Performance Degradation due to Cut Edge Effect for an Axial-Flux Induction Machine

Colombo, Leonardo; Tokat, Alexandra; Bitsi, Kostantina; Márquez-Fernández, Francisco J.; Alaküla, Mats

doi:10.1109/icem51905.2022.9910778

Cited by 3 publications

(6 citation statements)

References 14 publications

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“…These aspects are worth mentioning because the manufacturing effect must always be considered before a high-efficiency motor is designed, having to comply with predefined characteristics and specific applications. In Table 4 , some interesting approaches that were based on electromagnetic simulations in commercial programs or in-house developed software [ 80 , 84 , 86 , 89 , 90 , 92 , 93 , 94 , 95 , 96 , 97 , 98 , 99 , 100 , 101 , 102 ] are introduced. In Figure 8 are presented analytical and FEM approaches that include the cutting technology effect on magnetic properties variations of NO FeSi.…”

Section: Influence Of Cutting Technology On Magnetic Properties Of No...mentioning

confidence: 99%

“…The authors supposed that both hysteresis and total eddy current losses are influenced by the cutting procedure [87,88] M, magnetic susceptibility χ, The deterioration of the magnetic properties due to the cutting effect led to a decreased value of magnetic permeability and an increase in the core losses; -By incorporating the cutting technology effect in the FEM model led to a difference of about 8% in the output power in comparison with the motor model, in which this effect was not considered; -All the simulations were performed under the hypothesis that the material had an isotropic behavior even after cutting procedure [95] B maps, electromagnetic torque, harmonic analysis for magnetic flux density M330-50A/punching -FEM model of a double stator axial flux induction motor software: COMSOL Multiphysics v. 5.6 -A five-layer structure of 0.2 mm approximation of the damaged area was assumed; -An analytical model of magnetic permeability degradation was included in FEM; -A decrease in the magnetic flux density in the air gap and a 1.3% decrease in the electromagnetic torque were reported when the cutting technology effect was considered [96] B maps, torque-speed maps, total power loss-speed maps NO30-1600/punching -FEM model of a V-shape magnets PMSM and a double-layered aluminum stator winding software: Ansys Maxwell 2021 -An eight layer structure for the damaged area where was implemented a relative permeability degradation model; -An increase between 14% and 20% of hysteresis power losses and between 2% and 12% of total power losses was observed [97] torque-speed graphs, L q and L d computation, maximum current M270-35A/laser -FEM model of a SynRel software: Not specified -The degradation profile of the material was considered by using different values of relative permeability on specific areas on rotor and stator cores; -It was noticed that the manufacturing process had a degradation effect, especially on the stator part, because of higher magnetization current, while in the rotor core, it led to a performance improvement by increasing the inductance ratio [98] Cogging torque, efficiency, B maps M330-50A/punching -FEM model of V-shape magnets 8-pole PMSM software: FEMM 4.2 and SyMSpace for the automatization of the problem solver [104] -A layer-based approach was used, in which a magnetic permeability analytical model was implemented; -…”

Section: Analytical and Numerical Modelsmentioning

confidence: 99%

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Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review

Paltanea,

Manescu (Paltanea),

Antoniac

et al. 2024

Materials

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The problem of energy consumption reduction establishes important challenges for electric motor producers in the framework of new international regulations regarding the conditions that must be accomplished by motors in the near future. One of the most important topics is related to the core loss decrease directly linked to the effect of electrical steel degradation induced by the cutting technology. Understanding exactly how this phenomenon occurs by analyzing the chemical, mechanical, crystallographic, magnetic domain, and magnetic properties is of utmost importance when manufacturing processes must be changed and adapted to a new market characterized by high-efficiency motors. Today, mechanical and laser cutting technologies are the most used because of their reduced price and high-speed process. Still, unfortunately, these methods are not the best due to the fact that they lead, in most cases, to a high value of magnetic core losses, low electromagnetic torque, and hence reduced efficiency. This review paper shows that non-conventional technologies such as water jetting and electroerosion could be applied if proper modifications are added. This paper’s main idea is to present a comprehensive study regarding the impact of cutting technologies on microhardness and residual stresses, crystallographic texture, magnetic domain structure, and magnetic properties of some non-oriented electrical steels used in motor production. It provides a detailed analysis of the abovementioned aspects by including the authors’ research and findings in the wider context of other research group contributions. It also offers a general idea of the mechanisms present at the macro- and microscopic levels. The readers can find some of the most used analytical models, including the cutting process’s damaged effect on the magnetic properties’ variation based on a simple mathematical approach and examples of finite element modeling performed on real motor designs implemented in various programs. Last but not least, some practical implementations of the cutting procedure’s influence on motor working conditions are presented in the last section of the paper. It provides an up-to-date analysis regarding how the cutting method should be included in high-efficiency motor production by emphasizing the importance of the topic and identifying where supplementary research must be undertaken. From the investigated literature, by analyzing specific sample geometries associated with different characterization methods, it can be concluded that all the cutting technologies have an important contribution to the mechanical and magnetic quantities. When the magnetic core of an electric motor is produced through non-conventional methods, the overall influence of the cutting procedure has a low percentage in the motor efficiency, as presented in this paper.

