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Estimation of Stator Iron Loss Build Factor from Shrink Fitting and Laser Cutting in a Permanent Magnet Synchronous Machine

Year: 2025
Type: conference-paper
Abstract: This paper presents an efficient method to investigate the combined impact of shrink-fit and laser cutting on the stator iron losses. It is applied to a 3-phase 12-slot 10-pole interior permanent magnet synchronous machine for twowheeler traction applications. Two grades of electrical steel, M250-35A and NO20-1200, are considered. The mechanical stress in the stator back iron is derived by FEA simulations and an average value is identified. Material magnetic properties are measured using a single sheet tester using EDM and laser cut samples. Data under compression load and laser cut damage are reported, including BH curves and derived iron loss model parameters. The grade NO20 is more influenced than M250-35A by compressive stress and laser cut. As expected, low flux densities and low frequencies are the most impacted (hysteresis loss). The stator iron losses are calculated with and without stress from shrink-fitting and cut edge damage. The stator iron loss build factors are presented on the torque-speed plane. The stator iron loss in the e-machine at low loads are considerably increased across the frequency range, while the efficiency is impacted the most at low load and 700 Hz. The WMTC drive cycle efficiency, with the M250-35A results in a drop of 0.8% and 0.9% for NO20-1200. However, no significant impact on the peak performance is predicted. The presented method estimates the impact of cut edge and shrink-fit effect on e-machine performance without increase in the simulation time, therefore it is optimal for initial selection of electrical steel grade.
DOI: 10.1109/ecce-europe62795.2025.11238268
Language: English
Open Access status: green
OpenAlex ID: W4416725720
FWCI: 3.412
Cites: 16
Cited by: 2
Related to: 10