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Iron losses in laser-cut toroidal samples of 12 mm thick steel laminations used in large synchronous motors are studied. Eddy currents in the lamination cross-section are solved with the 2-D finite element method while applying a constitutive law based on the Jiles-Atherton hysteresis model. The effect of cutting on the material properties is included by a continuous local material model approach, which enables to express the material properties as a function of distance from the cutting edge. The accuracy of the model is validated by comparing the simulations and experimental measurements of five toroidal samples assembled from concentric rings with different widths. Highly accurate results are obtained in terms of both the matching of B-H loops and the total loss values with an average relative error less than 2.9%. The results show that the hysteresis loss under quasi-static excitation increases up to 20.4% due to the effect of cutting. It is observed that the eddy-current loss becomes dominant over the hysteresis loss even at 5 Hz, and this eddy-current loss decreases up to 72.5% as the number of concentric rings increases. The presented model and the results accurately show how iron losses occur in thick materials and how they are affected by the cutting process.INDEX TERMS Cutting, eddy currents, hysteresis, iron loss, skin effect, thick materials.

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This paper proposes a new surrogate optimization routine for optimal design of a direct on line (DOL) squirrel cage induction motor. The geometry of the motor is optimized to maximize its electromagnetic efficiency while respecting the constraints, such as output power and power factor. The routine uses the methodologies of Latin-hypercube sampling, a clustering technique and a Box–Behnken design for improving the accuracy of the surrogate model while efficiently utilizing the computational resources. The global search-based particle swarm optimization (PSO) algorithm is used for optimizing the surrogate model and the pattern search algorithm is used for fine-tuning the surrogate optimal solution. The proposed surrogate optimization routine achieved an optimal design with an electromagnetic efficiency of 93.90%, for a 7.5 kW motor. To benchmark the performance of the surrogate optimization routine, a comparative analysis was carried out with a direct optimization routine that uses a finite element method (FEM)-based machine model as a cost function.

In this article, we propose an analytical method to compute the eddy-current loss in nonlinear thick steel laminations (3-12 mm) by considering the return path of the eddy currents. Initially, a 2-D finite-element (FE) model is applied to segregate losses measured from toroidal material samples into hysteresis and eddy-current loss components to use them as reference. Afterward, a 2-D analytical time-domain model is proposed for the eddy currents based on the solution of the 2-D field problem. The time-domain model is then used to derive a simple frequency-domain eddy-current loss formulation for the sinusoidal flux density case with the inclusion of a skin-effect correction factor, which accounts for the nonlinearity of the material. Highly accurate results are obtained from the proposed model compared to FE reference results with a mean relative error of 5.1% in the nonlinear region.