Loss reduction in a salient pole synchronous
machine due to magnetic slot wedge and semi-
closed stator slots
M. Jahirul Islam, Reza Rajabi Moghaddam

Abstract -- Influence of the magnetic slot wedge and semi-
closed stator slot is studied. The study focuses on the air-gap
flux density fluctuation due to the permeance harmonics and
associated rotor losses of the machine. Both, the no-load and
nominal load simulations are performed for the geometry with
non-magnetic slot wedge, with ferrite based magnetic slot
wedge and semi-closed slot geometry. The semi-closed stator
slot geometry in the field wounded synchronous machine has
remarkable influence to reduce the permeance harmonics and
as a consequence, the rotor surface and damper bar (DB) losses
of the machine. The air-gap length is studied to minimize the
total loss of the machine. Variation of the rotor core, damper
bar and field winding losses and root causes of these variations
are investigated. The study is performed by 2D time discretized
finite-element analysis (FEA).
Index Terms—Loss reduction, magnetic slot wedge, semi-
closed stator slot, air-gap length, permeance harmonics,
damper bar loss, rotor core loss.
I. NOMENCLATURE
A magnetic vector potential
Bn n th harmonic of the magnetic flux density
CEn eddy-current loss co-efficient of laminated iron
sheet associated with n th harmonic
CHn hysteresis loss co-efficient of laminated iron sheet
associated with n th harmonic
LD D-axis inductance
LQ Q-axis inductance
N total number of Fourier components included in
the iron loss calculation
Ns number of symmetry sectors
PDB resistive losses in the damper bars
PFeH hysteresis loss in the laminated iron
PFeE eddy current loss in the laminated iron
Qbr number of the damper bar in the solution sector
t time
ub voltage across a damper bar
V volume
 fundamental angular frequency
 permeability
 conductivity
II. INTRODUCTION
T HE efficient, reliable and economical design of
electrical machines has been a standard demand for
M. Jahirul Islam and Reza Rajabi Moghaddam are with Corporate
Research Centre, ABB AB, Västerås, Sweden. (e-mails:
jahirul.islam@se.abb.com, Reza.R.Moghaddam@se.abb.com)
978-1-5386-2477-7/18/$31.00 ©2018 IEEE
researchers and engineers since the very beginning of
electrical engineering. As a consequence, electrical machine
nowadays have good efficiency. However, there is still high
demand from the customer to deliver electrical machine with
higher efficiency. Electrical machine, in the form of
generators, produce most of the electric power on earth, and
as motor consume approximately 60% of industrial
electricity consumptions [1]. Even a small improvement in
efficiency can provide significant financial savings as well
as reduce carbon emission. To design even more efficient
machine requires accurate knowledge of the electrical
machine, consideration of the detailed electromagnetic
phenomena, magnetic field distribution and its origins [2-4].
Harmonics generated by the slot openings of the rotating
electrical machine are defined as the permeance harmonics
or slot harmonics [2-5]. The permeance harmonics are
generated by the stator slots with the rotation of the rotor
and affect the flux density fluctuation. Consequently, the
rotor core as well as the damper bar (DB) of the machine are
subjected to produce eddy-current losses [6-7]. For an open
slot machine, the air-gap length needs to be selected high
enough to avoid exposure of the rotor surface to these
harmonics to reduce the losses. However, with increasing
the air-gap length of a synchronous machine, higher
magnetizing current is required to magnetize the machine.
As a consequence, the field winding resistive loss will
increase. By using the magnetic slot wedge, the permeance
harmonics can be reduced considerably and consequently,
the rotor losses of the machine [8-24]. On the other hand, the
semi-closed stator structure has remarkable influence to
reduce the permeance harmonics as well as the rotor losses
of a synchronous machine.
The main objective of this study is to investigate the
influence of magnetic slot wedge and semi-closed stator slot
to reduce the losses and improve the efficiency of a
synchronous machine. For a relative comparison, the
machine with non-magnetic slot wedge is considered as a
reference. The no-load and nominal load simulation has
been conducted to investigate loss reduction. The air-gap
length has been studied to minimize the total loss of the
machine. Variation of the rotor core, damper bar and field
winding losses and their root causes are investigated.
III. METHODS
A. Finite element analysis
The study has been performed by 2D time discretized
finite element simulation. The circuit equations of the
windings consist of the coil resistance, end-winding
reactance and the flux linkage, which couples the field and
the circuit equations with each other. The magnetic vector
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potential at each mesh nodes is calculated by using 2D time-
discretized finite element analysis and the rotor mesh is
changed at each time step as the rotor is rotated. The
Newton-Raphson iteration method has been used to solve
the magnetic field at each time step and at changed position
of the rotor. The more detail about the field calculation with
rotor movement can be found [25-27].
B. Loss calculation
The total electromagnetic losses of a synchronous
machine are the summation of the stator and field winding
copper losses, iron losses and damper bar losses. However,
the geometrical change in the stator slot with non-magnetic
slot wedge, magnetic slot wedge or semi-closed stator
influence mainly on the rotor losses. The rotor losses consist
of field winding resistive loss, rotor core loss and damper
bar loss. The field winding is excited by the DC voltage to
have current flow in the field winding. The field winding
loss can be calculated from the resistance and current of the
field winding.
The damper has been modeled as conductive material and
taken into account by coupling the field and circuit equation.
A. Slot geometry
Three different stator slot geometry has been considered
to study the influence. The slot geometry with non-magnetic
slot wedge, magnetic slot wedge and semi-closed slot wedge
are presented in Fig. 1a, b and c respectively. The geometry
with non-magnetic slot wedge are modelled as air and the
relative permeability is one. The relative permeability of the
magnetic slot wedge and the laminated stator, which will be
extended to construct semi-closed stator slot opening are
provided in Fig. 2. The teeth need to be segmented and
attached after inserting the winding of the machine [29-32].
Slot area Slot area
Slot area
Non‐magnetic 
slot wedge
Magnetic slot 
wedge Semi‐closed

