The impact of the self-sealing coolant channel across the stator core on the electromagnetic performance of the permanent magnet motor

For avoiding the damage of the insulation and permanent magnet, the temperature rise of the PMSM (permanent magnet synchronous motor) should be controlled strictly, it is usually one of the main objectives during improving the output power and torque density beyond the state-of-the-art in motor design. In this research, the coolant channel will be placed within the yoke of the stator core to enhance the heat transfer between the stator core and the coolant. Hydrophobic coating is applied to replace the metal tube for increasing the utilization of the cross area of the coolant channel. The impact of the coolant channel on the performance of the permanent magnet motor is analyzed. A general design method of the coolant channel is presented. The result shows that the change of the stator core loss is within about 10% as the coolant channel is moved away from the slot along the radial direction while the back electromotive force of the motor could keep constant through appropriate design. The impacts of the coolant channels on the magnet performance and the heat dissipation performance could be divided completely with the design method. The method can be applied on various PMSM including SPM (surface-mounted permanent magnet motor) and IPMSM (interior permanent magnet synchronous motor). Sufficient coolant flow could be provide to help conduct the temperature rise of the motor.

Simulation of iron losses in induction machines using an iron loss model for rotating magnetization loci in no electrical steel

Purpose Various iron loss models can be used for the simulation of electrical machines. In particular, the effect of rotating magnetic flux density at certain geometric locations in a machine is often neglected by conventional iron loss models. The purpose of this paper is to compare the adapted IEM loss model for rotational magnetization that is developed within the context of this work with other existing models in the framework of a finite element simulation of an exemplary induction machine. Design/methodology/approach In this paper, an adapted IEM loss model for rotational magnetization, developed within the context of the paper, is implemented in a finite element method simulation and used to calculate the iron losses of an exemplary induction machine. The resulting iron losses are compared with the iron losses simulated using three other already existing iron loss models that do not consider the effects of rotational flux densities. The used iron loss models are the modified Bertotti model, the IEM-5 parameter model and a dynamic core loss model. For the analysis, different operating points and different locations within the machine are examined, leading to the analysis of different shapes and amplitudes of the flux density curves. Findings The modified Bertotti model, the IEM-5 parameter model and the dynamic core loss model underestimate the hysteresis and excess losses in locations of rotational magnetizations and low-flux densities, while they overestimate the losses for rotational magnetization and high-flux densities. The error is reduced by the adapted IEM loss model for rotational magnetization. Furthermore, it is shown that the dynamic core loss model results in significant higher hysteresis losses for magnetizations with a high amount of harmonics. Originality/value The simulation results show that the adapted IEM loss model for rotational magnetization provides very similar results to existing iron loss models in the case of unidirectional magnetization. Furthermore, it is able to reproduce the effects of rotational flux densities on iron losses within a machine simulation.

A Novel Axial-Flux Dual-Stator Toothless Permanent Magnet Machine for Flywheel Energy Storage

This paper presents an alternative system called the axial-flux dual-stator toothless permanent magnet machine (AFDSTPMM) system for flywheel energy storage. This system lowers self-dissipation by producing less core loss than existing structures; a permanent magnet (PM) array is put forward to enhance the air–gap flux density of the symmetrical air gap on both sides. Moreover, its vertical stability is strengthened through the adoption of an axial-flux machine, so expensive active magnetic bearings can be replaced. The symmetry configuration of the AFDSTPMM system is shown in this paper. Then, several parts of the AFDSTPMM system are optimized thoroughly, including stator windings, number of pole pairs and the PM parameters. Further, the performance of the proposed PM array, including back-EMFs, air–gap flux density, average torque, torque ripple and over-load capacity, are compared with the Halbach PM array and spoke PM array, showing the superiority of proposed configuration. Finally, 3D simulations were made to testify for the 2D analyses.

Investigation of Torque Performance and Flux Reversal Reduction of a Three-Phase 12/8 Switched Reluctance Motor Based on Winding Arrangement

The goal of this paper is to present a comparative analysis of two types of winding arrangements for a three-phase 12/8 switched reluctance motor (SRM), where short- and fully-pitched winding arrangements under unipolar operation are considered. From the analytical results, the short-pitched winding has the best torque per copper weight ratio. The core loss based on counting the number of flux reversals in the stator yoke for each winding arrangement is also proposed and mentioned. To reduce the magnetic flux reversals in the stator core, changing the direction of the magnetic flux path by modifying the winding polarities of the short-pitched winding could reduce 10–13% of core loss compared to the conventional winding. A 1 kW, 12/8 SRM prototype for the ventilation fan application is constructed and tested in order to verify the design consideration of winding configuration. At the rated condition, a maximum efficiency around 82.5% could be achieved.

