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This paper deals with the numerical modelling of electromagnetic losses in electrical machines, using electromagnetic field computations, combined with advanced material characterisations. The paper gradually proceeds to the actual reasons why the building factor, defined as the ratio of the measured iron losses in the machine and the losses obtained under standard conditions, exceeds the value of 1.

In rotational alternating current machines, interlocking is a commonly used manufacturing method to fix laminated silicon steel cores. The purpose of this study is to measure the localized magnetic properties more comprehensively and to analyze the deteriorated magnetic properties caused by interlocking more accurately.

A movable B–H sensor is designed in this paper. The localized magnetic properties measurement was performed to investigate the magnetic properties around the interlocks with various sizes, various orientations and various numbers of laminations. Then, the damaged area caused by the interlocking was quantified, and the magnetic degradation of different degrees is layered.

The measurement results have shown that the interlocks with larger sizes, along the transverse direction and on 10-layer laminate, will lead to more serious magnetic degradation, and the maximum loss increment can reach up to 70%.

This work is an improvement and optimization based on the previous overall magnetic measurement of the interlock. The quantitative results of the localized magnetic measurement will have a certain significance for the accurate modeling and simulation of the electrical machines and provide valuable guidance for the optimization of the actual production process of the motor.

Due to the increasing amount of high power density high-speed electrical machines, a detailed understanding of the consequences for the machine’s operational behaviour and efficiency is necessary. Magnetic materials are prone to mechanical stress. Therefore, this paper aims to study the relation between the local mechanical stress distribution and magnetic properties such as magnetic flux density and iron losses.

In this paper, different approaches for equivalent mechanical stress criteria are analysed with focus on their applicability in electrical machines. Resulting machine characteristics such as magnetic flux density distribution or iron are compared.

The study shows a strong influence on the magnetic flux density distribution when considering the magneto-elastic effect for all analysed models. The influence on the iron loss is smaller due to a high amount of stress-independent eddy current loss component.

The understanding of the influence of mechanical stress on dimensions of electrical machines is important to obtain an accurate machine design. In this paper, the discussion on different equivalent stress approaches allows a new perspective for considering the magneto-elastic effect.

The purpose of this paper is to study the variation of the specific iron loss components of electrical steel sheets when applying a tensile mechanical load below the yield strength of the material. The results provide an insight into the iron loss behaviour of the laminated core of electrical machines which are exposed to mechanical stresses of diverse origins.

The specific iron losses of electrical steel sheets are measured using a standardised single-sheet tester equipped with a hydraulic pressure cylinder which enables application of a force to the specimen under test. Based on the measured data and a semi-physical description of specific iron losses, the stress-dependency of the iron loss components can be studied.

The results show a dependency of iron loss components on the applied mechanical stress. Especially for the non-linear loss component and high frequencies, a large variation is observed, while the excess loss component is not as sensitive to high mechanical stresses. Besides, it is shown that the stress-dependent iron loss prediction approximates the measured specific iron losses in an adequate way.

New applications such as high-speed traction drives in electric vehicles require a suitable design of the electrical machine. These applications require particular attention to the interaction between mechanical influences and magnetic behaviour of the machine. In this regard, knowledge about the relation between mechanical stress and magnetic properties of soft magnetic material is essential for an exact estimation of the machine’s behaviour.