The resistive losses of the damper bar are calculated from a) b) c)

the field distribution by using the equation
Fig. 1. Illustration of the stator slot geometry with a) non-magnetic slot
wedge, b) magnetic slot wedge and c) semi-closed slot wedge.
 A  u A 
Qbr 2

PDB  N s       bi . dV
(1)
i 1 Vi  t  le t 
Relative permeability

where, PDB is the resistive loss in the damper bar of the

machine, Vi is the volume of the i th rotor bar inside the 2D
core region and Qbr is the number of the damper bar in the
solution sector [25-26].
The laminated iron core is modelled as non-conducting
and non-linear materials having single valued magnetization
curve. Therefore, the iron losses are neglected in the solution
of the magnetic field. An estimate for the iron losses is
obtained from the Fourier decomposition of the magnetic
flux density in the laminated iron core of the machine based
on the Steinmetz formula [26], [28]
N 2
PFeH    CHn  n  Bn  dV (2)
V  i 1  zero. The loss distribution over the surface of the rotor and
N 2
PFeE    CEn  n   Bn  dV
2
(3)
V  i 1  It can be observed from the loss distribution that the no-load
where, PFeH and PFeE are respectively the hysteresis and
eddy-current losses, Bn is the n th harmonic of the magnetic
flux density, N is the total number of Fourier components
included in the iron loss calculation, CHn is the hysteresis
loss co-efficient associated with n th harmonic, CEn is the
eddy-current loss co-efficient associated with n th harmonic
and  is the fundamental angular frequency.
IV. RESULTS
In this study, a MW range field winding synchronous
machine has been considered.
Fig. 2. Relative permeability of the magnetic slot wedge and stator
lamination.
B. No-load simulation
No-load simulations have been conducted with the
nominal speed of the machine and by keeping the stator
winding open. Therefore, the current in the stator winding is
damper bar for the slot geometry with non-magnetic slot
wedge, magnetic slot wedge and semi-closed slot are
presented in Fig. 3a, b and c respectively.
stray losses over rotor surface and damper bar can be
reduced by using magnetic slot wedge. However, by using
semi-closed slot geometry with laminated steel can almost
eliminate these losses completely. The reason for this
significant loss reduction can be explained from the airgap
flux density distribution. The no-load radial, tangential and
fundamental flux density are presented in Fig. 4a, b and c
respectively. For the identical fundamental airgap flux
density, the permeance harmonics created the flux pulsation
and this pulsating flux variation induce eddy currents in the
rotor surface and in the damper bar due to the induced
current in the conductive material. The semi-closed slot
opening eliminate the pulsation to almost negligible range
and eliminate the damper bar and rotor core losses.

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 geometry with magnetic slot wedge and Fig. 5c for the semi-
closed slot. Similar to the no-load simulation, the air-gap
flux density distribution can explain the physics of the loss
reduction. The radial, tangential and fundamental harmonic
air-gap flux density as a function of the electrical angles at
the nominal load condition are presented in Figures 6a, b
and c respectively. Similar to the no-load loss, nominal load
loss of the damper bar and rotor iron core can be reduced by
using magnetic slot wedge and semi-closed slot opening by
using segmented stator teeth [29-32].

a) b) c)
Fig. 3. Loss density distribution over the surface of the rotor pole and
damper bar of a MW range synchronous machine with a) non-magnetic slot
wedge, b) magnetic slot wedge and c) semi-closed stator slot.
Radial air-gap flux density (pu)

a) b) c)
Fig. 5. Loss density distribution over the surface of the rotor pole and
damper bar of a MW range synchronous machine with a) non-magnetic slot
wedge, b) magnetic slot wedge and c) semi-closed stator slot.
a)
Radial air-gap flux density (pu)
Tangential air-gap flux density (pu)

a)
b)
Tangential air-gap flux density (pu)
Fundamental air-gap flux density (pu)

b)
c)
Fundamental air-gap flux density (pu)

Fig. 4. No-load a) radial, b) tangential and c) fundamental harmonic airgap

flux density as a function of the electrical angle of the machine with non-
magnetic slot wedge, magnetic slot wedge and semi-closed slot.

