2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

No-load Iron Loss of a Surface-Mounted Permanent

Magnet Synchronous Motor utilizing an Amorphous
Metal Stator Core
Wenming Tong Ruolan Sun Shengnan Wu
National Engineering Research Center National Engineering Research Center National Engineering Research Center
for Rare-earth Permanent Magnet for Rare-earth Permanent Magnet for Rare-earth Permanent Magnet
Machines Machines Machines
Shenyang University of Technology Shenyang University of Technology Shenyang University of Technology
twm822@126.com srl_email@163.com imushengnan@163.com

Abstract—The no-load iron loss characteristics of a radial
flux surface-mounted permanent magnet synchronous motor
(PMSM) with an amorphous metal stator core (AMSC) are
investigated using finite element method and verified by
experiments. Firstly, the magnetization curves and loss curves
of a stacked AMSC at different frequency are tested based on a
ring-shape specimen method. The loss coefficients and
correction factors for analyzing the iron losses are presented
based on the experiments. Then, finite element method is
adopted to investigate the iron loss at inverter supply and
sinusoidal supply, different inverter modulation ratios and air
gap lengths. An experimental platform is established to test the
total iron loss at different speed for both sinusoidal supply and
inverter supply, and the experimental results are compared with
the calculation results in the same situation. The comparison
shows that the accuracy of calculation results can meet the needs
of engineering practice.
Keywords—Permanent magnet synchronous motor;
amorphous metal; no-load iron loss
I. INTRODUCTION
Iron loss is known as one of the main loss components in
high frequency electrical machines, such as high speed
motorized spindles, high speed air compressor motors, electric
vehicle traction motors, especially working in field-
weakening regions. So, the efficiency of this kind of motor can
be improved remarkably by decreasing the iron loss. The
techniques on decreasing iron loss of motors with
conventional magnetic material have already reached a
breaking point. With the development of new magnetic
materials, employing low loss magnetic or conductive
materials instead of traditional counterpart becomes a feasible
way to improve motor efficiency [1]. The travelling distance
could be increased remarkably if the traction motor is changed
to an amorphous metal (AM) one. Since the AM motor is with
high-efficiency, it can be a new type of promising traction
machine served for the high-performance electric vehicles.
AM is characterized by extremely low losses relative to the
conventional silicon steel sheet (SSS). Therefore, the excellent
low loss properties offer some possibilities to increase the
motor efficiency in using AM stator core (AMSC) [2]-[4].
Some research achievements have been done on the loss
analysis of AM permanent magnet synchronous motors
(PMSMs) [5-13]. In [5], the loss and efficiency of an
inductance motor with an AMSC are analyzed. In [6-10], the
loss performances of permanent magnet machines are
analyzed and tested to demonstrate the superiority of applying
Supported in part by Science and Technology Planning Project of
Guangdong Province (2017B090904007)
AMSC to radial flux permanent magnet machines. In [11-13],
the AMSCs made by winding process are adopted to axial flux
permanent magnet machines, and good results have been
obtained.
This paper establishes an experimental platform and tests
the magnetization and loss characteristics of a stacked AMSC.
The loss coefficients of a stacked AMSC are obtained. The
influence of a few key parameters on the no-load iron loss of
the AM PMSM are investigated based on finite element
method. The parameters include modulation ratio of the
inverter, and the air gap length of the motor. Some conclusions
are obtained on the loss distribution and the variation
tendencies of AM PMSM under different conditions. Part of
the calculated results are compared with the experimental
results to verify the validity of the analysis.
II. PROPERTIES OF THE AMSC
The specifications of SS and AM used in this paper are
given in Table I. It can be seen from the table that the AM is
just 1/14 thickness and almost 3 times electric resistivity of
conventional SSS, so the loss of AM should be much lower
than that of SSS theoretically. However, the saturation flux
density of AM is much lower than that of SSS.
TABLE I. FEATURES OF SSS AND AM
Item SSS AM
Material 35W270 2605SA1
Electric resistivity 45μΩ·cm 130μΩ·cm
Density 7650kg·cm-3 7180 kg·cm-3
Lamination factor 0.97 0.86~0.88
Thickness 0.35mm 0.025mm
Saturation flux density 2.03T 1.56T
The manufacturing process for the AMSC is shown in [5].
The loss and magnetization performances of the
manufactured AMSCs deteriorate a lot compared with that of
AM strip. A big error may exist if the magnetic performance
of AM strip is used for analyzing the AM motors. One way
to solve this problem is researching the manufactured AM
cores by measurement using Epstein frame or single sheet
measuring system, but for AMSCs, measurement method of
ring specimens is more convenient. An experiment is
conducted on the AMSC under different supply frequencies
according to the standard of IEC 60404-6.
The experiment platform for testing the B-H and loss
curves of AMSCs is obtained by connecting all the equipment
according to the experimental principle diagram shown in Fig.
2.