Optimum Magnetic Properties of Non-Oriented Electrical Steel Produced by Compact Strip Production Process

Optimum grain size and effects of crystallographic textures on magnetic properties of Fe-0.65%Si non-oriented electrical steel produced by compact strip production (CSP) process were investigated by optical microscope, electron backscatter diffraction (EBSD), and X-ray diffraction (XRD) techniques. Magnetic induction and core loss show a decreasing trend with the increase of grain size, and grain sizes for optimal magnetic properties are in the range of 26–30 μm. Core loss would be mainly affected by grain size, whereas crystallographic texture would primarily affect magnetic flux density. Magnetic properties increase with increasing of texture factor (volume fraction ratio of {100}/{111}) and magnetic texture factor (volume fraction ratio of <100>/<111>), and increasing with the decrease of A-parameter (minimum angle between magnetization direction and the closest <100> direction) and A(h→), respectively. Simultaneously, with increasing of A-parameter and A(h→), a linear decrease of B50 was obtained.

Reduction of Core-loss in the High Frequency Band of the Fe-Si-Cr Crystalline Alloy According to Particle Size

In order for soft magnetic composites (SMCs) to achieve the high-performance requirements expected of them even at high frequencies, high permeability and low core-loss are required. In this study, we used different sizes of gas atomized Fe-Si-Cr alloy powder to produce SMCs, this alloy has higher resistivity than existing materials used in SMCs such as Fe-Si alloy or pure Fe. These powders were prepared by sieving raw materials which had an average size from less than 25 µm to over 63 µm. Our experiments show that as particle size decreases, the magnetic saturation tends to increase, the sample made from the powder with particles 25-38 µm in size recorded the highest magnetic saturation of 169.38 emu/g. Additionally, as particle size decreased, permeability increased. The sample made from powder with particles under 25 µm had a permeability of 20.7 H/m at 1 MHz. Also, the relationship between particle size and quality factor was found to be inversely proportional. Finally, the minimum core-loss was 187.26 kW/m3 at 1 MHz for the sample made from powder whose constituent particles are under 25 µm. We also observed that the core-loss is proportional to particle size.

Estimation of Energy Losses in Nanocrystalline FINEMET Alloys Working at High Frequency

Soft magnetic materials are at the core of electromagnetic devices. Planar transformers are essential pieces of equipment working at high frequency. Usually, their magnetic core is made of various types of ferrites or iron-based alloys. An upcoming alternative might be the replacement the ferrites with FINEMET-type alloys, of nominal composition of Fe73.5Si13.5B9Cu3Nb1 (at. %). FINEMET is a nanocrystalline material exhibiting excellent magnetic properties at high frequencies, a soft magnetic alloy that has been in the focus of interest in the last years thanks to its high saturation magnetization, high permeability, and low core loss. Here, we present and discuss the measured and modelled properties of this material. Owing to the limits of the experimental set-up, an estimate of the total magnetic losses within this magnetic material is made, for values greater than the measurement limits of the magnetic flux density and frequency, with reasonable results for potential applications of FINMET-type alloys and thin films in high frequency planar transformer cores.

Analytical Iron Loss Evaluation in the Stator Yoke of Slotless Surface-Mounted PM Machines

<div>One of the attractive benefits of slotless machines is low losses at high speeds, which could be emphasized by a careful stator core loss assessment, potentially available already at the pre-design stage. Unfortunately, mainstream iron loss estimation methods are typically implemented in the finite element analysis (FEA) environment with a constant-coefficients dummy model, leading to weak extrapolations with huge errors. In this paper, an analytical method for iron loss prediction in the stator core of slotless PM machines is derived. It is based on the extension of the 2-D field solution over the entire machine geometry. Then, the analytical solution is combined with variable- or constant-coefficient loss models (i.e., VARCO or CCM), which can be efficiently computed by vectorized post-processing. VARCO loss models are shown to be preferred at a general level.Moreover, the paper proposes a lookup-table-based (LUT) solution as an alternative approach. The main contribution lies in the numerical link between the analytical field solution and the iron loss estimate, with the aid of a code implementation of the proposed methodology. First, the models are compared against a sufficiently dense dataset available from laminations manufacturer for validation purposes. Then, all the methods are compared for the slotless machine case. Finally, the models are applied to a real case study and validated experimentally.</div>

Analytical Iron Loss Evaluation in the Stator Yoke of Slotless Surface-Mounted PM Machines

<div>One of the attractive benefits of slotless machines is low losses at high speeds, which could be emphasized by a careful stator core loss assessment, potentially available already at the pre-design stage. Unfortunately, mainstream iron loss estimation methods are typically implemented in the finite element analysis (FEA) environment with a constant-coefficients dummy model, leading to weak extrapolations with huge errors. In this paper, an analytical method for iron loss prediction in the stator core of slotless PM machines is derived. It is based on the extension of the 2-D field solution over the entire machine geometry. Then, the analytical solution is combined with variable- or constant-coefficient loss models (i.e., VARCO or CCM), which can be efficiently computed by vectorized post-processing. VARCO loss models are shown to be preferred at a general level.Moreover, the paper proposes a lookup-table-based (LUT) solution as an alternative approach. The main contribution lies in the numerical link between the analytical field solution and the iron loss estimate, with the aid of a code implementation of the proposed methodology. First, the models are compared against a sufficiently dense dataset available from laminations manufacturer for validation purposes. Then, all the methods are compared for the slotless machine case. Finally, the models are applied to a real case study and validated experimentally.</div>