Advanced Magnetic Core Loss Minimization Strategy for High-Speed Electrical Machines Using Hybrid Material Modeling

Abstract

High-speed electric machines are being used more and more in electric vehicles, in aerospace propulsion systems, and high-speed industrial drives because of their better power densities and smaller size. At very high rotational frequencies and electrical frequencies, however, magnet core losses become very substantial and system efficiency is compromised, as well as excessive thermal stress occurs inside the machine core. There is a current study that intends to suggest an advanced magnetic core loss minimization strategy that is founded on hybrid models of the magnetic material. The suggested approach involves the laminated silicon steel and soft magnetic composite (SMC) materials in areas of the stator core that are strategically chosen in order to minimise the hysteresis and eddy current losses but retain sufficient magnetic flux and mechanical strength. There is a detailed analytical loss model that is created to approximate hysteresis, eddy current, and excess losses when excitation occurs at high frequencies. Mathematical modelling on magnetic flux distribution, core loss density, and machine efficiency is considered by carrying out finite element electromagnetic simulations, to assess the proposed hybrid configuration. Simulation with the results show that the hybrid material design and configuration can balance total magnetic core losses by about 2025 per cent as opposed to the traditional laminated cores. Moreover, the design suggested enhances the efficiency of the machines as a whole and reduces the increase in temperature of stator in high speed running. These results have shown that the hybrid magnetic material modelling can be an efficient design approach to enhance the efficiency, thermal performance, and reliability of the coming generation high-speed electrical machines.