978-1-7281-3398-0/19/$31.00 ©2019 IEEE

978-1-7281-3398-0/19/$31.00 ©2019 IEEE

 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

The B-H curves and relative permeability curves of the 1.4

AM core at different frequencies were tested according to Fig.
AAM stator core

Relative Permeability(×104)
2, and the results are shown in Fig. 3 and Fig. 4. 1.2
SSS
1.0

0.8

0.6

0.4

0.2

0.0
0 0.5 1 1.5
H(A/m)
Fig. 4. Relative permeability curve of AM stator core and SSS
Fig. 1. Photo of an AMSC.

The loss curves of AMSC under different frequencies are

tested as shown in Fig. 5. The regression analysis of the
AMSC loss data at different frequencies is carried out to
obtain the loss coefficients in equation (1). The eddy current
loss coefficient ke, hysteresis loss coefficient kh and
coefficient α are obtained as show in Table I. The coefficients
can be used for analyzing the iron losses of radial flux
AMPMSMs adopting the same machining process.
p Fe = k h B mα f + k e B m2 f 2 (1)

where pFe is the experimental data of specific loss of the

AMSC.
Fig. 2. Experimental platform for testing the B-H and loss curves of AMSCs 45
40 550Hz
The saturated flux density of the AM core is almost 1.4T, 35 450Hz
Specific Loss(W/kg)

which is lower than the data of AM strip 1.56T, and the data 30 400Hz
of SSS, and what is more, the permeability in the common use
core flux density range is lower than SSS as shown in Fig. 4. 25 350Hz
20 300Hz
The B-H curves of the AMSC at different frequencies
coincide approximately according to the test. The 15 267Hz
permeability of the processed stacked AM core decreased a lot 10
compared with the AM strip. The saturated flux density and
5
the inflection point of the stacked AM core are lower than that
of the SSS materials, so the AM PMSM will enter the 0
saturated zone earlier than the SSS motor at the same running 0 0.5 1 1.5
condition. This will increase the exciting current, decrease the B(T)
power factor and cause other issues of AM induction motors. Fig. 5. Specific loss curves of AMSC under different frequencies.
The relative permeability of the stacked AM core is much
higher than that of SSS at a low flux density, lower than that
TABLE II. LOSS COEFFICIENTS OF THE STACKED AMSC
of SSS at the common flux density scope of the motor (0.8T-
Loss coefficients kh α ke
1.3T). For example, the relative permeability of SSS is about
7000 and that of AM is about 4500 at 0.1T. The latter is 35.7% Value 5.7×10-3 1.83 5.7×10-5
smaller than the former.
1.8 As can be seen from Fig. 5, the loss of the processed
1.6 laminated AM core is much higher than that of the AM strip
1.4 because the stress loaded on the AM during the machining
1.2 process will deteriorate the loss property of AM. However, the
1
AAM stator core loss of the laminated AAM core is still lower than that of
B(T)

