Conductor Design Method considering AC Resistance for High Efficiency of PMSM using High Fill Factor Winding

Abstract

This article proposes the design method of conductor considering ac resistance for high efficiency of permanent magnet synchronous motor (PMSM) using high fill factor winding. To achieve high power density of the motor, high fill factor winding, such as hairpin winding, is used. maximum slot occupation (MSO) coils were also developed for the same purpose. However, ac resistance is generated in the high fill factor winding used in the motor, which adversely affects the efficiency of the motor. For high efficiency of the motor using high fill factor windings, the ac resistance must be reduced. Therefore, in order to reduce the ac resistance, a design method in which the size of the respective conductor layers is different is proposed. In this article, the method of reducing ac resistance is verified through analytical methods and FEA. Next, the validity of the proposed method is verified through performance evaluation of the prototype motor designed through the proposed method.