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Shima 2012
Shima 2012
Shima 2012
Abstract -- In stator end regions of turbogenerators, the FEA. The simple flux distribution makes the modeling less
in-plane eddy current arises in the lamination steel. In this complex than that of the tester in [2], [3]. The validity of
paper, a simple tester to measure the in-plane eddy current the FEA is evaluated by comparing the computed and
losses in lamination steel is newly designed and built. A
measured results. The phenomena in the tester are
measurement method to separate the in-plane losses from the
total core losses in the tester is presented. The in-plane losses examined by the FEA.
are measured and computed by finite element analysis. The
computed losses agreed well with the measured ones. The II. IN-PLANE EDDY CURRENT LOSS TESTER
accuracy of the analysis has been confirmed. The eddy-
An in-plane eddy current loss tester is newly designed
current phenomena in the tester are examined by the analysis.
The computed results show that the in-plane eddy current has and built. Fig. 1 shows the tester. The core thickness of the
nearly resistance-limited characteristics. The eddy current specimen and the yoke is 21 mm. The core material is the
generates the looped flux inside a steel sheet. non-oriented electrical steel sheet 35A210 [4]. The nominal
thickness of the sheet is 0.35 mm. The density is 7.60
Index Terms--3-D finite element method, core loss, in-plane kg/dm3. The maximum core loss for 1.5 T at 50 Hz is 2.10
eddy current, lamination steel, perpendicular flux, stator end W/kg. The material is cut into the specimen and the yoke
region, turbine generator
by wire electrical discharge machining. Four excitation
windings (EWs) are wound around the center yoke. Seven
I. INTRODUCTION
search coils (SCs) are wound around the cores. Seven
conditions are not shown in the literature. Also in this tester, (a) In-plane (b) Lamination
21 mm
it is difficult to separate the in-plane eddy current losses direction direction Search coils
SC4 under ID
in LD and AC demagnetization is performed. Finally, the 0.1 SC4 under LD
in-plane eddy current loss P is obtained by the following 0
equation, assuming that Pld nearly equals the yoke core loss 0 5 10 15 20
-0.1
under the Pid measurement:
-0.2
P Pid Pld (1)
-0.3
Each loss Pid or Pld is obtained by averaging the
-0.4
instantaneous power calculated by multiplying the Time (ms)
measured excitation current waveform and induced voltage (b) Yoke search coils SC2 and 4.
waveforms of the yoke SC1 and 3 together. The magnetic
flux densities in the specimen and the yoke are obtained by 0.3
SC5 under ID
integration of the voltage waveforms of the SCs and 0.2 SC5 under LD
division by the core cross section.
Flux density (T)
SC6 under ID
0.1 SC6 under LD
B. Measurement Results
0
0 5 10 15 20
16 -0.1
Total loss
P1 under ID, Pid SC6
14 SC5
Total loss
P2 under LD, Pld -0.2
12
PIn-plane eddy current loss
Core loss (W)
10 -0.3
under ID, P Time (ms)
8 (c) Yoke search coils SC5 and 6.
6
Fig. 5. Measured magnetic flux densities in the yoke.
4
2 Figs. 4 and 5 show the measured flux density waveforms
0 of the specimen and yoke SCs under the condition that the
0 0.2 0.4 0.6 0.8 1
rms flux density in the specimen is 0.60 T. Fig. 6 shows the
Specimen rms flux density under ID (T)
Fig. 3. Measured core losses.
measured excitation current waveforms under the same
condition. The horizontal axes in Figs. 4–6 represent the
Fig. 3 shows the measured losses. The losses Pld under same time. All the waveforms are almost sinusoidal. All the
the LD conditions are 9.6–11.1% of the losses Pid under the form factors are within 111.1±0.4%. From Figs. 5(a)–(c),
ID conditions. That is, the in-plane eddy current loss P is the yoke flux density waveforms under LD agree well with
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those under ID. Conversely from Fig. 4, the amplitude of IV. VALIDATION OF MEASUREMENT
the specimen flux density waveform under LD is a little Validity of the measurement is discussed. In order to
larger than that under ID. This is because the magnetic evaluate the results of the in-plane eddy current losses P
reluctance in the specimen under LD is smaller than that measured with (1), the following two requirements should
under ID, and there are no in-plane eddy current under LD. be investigated. First, the yoke core losses under the ID and
However, it should be noted that the difference between the the LD conditions should be almost the same. Second, the
specimen flux density waveforms under ID and LD is small. core losses in the specimen under LD should be small
compared to the total loss Pld.
