An Application-Oriented Approach for Consideration of Material Degradation Effects Due to Cutting on Iron Losses and Magnetizability

Steentjes, Simon; Pfingsten, Georg von; Hameyer, Kay

doi:10.1109/tmag.2014.2334699

Cited by 28 publications

(6 citation statements)

References 15 publications

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“…However, by applying stator segmentation, the magnetic circuit is changed (i.e. introduction of additional air gaps), and the cut-edge effect is increased (Rens et al , 2016; Balluff et al , 2018; Steentjes et al , 2014; Vandenbossche et al , 2010). These changes also have an impact on iron losses (Rens et al , 2016; Vandenbossche et al , 2010; Vandenbossche et al , 2013; Petrun et al , 2016; Caunes et al , 2020; Soda et al , 2021; Baker et al , 2018).…”

Section: Introductionmentioning

confidence: 99%

Influence of stator segmentation on iron losses in PMSMs for traction applications

Garmut

Petrun

2022

COMPEL

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Purpose This paper presents a comparative study of different stator-segmentation topologies of a permanent magnet synchronous machine (PMSM) used in traction drives and their effect on iron losses. Using stator segmentation allows one to achieve more significant copper fill factors, resulting in increased power densities and efficiencies. The segmentation of the stators creates additional air gaps and changes the soft magnetic material’s material properties due to the cut edge effect. The aim of this paper is to present an in-depth analysis of the influence of stator segmentation on iron losses. The main goal was to compare various segmentation methods under equal excitation conditions in terms of their influence on iron loss. Design/methodology/approach A transient finite element method analysis combined with an extended iron-loss model was used to evaluate discussed effects on the stator’s iron losses. The workflow to obtain a homogenized airgap length accounting for cut edge effects was established. Findings The paper concludes that the segmentation in most cases slightly decreases the iron losses in the stator because of the overall reduced magnetic flux density B due to the additional air gaps in the magnetic circuit. An increase of the individual components, as well as total power loss, was observed in the Pole Chain segmentation design. In general, segmentation did not change the total iron losses significantly. However, different segmentation methods resulted in the different distortion of the magnetic field and, consequently, in different iron loss compositions. The analysed segmentation methods exhibited different iron loss behaviour with respect to the operation points of the machine. The final finding is that analysed stator segmentations had a negligible influence on the total iron loss. Therefore, applying segmentation is an adequate measure to improve PMSMs as it enables, e.g. increase of the winding fill factor or simplifying the assembly processes, etc. Originality/value The influence of stator segmentation on iron losses was analysed. An in-depth evaluation was performed to determine how the discussed changes influence the individual iron loss components. A workflow was developed to achieve a computationally cheap homogenized model.

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Section: Introductionmentioning

confidence: 99%

Influence of stator segmentation on iron losses in PMSMs for traction applications

Garmut

Petrun

2022

COMPEL

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“…The interlocking process introduces stress in the material, causing undesired electromagnetic effects in the material which influence the efficiency of the machine. Numerous researchers studying lamination manufacturing processes such as laser cutting, water‐jet cutting and punching have demonstrated that residual stress near the cut edge has an impact on the magnetic properties of electrical steel [1,2]. Up to 40% core loss increase was reported between different cutting techniques at 50 Hz saturation flux density [3].…”

Section: Introductionmentioning

confidence: 99%

Modeling Interlocking Effects on Core Losses in Electrical Steel

Daem

Sergeant

Dupré

et al. 2020

IEEJ Transactions Elec Engng

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When optimizing the design of electrical machines, it is recommended to take into account the effect of the manufacturing processes on the core losses and magnetic properties of the electrical steel. This paper demonstrates a methodology for incorporating the effects of interlocking, a process frequently applied to fix a stack of laminations, on the magnetic properties of the machine core. The methodology requires magnetic measurements on several sets of Epstein strips. The proposed methodology is demonstrated on NO27, a low loss grade of electrical steel. A validation is done to show the transferability from Epstein strips to a realistic stator core geometry. The results show that the proposed methodology succeeds accurately in predicting the degrading impact of interlocking on the magnetic properties of electrical steel laminations. Additionally, the effect of magnetic anisotropy on the degrading impact of interlocking is investigated.

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“…This high Si% improves properties such as electrical resistivity and magnetic permeability, however formability of these alloys are adversely affected making them brittle and very difficult to cut and handle at low strip thickness [2]. Blanking is the most widely applied process to cut ES sheets compared with other manufacturing processes such as abrasive water jet [3], laser [4,5] and wire-EDM [6,7] cutting. The material experienced large plastic deformation at the vicinity of the cut edge during blanking that negatively affects magnetic properties of the produced laminations [8].…”

Section: Introductionmentioning

confidence: 99%

“…The plastic deformation and shearing during the blanking process results in residual stresses, residual deformation and dislocation build-up at the cut edge [9][10][11] which adversely affect the magnetic properties by either reducing the magnetic permeability or enhancing the losses [5,10,12] with higher magnetic losses reported for sheets with larger grains [13]. Grains sizes become a predominant factor as the sheet thickness is reduced by which individual grains can alter active deformation and failure mechanisms during the blanking and shear process [14,15].…”

Section: Introductionmentioning

confidence: 99%

Blanking induced damage in thin 3.2% silicon steel sheets

Ghadbeigi

Al-Rubaye

Robinson

et al. 2019

Prod. Eng. Res. Devel.

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The cores of electrical motors and transformers are made by blanking, piercing and stacking of thin metallic sheets having various features cut from the original blank. The material experiences local plastic deformation near the cut edge due to the blanking operation. The quality and efficiency of the produced products are directly affected by the mechanical and magnetic properties of the blanks at the cut edge. The effects of the blanking process on deformation evolution in thin sheets of high Si electrical steels was investigated. In-situ blanking experiments together with the digital image correlation (DIC) technique were used to quantify local deformation evolution during thin sheet blanking operations. Magnetic hysteresis losses were measured using a purpose-built single sheet tester and linked to the measured deformation maps. The residual stresses were qualitatively assessed by means of nano-hardness measurements while the local microstructural properties and dislocation generations were determined using EBSD analysis of the blanked parts. The results indicated that for the tested materials with 0.1t blanking clearance, electrical steel sheets with 0.2 mm thickness experiences larger deformation prior to fracture during blanking compared with samples having 0.35 mm thickness. This has a direct relationship with the measured hysteresis losses. However, the dislocation maps indicated that dislocations of GNDs are more pronounced for thicker samples that aligns with the effect of dislocations on magnetic power losses rather than hysteresis losses measured in this research.

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An Application-Oriented Approach for Consideration of Material Degradation Effects Due to Cutting on Iron Losses and Magnetizability

Cited by 28 publications

References 15 publications

Influence of stator segmentation on iron losses in PMSMs for traction applications

Influence of stator segmentation on iron losses in PMSMs for traction applications

Modeling Interlocking Effects on Core Losses in Electrical Steel

Blanking induced damage in thin 3.2% silicon steel sheets

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