C. Nominal-load simulation
The slot harmonics or permeance harmonics are mainly
responsible for the no-load losses in the rotor. Additional
loss components will be added in the rotor due to the
winding harmonics of the machine and these loss
components vary with the variation of the load [7]. The loss
distribution of the studied synchronous machine is presented c)
Fig. 6. Nominal-load a) radial, b) tangential and c) fundamental harmonic
in Fig. 5a for the slot geometry without any magnetic slot airgap flux density as a function of the electrical angle of the machine with
wedge (non-magnetic slot wedge), in Fig. 5b for the slot non-magnetic slot wedge, magnetic slot wedge and semi-closed slot.

1269
D. Influence of air-gap length on losses
The normalized total electromagnetic losses of the
studied synchronous machine is presented in Fig. 7 as a
function of the ratio between the air-gap length and stator
slot width for the geometry with non-magnetic slot wedge
(without any magnetic slot wedge), with magnetic slot
wedge and semi-closed slot with 1 mm opening width.
It can be observed that the magnetic slot wedge can
reduce the total losses of the machine, compare to the
machine with non-magnetic slot wedge. The main
contribution of the total loss reduction is coming from rotor
losses become higher than the geometry with magnetic or
non-magnetic slot wedge. Higher field winding loss
contributing to this loss variation. The variation of the
normalized field winding loss with total electromagnetic loss
is presented in Fig. 9 as a function of the ratio between the
air-gap length and stator slot width. To explain this
phenomena, the saliency ratio as well as the D- and Q- axis
inductance of these three geometries are presented in Fig.
10a, b and c, respectively.

Field winding loss (%)

iron and damper bar losses. The variations of the rotor core
and damper bar losses for the above mentioned three
geometry are presented in Fig. 8a and b as a function of the
air-gap length and stator slot width.
Total electromagnetic loss (%)

Fig. 9. Variation of the normalized field winding losses as a function of the

ratio between the air-gap length and stator slot width of the machine with
non-magnetic slot wedge, magnetic slot wedge and semi-closed slot.

Saliency ratio (LD/LQ)

Fig. 7. Variation of the normalized total electromagnetic losses as a function

of the ratio between the air-gap length and stator slot width with non-
magnetic slot wedge, magnetic slot wedge and semi-closed slot.

a)
Rotor core loss (%)

D-axis inductance, LD(Henry)

a)

b)
Damper bar loss (%)

Q-axis inductance, LQ(Henry)

b)
Fig. 8. Variation of the normalized a) rotor core and b) damper bar losses as
a function of the ratio between the air-gap length and stator slot width of the
machine with non-magnetic slot wedge, magnetic slot wedge and semi-
closed slot.
The semi-closed slot geometry reduce the air-gap
harmonics significantly by smoothing the air-gap flux
density. Therefore, rotor core and damper bar losses are
minimized significantly. As a consequence, the total losses
of the machine reduce significantly when the air-gap length
is smaller. However, for the higher air-gap length, the total
c)
Fig. 10. Variation of the a) saliency ratio, b) D-axis inductance and c) Q-
axis inductance as a function of the ratio between the air-gap length and
stator slot width of the machine with non-magnetic slot wedge, magnetic
slot wedge and semi-closed slot.
In general, with increasing the air-gap length, the saliency
ratio is decreased and as a consequence for the same
required power output, efficiency will be reduced. However,

