Analysis of Electric Motor Magnetic Core Loss under Axial Mechanical Stress

The electrical machine core is subjected to mechanical stresses during manufacturing processes. These stresses include radial, circumferential and axial components that may have significant influence on the magnetic properties and it further leads to increase in iron loss and permeability in the stator core. In this research work, analysis of magnetic core iron loss under axial mechanical stress is investigated. The magnetic core is designed with Magnetic Flux Density (MF) ranging from 1.0 T to 1.5 T with estimated dimensions under various input voltages from 5 V to 85 V. Iron losses are predicted by the axial pressure created manually wherever required and is further applied to the designed magnetic core in the range of 5 MPa to 50 MPa. Finite element analysis is employed to estimate the magnetic core parameters and the magnetic core dimensions. A ring core is designed with the selected dimensions for the experimental evaluation. The analysis of iron loss at 50 Hz frequency for non-oriented electrical steel of M400-50A is tested experimentally using the Epstein frame test and force-fit setup test. Experimental evaluation concludes that the magnetic core saturates when it reaches its knee point of the B-H curve of the chosen material and also reveals that the axial pressure has a high impact on the magnetic properties of the material.

[1]  S. V. Kulkarni,et al.  A Frequency-Dependent Scalar Magneto-Elastic Hysteresis Model Derived Using Multi-Scale and Jiles–Atherton Approaches , 2020, IEEE Transactions on Magnetics.

[2]  Katsumi Yamazaki,et al.  Effects of Multi-Axial Mechanical Stress on Loss Characteristics of Electrical Steel Sheets and Interior Permanent Magnet Machines , 2018, IEEE Transactions on Magnetics.

[3]  Shaohua Wang,et al.  Core Losses Analysis of a Novel 16/10 Segmented Rotor Switched Reluctance BSG Motor for HEVs Using Nonlinear Lumped Parameter Equivalent Circuit Model , 2018, IEEE/ASME Transactions on Mechatronics.

[4]  Jean-François Brudny,et al.  Determination of Specific Losses in the Limbs of an Epstein Frame Using a Three Epstein Frame Methodology Applied to Grain Oriented Electrical Steels , 2016, Sensors.

[5]  Paavo Rasilo,et al.  Equivalent Strain and Stress Models for the Effect of Mechanical Loading on the Permeability of Ferromagnetic Materials , 2019, IEEE Transactions on Magnetics.

[6]  Peter Sergeant,et al.  Magnetic Properties of Silicon Steel after Plastic Deformation , 2020, Materials.

[7]  Jianguo Zhu,et al.  Multi-Objective Design Optimization of an IPMSM Based on Multilevel Strategy , 2021, IEEE Transactions on Industrial Electronics.

[8]  Oskar Wallmark,et al.  High-Frequency Characterization of Losses in Fully Assembled Stators of Slotless PM Motors , 2018, IEEE Transactions on Industry Applications.

[9]  Rik W. De Doncker,et al.  Fast Iron Loss and Thermal Prediction Method for Power Density and Efficiency Improvement in Switched Reluctance Machines , 2020, IEEE Transactions on Industrial Electronics.

[10]  Frank Jenau,et al.  Causes of cyclic mechanical aging and its detection in stator winding insulation systems , 2019, IEEE Electrical Insulation Magazine.

[11]  Ingo Hahn,et al.  Different Iron Loss Models for Electrical Steel Sheets considering Harmonic Flux Signals , 2019, 2019 IEEE 28th International Symposium on Industrial Electronics (ISIE).

[12]  J. C. Kappatou,et al.  Finite Element Method Investigation and Loss Estimation of a Permanent Magnet Synchronous Generator Feeding a Non-Linear Load , 2018 .

[13]  Honghui Wen,et al.  Unified Analysis of Induction Machine and Synchronous Machine Based on the General Airgap Field Modulation Theory , 2019, IEEE Transactions on Industrial Electronics.

[14]  Paavo Rasilo,et al.  Magnetomechanical Model for Hysteresis in Electrical Steel Sheet , 2016, IEEE Transactions on Magnetics.

[15]  A. Belahcen,et al.  Coupled Magneto-Mechanical Analysis of Iron Sheets Under Biaxial Stress , 2016, IEEE Transactions on Magnetics.

[16]  Masato Enokizono,et al.  Stator Core Shape Design for Low Core Loss and High Power Density of a Small Surface-Mounted Permanent Motor , 2020, Sensors.

[17]  N. Sadowski,et al.  Magnetic Hysteresis Under Compressive Stress: A Multiscale-Jiles–Atherton Approach , 2020, IEEE Transactions on Magnetics.

[18]  P. Rasilo,et al.  Effect of multi-axial stress on iron losses of electrical steel sheets , 2019, Journal of Magnetism and Magnetic Materials.

[19]  Katsumi Yamazaki,et al.  Iron Loss Analysis of Permanent-Magnet Machines by Considering Hysteresis Loops Affected by Multi-Axial Stress , 2020, IEEE Transactions on Magnetics.

[20]  Ashwin Dhabale,et al.  Modified Distributed Winding for Harmonic Reduction in Space MMF Distribution , 2018, 2018 IEEE International Conference on Power Electronics, Drives and Energy Systems (PEDES).

[21]  Deliang Liang,et al.  Design and Comparison of Three Different Types of IE4 Efficiency Machines , 2019, 2019 22nd International Conference on Electrical Machines and Systems (ICEMS).

[22]  Lode Vandenbossche,et al.  Iron Loss Modelling of Electrical Traction Motors for Improved Prediction of Higher Harmonic Losses , 2020, World Electric Vehicle Journal.

[23]  Hongze Wang,et al.  Laser welding of laminated electrical steels , 2016 .

[24]  A. Belahcen,et al.  Analysis of the Magneto-Mechanical Anisotropy of Steel Sheets in Electrical Applications , 2020, IEEE Transactions on Magnetics.

[25]  G. Krebs,et al.  An alternative approach to model mechanical stress effects on magnetic hysteresis in electrical steels using complex permeability , 2019, Computational Materials Science.

[26]  Thomas X. Wu,et al.  An Analytical Iron Loss Calculation Model of Inverter-Fed Induction Motors Considering Supply and Slot Harmonics , 2019, IEEE Transactions on Industrial Electronics.

[27]  Yansong Zhang,et al.  Modeling of Eddy-Current Losses of Welded Laminated Electrical Steels , 2017, IEEE Transactions on Industrial Electronics.

[28]  A. Belahcen,et al.  Rotational Single Sheet Tester for Multiaxial Magneto-Mechanical Effects in Steel Sheets , 2019, IEEE Transactions on Magnetics.

[29]  Kazuhiro Muramatsu,et al.  Coupled Magneto-Mechanical Analysis in Isotropic Materials Under Multiaxial Stress , 2014, IEEE Transactions on Magnetics.

[30]  Jianguo Zhu,et al.  System-Level Robust Design Optimization of a Switched Reluctance Motor Drive System Considering Multiple Driving Cycles , 2021, IEEE Transactions on Energy Conversion.

[31]  Hongze Wang,et al.  Joining of the Laminated Electrical Steels in Motor Manufacturing: A Review , 2020, Materials.

[32]  Deliang Liang,et al.  Analysis of Winding MMF and Loss for Axial Flux PMSM With FSCW Layout and YASA Topology , 2020, IEEE Transactions on Industry Applications.

[33]  Paavo Rasilo,et al.  Analysis of iron losses on the cutting edges of induction motor core laminations , 2016, 2016 XXII International Conference on Electrical Machines (ICEM).