Analysis of Winding AC Loss in a Permanent Magnet Synchronous Machine With High Slot Fill Aluminum Winding

This paper proposes a novel permanent magnet machine with high slot fill aluminum winding. The slot fill factor is 83.8%, and then, the winding DC loss can be reduced. Generally, copper windings are used for reducing a DC loss. On the other hand, it generates high AC losses at high frequency region because of high electrical conductivity. In this paper, the proposed aluminum winding machine achieves both reductions of winding AC losses and the motor weight. In three-dimensional finite-element-method (3D-FEM), it is analytically investigated that AC losses are concentrated around corners of coils due to fringing fluxes between stator tooth tips. In addition, it is found that sum of winding DC and AC losses is low in high-speed region over 820 Hz in the proposed aluminum winding machine compared with that of copper winding machine.