Compact Electrical Machine Design

with substantial Copper savings

Göran Nord Höganäs AB

XXXX CCCCCC, Höganäs AB, XXXXX CCCCCC, Höganäs AB
2007 Magnetic Conference April 4-5, Chicago, Ill
 Outline

Introduction 8
Case Study: 28
-Compact Electrical Machine Design with substantial copper savings

Case Study Conclusions 1

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Höganäs AB ct
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• Founded in 1797
• Today a leader within the iron and metal powder industry
• End products are mainly used by the automotive industry and
home appliances, lawn and garden and hand-tools
• 1600 employees in 14 countries (2005)
• Turnover 2005 was 621MUSD (1USD=7.4SEK average 2005-2007)
• Magnetic: Soft Magnetic Components - Somaloy®
US – North American Höganäs Inc.
Iron Powder Plant in Höganäs, Sweden

Brazil Japan

Belgium
India UK

China
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Somaloy® Materials ct
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0,1mm

Electrically insulated Fe-powder particles

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Magnetic Materials Application Areas ct
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2,0
Grain-oriented Si-steel sheet
Non-oriented
Si-steel sheet

1,5

Sintered
P/M-Materials Somaloy®
1,0

Flux density (T)

Stainless High frequency
Steel Si-steel sheet

0,5 Ferrites

0.0
1 10 100 1k 10k 100k 1M 10M
Operating frequency (Hz)
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Components made out of Somaloy® ct
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3D-Magnetic properties Net-shaped 3D geometries

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Somaloy® Component Production ct
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Powder Metallurgy (P/M)

• Net shape
• Low cost
• Large scale production
• Globally well established since 60 years
• Good tolerances
• Smooth surfaces
• Low material waste
• Complex shapes (3D)

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Design Using Somaloy® ct
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A. 3D
3D magnetic properties
3D geometry
⇒ flux paths in 3 directions

B. Flux concentration
Lower performance magnets
Lams
can be used

SMC

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Design Using Somaloy® ct
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C. Copper savings
Circular cross section
=> smallest ratio between peripheral length and cross-section area

Somaloy® technology: => Less copper

• rounds off structures easily ⇒ Less total loss
• winding with reduced peripheral length ⇒ Reduced costs

Lamination SMC core body Example of a short coil

on a rounded core body

ASMC
ALAM

ALAM = ASMC

2007 Magnetics Conference April 4-5, Chicago, Ill Prof. Alan Jack, Newcastle University
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Somaloy® Commercial Examples ct
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1. Actuator – LYNG Motor A/S, Norway
2. ABS Pump Motor – AISIN SEIKI, Japan 1
3. Servo Motor – Phase Motion Control S.r.l., Italy
4. Linear motor – Twinbird, Japan
5. Water pump – LAING GmbH, Germany
6. Diesel actuator – Robert Bosch GmbH, Germany

2
4 5

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Acknowledgment St
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to
Professor Alan Jack
and project leader Glynn Atkinson

Power Electronics, Drives & Machines Group

University of Newcastle upon Tyne, UK

for the cooperation

and excellent design work in this study!

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Outline Case Study St
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• Driving forces
• Case study reference and target
• Materials comparison
• Redesign Philosophy
• Somaloy® Component Design
• Results
• Conclusions

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Project Driving Forces St
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Savings in
1. Space
2. Copper

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Case Study Reference St
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Reference:
• Home appliance Split-system air conditioner
energy rating “A”
• ‘State-of-art’ variable speed BLDC drive
• Low-noise Scroll compressor
• Representing top level efficiency on the market

Target:
• Focus on compressor drive
• Maintain or improve high efficiency
• Redesign stator for Somaloy®
• Equal or smaller motor size
• Analyze cost driving factors

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Case Study Reference St
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Laminated motor performance:

• Outer diameter 112.2 mm
• Axial length 95 mm
• Speed 3360 rpm
• Torque 2,5Nm
• Operating frequency 112 Hz
• Input power max. 956 W
• Efficiency at max. power 91.2%

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Case Study Performance Target St
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• Maintain the high efficiency

• Reduction of motor size
• Redesign stator core for Somaloy®
• Keep original rotor design

Rotor characteristics
• 0.35 mm lamination
• 4 pole
• Buried sintered NdFeB
magnets
• OD 60 mm
• Length 48 mm

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Material Comparison – BH-curve St
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2,0

1,6

1,2
3% Silicon steel

B (T)
Somaloy® 3P
0,8 Somaloy® 500

0,4

0,0
0 2000 4000 6000 8000 10000
H (A/m)

