轴向磁通永磁电机扁铜线交流铜耗的混合解析计算及抑制

doi:10.19595/j.cnki.1000-6753.tces.221828

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Abstract

Axial flux permanent magnet motor is suitable for the field with high requirements on motor performance and installation space due to the advantages such as high power density, small volume, and light mass. In the field of high power density motors, flat copper wire is used for its high slot filling rate and excellent heat dissipation performance. However, due to the influence of skin effect, proximity effect, and external magnetic field, the flat copper wire has a higher AC copper loss, which can seriously affect the motor performance and the insulating material life. Therefore, accurate calculation and suppression of AC copper loss of flat copper wire are significant.
Although accurate results can be obtained using the three-dimensional transient field to calculate AC copper loss, there are some problems, such as long computing time and high computer performance requirements. Therefore, a hybrid analytical calculation method is proposed to balance calculation accuracy and calculation time. This method combines the three-dimensional finite element with the analytical method, which can consider the influence of skin effect, proximity effect, and external magnetic field on AC copper loss. Meanwhile, a conductor arrangement of flat wire vertical winding is proposed to suppress AC copper loss.
Firstly, according to the actual size of the winding, a detailed three-dimensional model of flat copper wire is established in the eddy current field, and the magnetic flux density is calculated. Secondly, the combined sampling method of parts, segments, and layers is adopted. Finally, the sampling magnetic flux density is combined with the analytical model to calculate the AC copper loss.
A 60kW, 18-slot, 20-pole double-rotor single-stator axial flux permanent magnet motor was taken as an example for verification. Firstly, the proposed method analyzed the AC copper loss of different conductor arrangements, verified by a three-dimensional transient field finite element. The results show that the AC copper loss of flat wire vertical winding is reduced by 36.9% compared with that of flat wire parallel winding, and the calculation time of hybrid analytical calculation is reduced by 97.96% compared with the three-dimensional transient finite element. Secondly, the AC copper loss and motor efficiency under different working conditions were analyzed. The results show that the performance of flat wire vertical winding motor is better than that of flat wire parallel winding motor in all working conditions, and the advantages of flat wire vertical winding motor are more obvious with the increase of frequency. Finally, the prototype was tested, and the experimental results, the finite element results, and the hybrid analytical calculation results were basically consistent, which verified the accuracy of the hybrid analytical calculation and the effectiveness of the flat wire vertical winding.
The following conclusions can be obtained by comparing the calculation results of the three methods: 1) The conductor arrangement of flat wire vertical winding is proposed, which can effectively suppress the AC copper loss of flat copper wire and improve motor efficiency. The number of conductors at the slot opening should be reduced, and the conductor arrangements should be changed to suppress AC copper loss without changing the motor topology structure. 2) The influence of skin effect, proximity effect, and external magnetic field on AC copper loss of flat copper wire can be considered by the hybrid analytical calculation method. This method has the advantages of high accuracy and short calculation time in calculating AC copper loss. This method is also suitable for rapidly analyzing the effect of different flat copper wire conductor arrangements on AC copper loss.

Key words： Axial flux permanent magnet motor flat copper wire AC copper loss hybrid analytical calculation conductor arrangement

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TM351

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	Wu Yue
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Cite this article:

Wu Yue,Zhang Zhifeng. Hybrid Analytical Calculation and Suppression of AC Copper Loss of Flat Copper Wire in Axial Flux Permanent Magnet Motor[J]. Transactions of China Electrotechnical Society, 0, (): 20235408-20235408.

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https://dgjsxb.ces-transaction.com/EN/10.19595/j.cnki.1000-6753.tces.221828 OR https://dgjsxb.ces-transaction.com/EN/Y0/V/I/20235408

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