetic model. It is found that the (6k +/- 1)th current harmonic will affect the amplitude of the original force harmonics, while the (6k +/- 3)th current harmonic will produce extra frequency components of the electromagnetic force. The change of electromagnetic force will further affect the vibroacoustic performance of the motor. Finally, the electromagnetic vibration and noise with/without Hall errors are compared through a numerical method, which is verified via the vibration and noise tests, and the influence laws of Hall errors are clarified through analysis of the dominant electromagnetic force and structural mode. This study lays a foundation for the source identification and reduction of electromagnetic vibration and noise of integer-slot inset PMSMs in electric vehicles.