IEEE Electrification Magazine - June 2014 - 27

effect are neglected, the copper loss is proportional to the
a detailed magnetic circuit design and thermal circuit
product of specific electric loading A by armature current
design are carried out based on other design constraints
density J. the product of A by J is
such as voltage, mechanical characterdefined as the armature thermal load
istics, and efficiency.
q. A is related to the stator's inner
however, there might be other
diameter, and J is an intermediate
optimal goals to pursue besides power
parameter related to the detailed stadensity. in general, the iron loss of a
tor geometries. therefore, these two
motor in the design must be proporhigh-level parameters contain infortional to the copper loss to achieve
mation of both the geometries and
high efficiency in the rated conditions.
output power capacity. the inner and
the influence of the air-gap flux denouter diameters of the stator can be
sity and the stator saturation on the
expressed by a function of variables
core loss must be checked. therefore,
A and J. the peak power density
electromagnetic fea and thermal fea
t peak is then given by the output
must be conducted for evaluation and
torque T, the stator's outer diameter d o, and the length of
further optimization as the follow-up steps.
end winding.
figure 2 shows the trends of d o with respect to q and
figure 3 t peak with respect to q for an ipM of
80 kw. the dotted lines in both figures represent the con200
stant q contour. the solid lines represent d o and t peak . as
150
can be observed, the minimum value of copper loss for
the peak power capability can be reached near the corner
100
area of the peak power density curve for a given design.
the inner diameter of the stator and slot's geometries can
50
then be calculated.
0
for example, when the design objective of a stator outer
0
50
100 150 200 250 300 350
diameter is 0.2 m, the curves of q have many intersected
Time (s)
points with the curve of d o and each point corresponds to
Pcu: 1,238 W Pfe: 2,761 W
a set of A and J. it can be found that the minimum value
Pcu: 1,315 W Pfe: 2,185 W
of q is about 1,200 a2/mm3, and the corresponding point is
Pcu: 1,514 W Pfe: 1,745 W
the tangency point of 0.2 m-d o curve and 1,200 a2/mm3-q
Pcu: 1,845 W Pfe: 1,674 W
curve. the corresponding electric loading is 64 a/mm, and
the armature current density is 19 a/mm2.
Figure 1. The measured transient temperature rise at 80 kW with
different loss distributions.
when the design factors change within a range, the
optimal combination of A and J also
change. the ipM designed with the
peak power optimization method
120
2,6
2,
2,
mentioned previously will have a
20 400 00
2,
1,
0
110
0
1,
00
80
lower winding temperature rise, and,
60
0
0
100
thus, it is possible to work for a longer
duration at peak power. on the other
90
hand, when the design objectives are
80
0. 1
92
peak power and operating duration,
18
0.2
70
0
the minimum outer diameter and
4 36
60
maximum power density can also be
found through a similar optimization
0.216 54
50
40
0.228 7
0
1
process. an integrated circuit design
0
.
2
0. 22871
4
40
0.253 07 0 89
0.2
0.240 89
80 0
process is summarized in a flow
0.2 0. 277 65 24
0.253 07
89 6
42
0.2
30
65
24
0.26
524
0
chart shown in figure 4. according to
0.277 42
0.27742 60 0
0.2896
0.3
.30
11
0.28
96
37
0.30177
97
0.30
177
0.
3238
0.31395
20
61353
the goal of power density, the initial
0.31395
0.3
0.32613
0.32613
0.3
504
0.3383
0.3383
8
0.3
0.35048
626
0.35048
6
0.36266
0.36266
3
0.3748
870
0.37483
0.37483
1
0.39
0.38701
20 0 0.38701
0.41
0.39919
136
0.39919
values of the design parameters are
0.41136
0.41136
0.42919
354
0 42354
10
6
8
10
12
14
16
18
20
22
24
input to the design flow chart for
2)
Armature
Current
Density
J
(A/mm
power density optimization. then,
the range of electric loading and
armature current density is calculated. Figure 2. The trends of d o with respect to q.
0.204 3

0.21
6

54

0.
0 326
0.3.3013 9153
1 77
0.2
77 4
0.2 2
0. 25 65 24
3 07
0.24
0 89

0

4
65
21
0.

1
0.228 7

0.240 89

0.25307

0.2
0.277 89 6
42
0.265 2
4

0
40

1,

20
1,

0
00
1,

0
60

Specific Electric Loading A (A/mm)

80 0

	

6

Temperature (°C)

The major purpose
of thermal
management is
to control both the
heat generation
and dissipation.

IEEE Electrific ation Magazine / j une 2 0 1 4

27



Table of Contents for the Digital Edition of IEEE Electrification Magazine - June 2014

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