VP19-05 Loss analysis of amorphous high-speed PMSMs considering the effect of cutting damage
Creators: Xusheng Lu
Leyiran Zhang
Pengpeng Meng
Deji Ma
Lubin Zeng
and Ruilin Pei
Publisher: name: IEEE
Year: 2025

The weight share of soft magnetic materials in permanent magnet synchronous machines (PMSMs) is usually around 70%, and the proportion of iron loss in the total loss is also large [1]. Currently, researchers have begun to study the use of high permeability, low iron loss amorphous materials(AM) for high-speed PMSM to reduce iron loss, but the measured iron loss performance of AM in motors has a large difference with the simulation results [2]. The reason may be that AM core generates stress and crystallization occurs at the cutting edges during processing, which leads to an increase in losses [3]. Therefore, the analysis of AM losses considering the effect of cutting is crucial for the design and application of AM HS PMSM, and there are fewer researches in this area. In the second part of this paper, in order to investigate the effect of cutting on the magnetic performance of AM, the core is cut into four rings with the same outer diameter and different inner diameters using wire cutting, as shown in Fig. 1(a). Using the self-developed variable temperature magnetic performance test system, the iron loss value of AM at different temperatures (298.15K ~423.15K) was measured to reveal the change rule of the magnetic performance of AM under the coupling of variable temperature and cutting method. In the third part, the part affected by cutting is explored, and the equivalent depth of the performance degradation part is calculated, schematically shown in Fig. 1(b). The unit weight loss of the degraded part is further separated from that of the normal AM to optimize the iron loss model. In the fourth part, a AM HS PMSM prototype is fabricated, and the measured iron loss values of the motor are compared with the optimization model data of this paper and the traditional iron loss model data to verify the correctness of the optimization analysis. This will provide more accurate guidance for the design and application of AM HS PMSMs.References: [1] T. Li, Y. Zhang, Y. Liang, "Multiphysics Analysis of an Axial-Flux In-Wheel Motor With an Amorphous Alloy Stator," IEEE Access, vol. 8, pp. 27414-27425, 2020. [2] Z. Wang, Y Enomoto, M Ito, "Development of a Permanent Magnet Motor Utilizing Amorphous Wound Cores," IEEE Transactions on Magnetics, vol. 46, no. 2, pp. 570-573, Feb. 2010. [3] F. Chai, Z. Li, L. Chen, "Effect of Cutting and Slot Opening on Amorphous Alloy Core for High-Speed Switched Reluctance Motor," IEEE Transactions on Magnetics, vol. 57, no. 2, pp. 1-5, Feb. 2021.
The weight share of soft magnetic materials in permanent magnet synchronous machines (PMSMs) is usually around 70%, and the proportion of iron loss in the total loss is also large [1]. Currently, researchers have begun to study the use of high permeability, low iron loss amorphous materials(AM) for high-speed PMSM to reduce iron loss, but the measured iron loss performance of AM in motors has a large difference with the simulation results [2]. The reason may be that AM core generates stress and crystallization occurs at the cutting edges during processing, which leads to an increase in losses [3]. Therefore, the analysis of AM losses considering the effect of cutting is crucial for the design and application of AM HS PMSM, and there are fewer researches in this area. In the second part of this paper, in order to investigate the effect of cutting on the magnetic performance of AM, the core is cut into four rings with the same outer diameter and different inner diameters using wire cutting, as shown in Fig. 1(a). Using the self-developed variable temperature magnetic performance test system, the iron loss value of AM at different temperatures (298.15K ~423.15K) was measured to reveal the change rule of the magnetic performance of AM under the coupling of variable temperature and cutting method. In the third part, the part affected by cutting is explored, and the equivalent depth of the performance degradation part is calculated, schematically shown in Fig. 1(b). The unit weight loss of the degraded part is further separated from that of the normal AM to optimize the iron loss model. In the fourth part, a AM HS PMSM prototype is fabricated, and the measured iron loss values of the motor are compared with the optimization model data of this paper and the traditional iron loss model data to verify the correctness of the optimization analysis. This will provide more accurate guidance for the design and application of AM HS PMSMs.References: [1] T. Li, Y. Zhang, Y. Liang, "Multiphysics Analysis of an Axial-Flux In-Wheel Motor With an Amorphous Alloy Stator," IEEE Access, vol. 8, pp. 27414-27425, 2020. [2] Z. Wang, Y Enomoto, M Ito, "Development of a Permanent Magnet Motor Utilizing Amorphous Wound Cores," IEEE Transactions on Magnetics, vol. 46, no. 2, pp. 570-573, Feb. 2010. [3] F. Chai, Z. Li, L. Chen, "Effect of Cutting and Slot Opening on Amorphous Alloy Core for High-Speed Switched Reluctance Motor," IEEE Transactions on Magnetics, vol. 57, no. 2, pp. 1-5, Feb. 2021.