Abstract
Soft magnetic composite (SMC) is composed of ferromagnetic particles surrounded by electrical insulation layer. During the manufacturing process, the electric insulation layer may be destroyed and thus the eddy current will be induced, which makes it difficult to calculate the accurate eddy current loss. In this paper, the inter-particle eddy current loss is calculated at the macro-scale by modeling the actual sample and using the measured conductivity of the sample, moreover intra-particle eddy current loss is calculated by modeling single particle of SMC base on the existing model. Then, under different particle sizes and frequencies, the influence of skin effect on the calculation of eddy current loss is analyzed. Finally, to verify the proposed model, the iron losses of two SMC materials are calculated and they are compared with measured results. It can be seen that when the inter-particle eddy current loss has been considered, then the core loss of SMC will be agreed very well with the measurement results, thus the proposed model can be used for the actual core loss calculation for the electrical machine or other electromagnetic device with SMC cores.
Highlights
Soft magnetic composite (SMC) is a relatively new soft magnetic material, which is composed of ferromagnetic particles surrounded by electrical insulation.1 Compared with traditional laminated materials, SMC has some advantages, such as isotropic 3-D magnetic flux paths, low eddy current loss and easy to be manufactured into complex shapes
To calculate the core loss quickly and accurately in the determined electromagnetic device, this paper proposes a method to calculate the core loss of the SMC by integrating the single particle model at the mesoscopic scale and the ring sample model at the macroscale
As shown, compared with the model proposed in Ref. 6, the core losses of two SMC materials calculated by the proposed model coincide with the measured ones
Summary
Soft magnetic composite (SMC) is a relatively new soft magnetic material, which is composed of ferromagnetic particles surrounded by electrical insulation. Compared with traditional laminated materials, SMC has some advantages, such as isotropic 3-D magnetic flux paths, low eddy current loss and easy to be manufactured into complex shapes. In Ref. 6, homogenization method is used to simulate single SMC particle, and the 3-D SMC particle model is proposed to calculate the core loss. This method greatly reduces the calculation cost and can be used in calculation of core loss for actual electromagnetic device. The random contact of simulated particles is very complicated and computationally expensive, it is difficult to apply this method in analyzing the core loss in actual electromagnetic device. To consider the inter-particle and intra-particle eddy current loss, the actual SMC sample is modeled on the macro scale and SMC particles are simulated on the mesoscopic scale. Based on the model proposed in Ref. 6, single particle model is established, as shown in
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