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Section: Influence Of Cutting Technology On Magnetic Properties Of No...mentioning

confidence: 99%

Section: Analytical and Numerical Modelsmentioning

confidence: 99%

Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review

Paltanea,

Manescu (Paltanea),

Antoniac

et al. 2024

Materials

View full text Add to dashboard Cite

show abstract

“…This method can be laborious, especially in areas with complicated geometry. The implementation process of this approach is described in [7,15,[65][66][67][68][69][70][71][72][73][74][75]. As shown in Figure 9, the third approach involves assigning material properties at the mesh level of finite element software to have more continuous modelling.…”

Section: Implement the Developed B-h Curves Into Femmentioning

confidence: 99%

A Review on the Effect of Electrical Steel Manufacturing Processes on the Performance of Electric Machines

Mahmouditabar,

Baker

2023

Energies

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The manufacturing processing of Electrical Steel Laminations (ESLs) for electric machines comprises cutting, stacking, and housing techniques which can result in plastic deformation and residual stress in the soft magnetic material. These manufacturing processes result in decreasing the magnetic quality and a local increase in both the static and dynamic hysteresis losses near the cut edges and consequently a reduction in the performance of the designed motor. The iron losses resulting from cutting can vary by a factor of two or more depending on geometrical, material, and processing parameters as well as the magnetic field strength. It is advantageous to consider these manufacturing effects in the design stage to reduce the probability of underperforming mass production. In this paper, the manufacturing processes of ESLs and their modelling methods are comprehensively surveyed. The gaps in scientific understanding and the research need for the expansion of accurate modelling of the cutting and joining of ESLs are subsequently discussed.

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“…The most significant difference between the basic sizes of the optimized flute shapes with and without considering the cutting effects is about 0.3 mm. [110] DS-AFIM Double-stator axial-flux induction machine, total active length 103.41 mm, outer torus diameter 220 mm.…”

Section: Paper Motor Type Short Description Contents and Conclusionmentioning

confidence: 99%

“…This approach was used, for example, in [30,61,78,108,112]. The second is dividing the solution area into layers with different properties [34,78,85,93,[104][105][106][107][108]110,[117][118][119]. Since these layers are usually narrow, it creates a problem in the construction of the mesh, forcing the use of small-sized elements because otherwise, similarly to the air gap, degenerate elements with too sharp angles are created.…”

Section: Consideration Of the Cutting Effect In The Fem Simulationmentioning

confidence: 99%

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

2023

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The global drive to reduce energy consumption poses new challenges for designers of electrical machines. Losses in the core are a significant part of losses, especially for machines operating at an increased rotational speed powered by PWM inverters. One of the important problems when calculating core losses is considering the effect of material degradation due to mechanical or laser cutting. To this aim, this paper analyzes and summarizes the knowledge about the sources of material property deterioration and ways of describing this phenomenon. The cited results of material tests indicate the lack of unequivocal relationships allowing us to estimate the degree of material damage and the resulting deterioration of material properties. The main task of this article is to present the state of knowledge on the possibility of taking into account the impact of cutting the core sheets of electric motors on core losses and their impact on the efficiency of the machine. This is a significant problem due to the need to design and manufacture energy-saving electric motors powered with a voltage of 20 to 350 Hz, whose magnetic cores are made of laminates. However, the performed analysis indicates the most important parameters of the cutting process, affecting the degree of material structure destruction. The method of the solution proposed by the authors for core punching and laser cutting, illustrated with a practical example, is also presented.

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Performance Degradation due to Cut Edge Effect for an Axial-Flux Induction Machine

Cited by 3 publications

References 14 publications

Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review

Mechanical and Magnetic Properties Variation in Non-Oriented Electrical Steels with Different Cutting Technology: A Review

A Review on the Effect of Electrical Steel Manufacturing Processes on the Performance of Electric Machines

The Influence of Cutting Technology on Magnetic Properties of Non-Oriented Electrical Steel—Review State of the Art

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