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This paper aims to analyze the influence of welding-induced mechanical stress of a magnetic core material on the performance behavior of a permanent magnet excited synchronous machine (PMSM). Welding, interlocking, clinching and the use of adhesives are state-of-the-art packaging technologies used in the manufacturing of electrical machines. However, the packaging processes degrade the electromagnetic properties of the electric steel sheets, thereby decreasing the performance and achievable range of the electric vehicle.

In this paper, an approach that maps the local changes in magnetic properties due to welding induced stress with the stress values is developed. The welding process induces internal stress inside the steel sheet due to the diffusion of thermal energy into the sheets. Other effects are the changes in the micro structures of the steel sheets (grain sizes). These induced mechanical stresses lead to significant deterioration of the electromagnetic properties. They also lead to an increase in iron loss attributed to steel lamination.

A low speed (city), a high-speed (highway) and WLTC-c3 driving cycle will be used to analyze the effects of the induced stresses on the machine efficiency at the different operating conditions. A high-speed PMSM with a maximum speed of 26,000 min⁻¹ and maximum torque of 130 Nm is designed for this study.

The value of this study is in the development of a local varying modeling approach that analyses the influence of weld-induced stress on the performance of electrical machines. Its originality is evident in the mapping methodology. This will enable an application dependent improvement possibilities due to the understanding of the impact of weld-induced stress on the electromagnetic properties of weld-packaged core.