Lamination : typical single sheet data from catalogue

Somaloy 3P (0.3% lubricant), 800MPa : component data
Somaloy 500 (0.5% Kenolube), 800MPa : component data
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Materials Comparison - Loss St
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20

15

(W/kg)
10

0
0,35mm 3% Silicon Somaloy 500 + Somaloy 3P (800MPa)
lamination 0,5%Kenolube
(800MPa)

Motor operating condition;

• 1,3T
• 112Hz

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Components made out of Somaloy® St
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SMC Opportunities:
• 3D properties
• Design freedom
• Complex, net shaped parts with tight tolerances

SMC Challenge:
• Somewhat lower saturation induction than laminations
• Lower iron loss than lamination at high frequency
• Higher iron loss than lamination at low frequency

Matching performance by redesign

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Redesign Philosophy St
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Round
Winding losses More c
ed stru
cture
ircular
Tighter cr o
windin ss-section
g Winding losses
Winding losses

Increas
ed iron
Iron losses cross-s
ection
Iron losses area Iron losses

Lamination Direct replacement < Somaloy® > Optimized re-design

Equal Compact
Geometry Geometry

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Somaloy® Component Design St
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Reference Somaloy® based design

Reduced
26m winding 19m
length

Winding configuration
Reduced length
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Somaloy® Component Design St
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Reference Somaloy® based design

Different cross
section area

768mm2 827mm2
(Minimum) (Constant)

Stator tooth shape

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Somaloy® Component Design St
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Winding configuration
Reference Somaloy® based design

Axial length: 92 mm 65 mm
Slot fill factor: 44% 66%
Wire length: 26 m 19 m
Weight: 762 g 533 g
No. turns: 132 142
Winding loss: 29.8 W 22.3 W
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Somaloy® Component Design St
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Stator Iron configuration
Reference Somaloy® based design

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Somaloy® Component Design St
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Stator Iron configuration
Reference Somaloy® based design

Soft magnetic material: 0.35 mm Si-lam. Somaloy® 3P

Tooth number: 6 6
3D design: No Yes
Tot. axial length: 48 mm 65 mm
Tooth body length: 48 mm 39 mm
Slot area: 150 mm2 108 mm2
Weight: 1690 g 2220 g
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Somaloy® Component Design St
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Stator assembly
Reference Somaloy® based design

Length
saving

length
Equal Fe
Length
saving

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Somaloy® Component Design St
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Stator assembly
Example of Modules/Sectioning Somaloy® based design

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Somaloy® Component Design St
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Stator assembly
Example of Modules/Sectioning Somaloy® based design

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Prototype St
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Material - Somaloy® 3P

• 0.3% lubricant
• 800 MPa compaction pressure
• Density:
– 7.45 g/cm3, Tooth
– 7.36 g/cm3, Core-back
• Resistivity
– 500 µOhm m

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Prototype St
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Tooled net-shaped Somaloy® component

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Prototype St
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Somaloy® Reference

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Prototype St
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Somaloy® Reference

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Prototype St
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Test Status
• Prototype Somaloy motor is now running in
bench test
• The laminated ref. stator will be identically
tested
• Test and verification of the design in progress

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Results St
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Comparison Somaloy® design v.s. ref. laminated design

Performance
125%

100%

75%
Lamination
Somaloy
50%

25%

0%
Efficiency Max Torque

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Results St
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Comparison Somaloy® design v.s. ref. laminated design

Design geometry parameters
125%

100%

75%
Lamination
Somaloy
50%

25%

0%
Motor length Motor diameter Weight, stator assembly

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Results St
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• Compact application design
• Material savings

Potential
~10 – 20 %
reduction

Automotive example:
Scroll compressor
Reference
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Somaloy® based design
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Results St
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Comparison Somaloy® design v.s. ref. laminated design

Cost related parameters
150%

125%

100%

Lamination
75%
Somaloy

50%

25%

0%
Cu-wire mass Shaft length Hermetic housing length Iron mass

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Conclusions St
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• Careful design of Somaloy® stator components

is shown to compete state-of-art efficiency in
HVAC compressor drives

• The compact Somaloy® stator design features:

– 30% shorter axial motor length
– 25% reduction of copper-winding
– Up to 20-30% shorter shaft
– Up to 10-20% shorter housing

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XXXX CCCCCC, Höganäs AB, XXXXX CCCCCC, Höganäs AB