A Computationally Efficient PM Power Loss Mapping for Brushless AC PM Machines With Surface-Mounted PM Rotor Construction

This paper describes a computationally efficient approach for mapping rotor power loss in permanent magnet (PM) machines. The PM loss mapping methodology discussed here utilizes a small number of time-step finite-element analyses (FEAs) to determine the parameters of a functional representation of loss variation with speed (frequency) and stator current and is intended for a rapid evaluation of machine performance over the entire torque–speed envelope. The research focus is placed on field-oriented-controlled brushless AC PM machines with surface-mounted PM rotor construction, although the method could be adapted for other rotor formats. The loss mapping procedure accounts for the axial segmentation of the PM array through the use of an equivalent electrical resistivity of the segmented PM array, which is obtained from three-dimensional (3-D) FEA. The PM loss can be accurately mapped across the full operational envelope, including the field-weakened mode, through a single 3-D and four two-dimensional time-step FEAs. The proposed methodology is validated on an 18-slot 16-pole surface-mounted brushless AC PM machine design. The loss mapping procedure results closely agree with the computationally demanding alternative of direct 3-D finite-element prediction of the PM power loss undertaken at each of the machine’s operating points.