4
3 Under ID A. Yoke Core Losses Under ID and LD
Excitation current (A)
TC1
70
TC2 B. Core Losses in Specimen Under LD
60 TC3 The second requirement is investigated. The core losses
TC1
50 TC4 in the tester shown in Fig. 1 under LD, Pld, are computed
40 TC3
TC5 by 3-D FEA. Fig. 8 shows the 1/4 mesh model. The
Others
TC6 commercial FEA software, JMAG® Ver. 10.0 (JSOL) [5],
30
is used. The initial magnetization curve provided by the
20 manufacturer is used as the input values to the FEA. A 50-
0 0.2 0.4 0.6 0.8 1 Hz, sinusoidal current source is connected to the excitation
Specimen rms flux density under ID (T) windings. After performing the FEA, the core losses in the
(a) Under in-plane direction. tester are calculated from the flux densities in the mesh
elements computed by the FEA and the core-loss data
90 Specimen
provided by the manufacturer [6], [7]. The core-loss
Room
80 computation program provided within the JMAG software
Temperature (deg C)
TC1
70 TC2
package is used. The average flux densities in the core
60 TC3
cross sections are calculated from the flux linkages in the
TC4
search coils.
50
TC5
40 Excitation windings
TC6
Others
30
Room
20
0 0.2 0.4 0.6 0.8 1
Specimen rms flux density under ID (T) Yoke
(b) Under lamination direction.
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under LD, Plds, are very much smaller than the specimen in- depth, which is calculated as follows:
plane eddy current losses under ID, P. 1
Fig. 10 shows the analyzed and measured losses Pld. The 0.485 mm (2)
f s 0
analyzed results agree well with the measured ones. The
measured values are the same as Pld in Fig. 3. where the frequency f is 50 Hz. The relative permeability μs
From these investigations, the measured results of the is 12732, which is the largest value in the initial
losses P have been validated. magnetization curve (at B = 0.64 T).
The 50-Hz sinusoidal excitation current is applied to the
1.2 excitation winding. The eddy current losses in the iron part
Total loss,
P2 Pld are computed. They correspond to the values P. The
1 Specimen loss,
P21 Plds hysteresis losses are neglected. The average flux densities
Yoke loss,
P22 Pldy
0.8 in the core cross section are calculated from the flux
Core loss (W)
0.6
linkages in the search coil.
0.4 Y
Y Search coil
0.2 21 mm Air
X
0
0 0.05 0.1 0.15 0.2 0.25 0.3
Z 10.5 mm
Yoke SC1 rms flux density (T) 21 mm
Steel sheet X
Fig. 9. Analyzed core losses under lamination direction. Steel sheet 10.5 mm
Specimen Excitation
Symmetrical winding
boundary
1.6
1.4 Measurement
1.2 Analysis
Core loss (W)
Z Natural boundary
1
Iron part
0.8
95%
0.6
X
0.4 5% Insulation 0.45 mm
Natural
Half of steel part boundary
thickness Side part of steel (X-Y plane)
0.2
Central part of steel (X-Z plane)
0
0 0.05 0.1 0.15 0.2 0.25 0.3
Yoke SC1 rms flux density (T) Fig. 11. 3-D FEA model of lamination steel in the specimen under in-
plane direction to compute in-plane eddy current losses.
Fig. 10. Analyzed and measured total core losses under lamination
direction.
B. Analysis Results
Fig. 12 shows the analyzed and measured in-plane eddy
V. ANALYSIS OF IN-PLANE EDDY CURRENT LOSSES current losses P. The measured values are the same as P in
Fig. 3. The analyzed results agree well with the measured
The in-plane eddy current losses P in the specimen ones. Fig. 13 shows the flux density waveforms in the
under ID are computed by 3-D FEA using a partial model. specimen. The rms values of them are 0.60 T. The analyzed
The computation accuracy is evaluated. The phenomenon and measured waveforms agree well. The validity of the
in the specimen is examined. FEA has been confirmed. Although the FEA results are not
A. Analysis Method for a real turbogenerator but for a tester, this conclusion
Fig. 11 shows the partial mesh model for the FEA. supports the efficacy of future application of this FEA
Instead of the whole tester, a lamination steel sheet in the methodology to a rotating machine. There remains future
specimen is modeled to reduce the computation time. The work to decrease computer resources needed for such
analyzed region is reduced to 1/8 of the sheet. The analysis.