0.8
SSS W270-35 SSS. Taking 1T as an example, the loss of the
processed laminated AM core is 7.46 times of the AM strip,
0.6
but it is only 63.6% of the 35W270 SS. This shows a big
0.4
advance of the laminated AM core in the aspect of loss.
0.2 During the machining process of the AM core, some
0 internal stress exists, and will lead to a deterioration of the
0 1000 2000 3000 4000 loss performance. The magnetic characteristics of AMSC are
H(A/m) greatly affected by the machining process, including stacking
Fig. 3. B-H curve of AM stator core and SSS. or winding, annealing, solidification and cutting slots.
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

Annealing could be used to partly release the stress. The B. Harmonic Loss Distribution in AMPMSM at Different δ
features of performances sensitive to stress, thin ribbon, hard The harmonic loss under no-load condition is obtained by
and brittle of AM limit its application in motors. subtracting the sinusoidal supply loss from the inverter
III. MOTOR SPECIFICATIONS supply loss under different air gap lengths.
In order to study the influence of air gap lengths on the
The specifications and main dimensions of the AM PMSM harmonic loss of the AM PMSM, the design of the 2.1kW
investigated in this paper are listed in Table III. The surface- AM PMSM is modified as follows: the air gap lengths are
mounted magnet with cutting angle is adopted for the designed as 1.0mm, 1.3mm, 1.5mm, 1.8mm and 2.0mm
optimization the waveform of air gap flux density. Fig. 6 while the pole-arc coefficient and dimensions of the stator are
shows the configurations of the AM PMSM. kept unchanged. The magnetization direction lengths of the
permanent magnets are modified to keep the ratios of those
TABLE III. MOTOR DIMENSIONS to air gap lengths constant, so the air gap lengths can be
Quantity Value
changed without changing the no-load air gap flux density
Stator outer diameter 123mm
Stator inner diamete 81mm amplitude and the back electromotive force value. The
Lamination length 55mm performances of the AM PMSM with different air gap lengths
Air gap length 1.5mm are shown in Table IV.
Rotor inner diameter 31mm The flux density variations at a point A located in the
Magnet thickness 3.6mm permanent magnet, point B located in the rotor core are
Pole arc coefficient 0.912 shown in Fig. 8 in order to illustrate the reason why the
Number of conductors per slot 28 harmonic loss variation in different parts of motor with
different air gap lengths. From the figure, the fluctuation of
the flux density in the points selected decreases from 1.0mm
to 2.0mm while the gap flux density increases.
TABLE IV. VARIATION OF MOTOR PARAMETERS VS. AIR-GAP LENGTH
Air gap Magnetization length of Back EMF Air gap flux
length(mm) permanent magnet(mm) (V) density (T)
1.0 2.20 310.6 0.670
1.3 2.50 310.0 0.640
1.5 3.60 313.1 0.691
1.8 4.62 312.6 0.670
Fig. 6. Configurations of the AM PMSM 2.0 5.20 309.0 0.660

IV. RESULTS AND DISCUSSIONS 0.73

1.0mm 1.5mm 2.0mm
In this section, the distribution of loss in each part of the 0.72
AM PMSM prototype, including stator core, rotor core and 0.71
permanent magnets, is analyzed under different inverter
B(T)

0.7
amplitude modulation ratios and different air gap lengths of
the motor on the basis of finite element method. 0.69
0.68
A. No-load Loss Distribution in AM PMSM at Different a
0.67
In order to investigate the influence of amplitude 0 1 2 3 4
modulation ratio a of the inverter on each loss in the t(ms)
AMPMSM, a =0.6, 0.65, 0.7 and 0.8 are chosen and the (a)
switching frequency is kept as a constant at the same time. Fig. 0.82
1.0mm 1.5mm 2.0mm
5 shows the loss in each area versus amplitude modulation 0.81
ratio. It can be seen that loss in stator core, rotor core,
0.8
permanent magnet and total loss decreases with the increase
B(T)

of amplitude modulation ratio. The average reduction of loss 0.79

in each area is 7.14%, 15.00%, 30.51% and 16.53%, 0.78
respectively. This is due to the fact that the amplitude of time 0.77
harmonics is lower when the modulation ratio turns higher.
0.76
40 stator core 0 1 2 3 4
rotor core t(ms)
30 permanent magnet (b)
Fig. 8. Flux density variation of each point vs. air gap length (a) Point A (b)
Point B
Loss (W)

