Soft magnetic material degradation due to manufacturing process: A comparison of measurements and numerical simulations

Iron losses are one major origin of losses in highly utilized electrical machines. This work presents how iron losses can be modeled including material deterioration due to manufacturing processes. The obtained model is used to improve the machine design process and understand currently used building factors. These factors are state-of-art in describing iron-loss increase by processing of electrical steel. Aim of this work is to understand the origins of these building factors and give the possibility to the machine designer to estimate the influence of magnetic circuit design and soft magnetic material choice on the machines iron losses and therefore efficiency and power density. The electrical steel is characterized by measurements in the Single-Sheet-Tester with various numbers of cutting edges. Finally, comparisons of measurements and numerical simulations of an 80kW interior permanent magnet machine are given.