schematic flux direction shown as the dashed arrow in Fig. Fig. 13 also shows the excitation current waveform in
1 is drawn assuming that the flux lines are perpendicular to the analysis. The phase difference between the excitation
the steel sheet surface under ID. In this model, this current and the specimen flux density is not large. The total
assumption is adopted. The validity is confirmed by amount of the analyzed eddy current flowing through the
comparing the FEA results with the measured ones. X-Z plane (Y = 0) in the specimen is shown in Fig. 13. The
In this model, the lamination factor is assumed to be phase difference between the excitation current and the
0.95. The thickness of the iron part in Z-axis direction is eddy current is nearer to 90 deg than 180 deg.
95% of that of the total thickness of the mesh. That of the Fig. 14 shows the analyzed eddy current densities on X-
insulation part is 5%. The material data, i.e., the Z plane (Y = 0) in the specimen. The horizontal axis
conductivity (σ = 1695000 S/m) and the initial denotes the distance from the side surface of the steel in the
magnetization curve, provided by the manufacturer are inverse X-axis direction. The origin corresponds to the side
used for the iron part in the FEA. The relative permeability surface. The point of 10.5 mm corresponds to the center of
in the insulation part is unity. The dimensions of the the steel. As seen from the side surface, the eddy current is
elements are determined considering the theoretical skin induced in the region much deeper than the theoretical skin
depth that is 0.485–1.87 mm by (2) when B = 0–1.5 T. One
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of the reasons is that the steel sheet is thinner than the skin excitation current reaches its maximum, shown as the point
depth. That is, seen from the in-plane surface, the eddy B in Fig. 13. In this moment, the eddy current is relatively
current flows within the skin depth. Further theoretical small. The flux density is large and its direction is largely
explanation of the phenomenon remains to be solved. in Z-axis direction, perpendicular to the in-plane surface.
From these results and Fig. 13, the fluxes generated by the
18 excitation current are not much reduced by the in-plane
Measurement eddy current.
In-plane eddy current loss (W)
16
14 Analysis From Figs. 13 and 15–18, the phase of the in-plane eddy
12 current is nearly 90 deg different from that of the external
10 magnetic field generated by the excitation current. The
8 phase difference between the flux density and the external
6 magnetic field is small.
4 The cause of these phenomena will be that the magnetic
2 reluctance of the main flux produced by the eddy current is
0
large, and the corresponding mutual inductance between
0 0.2 0.4 0.6 0.8 1 the eddy current and the excitation current is small due to
Specimen rms flux density (T) the insulations between the lamination steel sheets,
compared to massive solid iron [8]. That is, the in-plane
Fig. 12. Analyzed and measured in-plane eddy current losses. eddy current has nearly resistance-limited characteristics.
Further study about it needs to be done.
1 8
0.8 6
B VI. CONCLUSION
0.6
Flux density (T)
4
0.4 The in-plane eddy current loss tester is newly designed
Current (A)
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(a) Current density distribution (X-Y plane). (a) Current density distribution (X-Y plane).
(b) Current density distribution in side part of steel (X-Z plane). (b) Current density distribution in side part of steel (X-Z plane).
(c) Current density distribution in central part of steel (X-Z plane). (c) Current density distribution in central part of steel (X-Z plane).
Fig. 15. In-plane eddy current densities in the specimen at the moment Fig. 17. In-plane eddy current densities in the specimen at the moment
of zero excitation current at Point A in Fig. 13. of maximum excitation current at Point B in Fig. 13.
1.5 1.5
Flux density (T)
0.75 0.75
0 0
(a) Flux density distribution (X-Y plane). (a) Flux density distribution (X-Y plane).
(b) Flux density distribution in side part of steel (X-Z plane). (b) Flux density distribution in side part of steel (X-Z plane).
(c) Flux density distribution in central part of steel (X-Z plane). (c) Flux density distribution in central part of steel (X-Z plane).