20
The curve of the no-load harmonic loss at different air gap
10 lengths of the AM PMSM is shown in Fig. 9. The harmonic
loss in the stator core, rotor core and permanent magnets
0 decreases with the increase of the air gap length. When the air
0.5 0.6 0.7 0.8 0.9 gap length δ increases averagely by 10% as 0.1mm from 1mm
a to 2mm, the stator core harmonic loss is reduced by 9%, the
Fig. 7. Each loss vs. a rotor core harmonic loss is reduced by 9.78%, the permanent
magnet harmonic loss is reduced by 7.46%, and the total
 2019 22nd International Conference on Electrical Machines and Systems (ICEMS)

harmonic loss is reduced by 7.91%. With the increase of the The comparisons of measured and calculated results of
air gap length, the harmonic magnetic field produced by the AMPMSM are shown in Fig. 11. As can be seen from the
time harmonics is reduced and the amplitude of the harmonic figure, the value and change rules of the measured and
flux density decreases. calculated total loss agrees well and the latter is a little bit
lower. This is because some origins of no-load iron losses are
50
not taken into account, such as the eddy current loss in stator
Stator core harmonic loss supporting parts, copper loss generated by skin effect and
Harmonic loss (W)

40 proximity effect and core loss increase induced by external

Rotor core harmonic loss
30 applied stresses, such as wire-electrode cutting process, the
PM harmonic loss inserting winding process and shrink fitting of the stator yoke,
20 etc. A suitable correction factor can be used to make the
calculation results more accurate according to the
10
measurement and calculation results.
0
0.8 1 1.2 1.4 1.6 1.8 2 2.2 70
Air gap length (mm) 60 Inverter supply calcluation results

No load iron loss (W)

Fig. 9. Harmonic loss of the AMPMSM under different air gap lengths 50 Inverter supply test results

C. Measurement 40
In order to verify the accuracy of the iron loss calculation 30
results, an experimental platform is established as shown in 20
Fig. 10. The measurement system for testing the no-load iron
10
loss of the AM PMSM under inverter-fed condition is shown
in the figure. The input power Pin and current I are measured 0
by power meter. 2000 1000 3000 4000
Rotation speed (rpm)
According to the experiments, the no-load iron loss Piron
Fig. 11. Comparison of measured and calculated results of the AMPMSM
can be obtained as under both sinusoidal supply condition and inverter supply condition.
Piron = Pin − PCu − Pfw (2)
where Pfw is the rotor mechanical loss, and PCu is no-load V. CONCLUSION
copper loss. In this paper, an experiment for testing the magnetization
Mechanical loss and iron loss always coexist curves and loss curves of a stacked AMSC at different
simultaneously for permanent magnet motors. In this paper, frequency are presented based on a ring-shape specimen
another rotor with the same diameter and weight but without method by regarding the yoke of the stator core as a ring
permanent magnets is produced and tested to obtain the specimen, and the results show that the loss performances of
mechanical loss at different speeds. manufactured AMSC deteriorate a lot compared with that of
AC 380 AM strip, but the loss of AMSC is still just 63.6% the value
of SS. The loss coefficients for analyzing the iron losses of
radial flux AM PMSMs adopting the same machining process
are presented based on the experiments. The no-load iron loss
Regulator characteristics of the radial flux surface-mounted AM PMSM
Switch1 are investigated using finite element method and verified by
experiments. The total iron loss decreases with the increase of
Converter Prototype modulation ratio a and air gap length δ. A more attractive
AMSC could be obtained with the improvement of machining
process.
V Digital power meter
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