1270
by using magnetic slot wedge, the negligible change is
noticed in the saliency ratio, although both D- and Q-axis
inductance are increased compared to the geometry without
any magnetic wedge. The reason behind the increasing the
D- and Q-axis inductance is the relative permeability of the
magnetic slot wedge and consequently, reduce the airgap
and slot leakage flux of the machine. By using semi-closed
slot shape with stator lamination the saliency ratio is
reduced, as the increment of the Q-axis inductance is higher
compared to the D-axis inductance.
Due to the reduction of the saliency ratio, the required
field current is higher with increasing the air gap. The field
winding resistive loss is proportional to the square of field
current and consequently, this loss increases. For the same
reason (lower saliency ratio), the required field current of
the generator with semi-closed stator slot with laminated
steel is higher compared to the generator without any
magnetic slot wedge (non-magnetic slot wedge) or with
magnetic slot wedge.
V. DISCUSSION
The permeance harmonics, generated by the stator slots
and winding harmonics generated by winding distribution,
generate losses in the rotor of the electrical machine. For a
field winding synchronous machine with damper bar
winding, the losses are generated in the surface of the rotor
pole and in the damper bar windings. The minimization of
these permeance harmonics in the airgap of the electrical
machine can reduce these additional losses in the rotor. The
magnetic slot wedge, semi-closed or closed structure can be
employed to reduce this permeance/slot harmonics.
Therefore, the induced rotor eddy-current losses are reduced
and the efficiency of the electrical machine are improved.
The no-load simulation shows that the no-load rotor
resistive loss can be minimized by using magnetic slot
wedge. However, by using semi-closed slot geometry with
laminated steel can almost eliminate the no-load rotor losses.
The reason of this significant loss reduction can be
explained from the air-gap flux density distribution. The
permeance or slot harmonics created the flux pulsation in the
airgap and this pulsating fluxes induce eddy currents in the
rotor core and in the damper bars. The semi-closed slot
opening eliminates the pulsation almost negligible range and
eliminates the damper bar and rotor core losses.
The additional loss components will be added in the rotor
due to the winding harmonics of the machine and this loss
components increase with increasing load of the machine.
Similar to the no-load loss, nominal load loss of the damper
bar and rotor iron core can be reduced by using magnetic
slot wedge and closing the slot by using segmented stator
teeth. The semi-closed slot geometry with extended stator
lamination reduce the air-gap harmonics significantly by
smoothing out the air gap flux density. As a consequence,
the rotor core and damper bar losses are reduced
significantly. The minimum total losses can be obtained
when the ratio of air-gap length to the stator slot width is
0.5. The simulation results show that by using semi-closed
stator teeth more than 32% total loss can be reduced.
However, for the higher air-gap length total loss reduction is
lower than the geometry with magnetic slot wedge. With
increasing the air-gap length further, the total loss reduction
is even lower than the machine with non-magnetic slot
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wedge.
To understand the phenomena, variation of the saliency
ratio as well as D- and Q-axis inductances are presented.
The saliency ratio is decreased with increasing the airgap of
the synchronous machine. However, by using magnetic slot
wedge, the negligible change is noticed in the saliency ratio,
although both the D- and Q-axis inductance are increased
compared to the geometry without any magnetic wedge. By
using semi-closed slot shape with stator lamination the
saliency ratio is reduced, as the increment of the Q-axis
inductance is higher compared to the D-axis inductance
value increment. As a consequence, the required field
current of the machine with semi-closed stator slot is higher
compared to the machine non-magnetic or magnetic slot
wedge. Therefore, field winding resistive loss is increased.
VI. CONCLUSIONS
The influence of the magnetic slot wedge and semi-
closed slot by extending the tooth tip of stator laminated
steel has been studied to reduce the permeance harmonics
and as a consequence the induced eddy-current loss
reduction and efficiency improvement. However, the
efficiency improvement can be achieved for relatively lower
air-gap length. For higher air-gap length, due to the lower
saliency ratio, the required field current is increased and
efficiency is reduced. The simulation results showed that by
using semi-closed stator teeth and selecting proper air-gap
length, almost one third of the total loss of the machine can
be reduced. Practically, the semi-closed slot can be obtained
by using segmented stator teeth.
Although, the study focuses on the field winding
synchronous machine, the concept can be beneficial to other
machine such as PM permanent magnet and IM machine
where the form-wound type stator windings are exploited.
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VIII. BIOGRAPHIES
Jahirul Islam was born in Bangladesh, in 1978. He received the B.Sc.
degree in electrical and electronic engineering from Bangladesh University
of Engineering and Technology (BUET), Bangladesh in 2002. He received
the M.Sc. (Technology) and D.Sc. (Technology) degree from Helsinki
University of Technology (HUT) in 2005 and 2010 respectively. He has
been working as a Scientist in ABB Corporate Research Centre, Västerås,
Sweden since 2009.
Reza Rajabi Moghaddam was born in 1974 and received the BSc degree
in electrical power engineering from Sharif University of Technology,
Tehran, Iran, in 1997 and the MSc and PhD degrees in electrical
engineering from the Royal Institute of Technology (KTH), Stockholm,
Sweden, in 2007 and 2011, respectively.
During 1997 - 2005, the author worked in different industries in Iran as
an electrical engineer in areas such as distribution system (MV and LV)
design, lighting design, cubicle construction and design, installation (power
plants, GIS-HV substation, etc.), offshore installation, field electrical
engineer and consultant.
Since 2006, he has been with ABB Corporate Research, Västerås,
Sweden, as a researcher, scientist and technology development project's
leader in various areas. His interests include electromechanical energy
conversion systems design and optimization, losses in electromechanical
energy conversion systems, electromagnetism, installation, and electrical
machines and drives with electrical machine design orientation.