Fig. 16. Magnetic flux densities in the specimen at the moment of zero Fig. 18. Magnetic flux densities in the specimen at the moment of
excitation current at Point A in Fig. 13. maximum excitation current at Point B in Fig. 13.
[2] K. Yamazaki, S. Tada, H. Mogi, Y. Mishima, C. Kaido, S. Kanao, K. [7] HILITECORETM, Non-oriented electrical steel sheets, Nippon Steel
Takahashi, K. Ide, K. Hattori, and A. Nakahara, "Eddy current Corp. [Online], http://www.nsc.co.jp/en/product/kind/sheet/product-
analysis considering lamination for stator core ends of turbine list.html.
generators," IEEE Trans. Magnetics, vol. 44, no. 6, pp. 1502-1505, [8] R. L. Winchester, "Stray losses in the armature end iron of large
Jun. 2008. turbine generators," AIEE Trans. Power Apparatus and Systems, vol.
[3] H. Mogi, C. Kaido, S. Kanao, Y. Mishima, K. Yamazaki, Y. 74, pt. III, pp. 381-391, Jun. 1955.
Watanabe, A. Nakahara, K. Takahashi, K. Ide, K. Hattori, and T.
Watanabe, "Influence of Perpendicular flux in laminated core and
core losses," in Proc. Intl. Conf. Electrical Machines (ICEM), pp. 1–
IX. BIOGRAPHIES
5, Sep. 2006.
[4] Non-oriented magnetic steel sheet and strip, Japanese Industrial Kazuo Shima received the B. Eng. and M. Eng. degrees from Kyoto
Standard JIS C 2552: 2000, Feb. 2000. University, Kyoto, Japan, in 1993 and 1995, respectively, and the Dr. Eng.
[5] JMAG, JSOL Corp. [Online], http://jmag-international.com/. degree from Tohoku University, Miyagi, Japan, in 2004, all in electrical
[6] K. Yamazaki, “Harmonic copper and iron losses calculation of engineering.
induction motor using nonlinear time-stepping finite element Since 2005, he has been with the Department of Electrical and
method,” in Proc. IEEE Intl. Electric Machines and Drives Conf. Electronic Engineering, Kanazawa Institute of Technology, Ishikawa,
(IEMDC), pp. 551–553, Jun. 2001. Japan, where he is currently an Associate Professor. During 1995–2005, he
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was with the Hitachi Research Laboratory, Hitachi Ltd., Ibaraki, Japan. His Dr. Fukami is a Senior Member of the Institute of Electrical Engineers
research interests include the design and numerical analysis of electric of Japan.
machines.
Dr. Shima is a member of the Institute of Electrical Engineers of Japan. Yoko Furukawa received the B. Eng. and M. Eng. degrees from Oita
University, Oita, Japan, in 1988 and 1990, respectively.
Takeo Murai received the B. Eng. degree in electrical engineering in 2010 From 1990 to 1997, she was with the Energy Research Laboratory,
from Kanazawa Institute of Technology, Ishikawa, Japan, where he is Hitachi Ltd., Ibaraki, Japan. Since 1997, she has been with the Hitachi
currently working toward the M. Eng. degree. Research Laboratory, Hitachi Ltd., where she is currently a Researcher.
Her research interests include the design and numerical analysis of electric
Tadashi Fukami received the B. Eng., M. Eng., and Dr. Eng. degrees in machines.
electrical engineering from Kanazawa Institute of Technology, Ishikawa,
Japan, in 1985, 1987, and 1990, respectively. Akiyoshi Komura received the B. Eng. and M. Eng. degrees from Tohoku
Since 1992, he has been with the Department of Electrical and University, Miyagi, Japan, in 1991 and 1993, respectively.
Electronic Engineering, Kanazawa Institute of Technology, where he is Since 1993, he has been with the Hitachi Research Laboratory, Hitachi
currently a Professor. During 1990–1992, he was with the Central Ltd., Ibaraki, Japan, where he is currently a Senior Researcher. His
Research Laboratory, Mitsubishi Electric Corporation, Hyogo, Japan. His research interests include the design and numerical analysis, experimental
research interests include the design, analysis, and application of electric measurement of electric machines.
machines. Mr. Komura is a member of the Institute of Electrical Engineers of
Japan.
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