Modeling, Investigation, and Mitigation of AC Losses in IPM Machines with Hairpin Windings for EV Applications

Choi, Min-Gyu; Choi, Gilsu

doi:10.3390/en14238034

Cited by 5 publications

(3 citation statements)

References 30 publications

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“…The key content in [10][11][12][13][14][15] is research on optimizing the cooling method for high efficiency. It is mentioned that it is necessary to improve the thermal characteristics because the characteristics deteriorate as the high-temperature characteristics of the PM motor continue to be maintained.…”

Section: Discussionmentioning

confidence: 99%

“…The advantage of the hairpin winding technology is that it is possible to secure the fill factor, which is the ratio of conductors in the stator slot, to more than 70% [9][10]. In addition, the area of the winding required to produce the same output is required to be smaller than that of the round copper wire [12]. This is also related to the thermal properties.…”

Section: ░ 1 Introductionmentioning

confidence: 99%

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Analysis of Interior Permanent Magnet Synchronous Motor according to Winding Method

Lee

Shin

Kim

2022

IJEER

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In this paper, the hairpin method is applied to an Electric Vehicle (EV) driving motor with a stator winding designed with a round copper wire. The hairpin method is a method to secure a high space factor by using round copper wire instead of round copper wire for the stator winding. The applicable model is a 300kW Interior Permanent Magnet Synchronous Motor (IPMSM), and the cooling method is water cooling. The current density has a proportional relationship with the thermal characteristics, and in the case of a round copper wire, a method of lowering the current density by using the stator winding as a stranded wire is used. However, when the hairpin method is applied, it is expected that the current density will be low as the area of the conductor is increased, but in reality, this is not the case in most cases. Accordingly, thermal characteristics are supplemented by using oil cooling rather than water cooling as the cooling method. However, in this paper, the thermal characteristic change is analyzed using the same cooling method. The process of applying the hairpin method from the round copper wire method is sequentially described, and changes in the main electromagnetic characteristics of the motor are compared and analyzed. Additionally, by selecting an operating point, the thermal characteristics are also analyzed. In this study, the analysis is based on the finite element method (FEM)-based electromagnetic simulation.

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Section: Discussionmentioning

confidence: 99%

Section: ░ 1 Introductionmentioning

confidence: 99%

Analysis of Interior Permanent Magnet Synchronous Motor according to Winding Method

Lee

Shin

Kim

2022

IJEER

View full text Add to dashboard Cite

show abstract

“…Permanent magnet synchronous motors (PMSMs) have been widely used in a variety of industries (such as appliances, industrial tools, and driving motors for electric vehicles) because of their excellent efficiency, torque density, and low maintenance [4][5][6][7]. PMSMs with rectangular coils in hairpin winding arrangements can reduce the space factor by reducing the unnecessary space in the slots when compared with those with round coils [8]. In addition, since the copper loss is reduced by reducing the end turn of the coils, the efficiency and output density of the motor can be significantly improved [9].…”

Section: Introductionmentioning

confidence: 99%

Optimization of a Permanent Magnet Synchronous Motor for e-Mobility Using Metamodels

Kim

You

2022

Applied Sciences

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Permanent magnet synchronous motors (PMSMs) with rectangular coils in hairpin windings exhibit improved fill factor and reduced end turn of the coils, which in turn improve the efficiency and power density of PMSMs, making them ideal for e-mobility applications. Herein, the shape of a PMSM was optimized for torque ripple reduction using metamodels to improve the noise and vibrational performance of the motor. The objective function of the optimal design aimed to minimize the torque ripple, and the average torque and efficiency were set as constraints. The notch width and depth and barrier length were selected as the design variables to satisfy the objective function and constraints. Using the optimal Latin hypercube design technique, 27 experimental points were selected, and a finite element analysis (FEA) was performed for each point. Furthermore, a function approximation was performed using six metamodels, and the best metamodel was selected using the root mean square error test. Moreover, the optimization was performed by combining the best metamodels for each variable with a sequential two-point diagonal quadratic approximation optimization algorithm. The torque ripple was improved by approximately 1.63% compared with the initial model, whereas the constraint values remained constant. Finally, an FEA was performed on the optimal point, and the FEA results matched with those of the optimal method.

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Optimal Design of a Surface Permanent Magnet Machine for Electric Power Steering Systems in Electric Vehicle Applications Using a Gaussian Process-Based Approach

Choi,

Jang,

Choi

et al. 2023

Actuators

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The efficient design optimization of electric machines for electric power steering (EPS) applications poses challenges in meeting demanding performance criteria, including high power density, efficiency, and low vibration. Traditional optimization approaches often fail to find a global solution or suffer from excessive computation time. In response to the limitations of traditional approaches, this paper introduces a novel methodology by incorporating a Gaussian process-based adaptive sampling technique into a surrogate-assisted optimization process using a metaheuristic algorithm. Validation on a 72-slot/8-pole interior permanent magnet (IPM) machine demonstrates the superiority of the proposed approach, showcasing improved exploitation–exploration balance, faster convergence, and enhanced repeatability compared to conventional optimization methods. The proposed design process is then applied to two surface PM (SPM) machine configurations with 9-slot/6-pole and 12-slot/10-pole combinations for EPS applications. The results indicate that the 12-slot/10-pole SPM design surpasses the alternative design in torque density, efficiency, cogging torque, torque ripple, and manufacturability.

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Modeling, Investigation, and Mitigation of AC Losses in IPM Machines with Hairpin Windings for EV Applications

Cited by 5 publications

References 30 publications

Analysis of Interior Permanent Magnet Synchronous Motor according to Winding Method

Analysis of Interior Permanent Magnet Synchronous Motor according to Winding Method

Optimization of a Permanent Magnet Synchronous Motor for e-Mobility Using Metamodels

Optimal Design of a Surface Permanent Magnet Machine for Electric Power Steering Systems in Electric Vehicle Applications Using a Gaussian Process-Based Approach

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