Practical Aspects of Instantaneous Magnetization Power Functions of Silicon Iron Laminations.

Magnetic energy loss P of SiFe steel represents a key factor for the efficiency of soft magnetic machine cores. Traditionally, they are operated with 50 Hz (or 60 Hz), a frequency value that yields rather balanced portions of hysteresis loss and eddy current loss. In equivalent circuits of transformers, P tends to be represented by a magnetic power resistance R M, as a constant. For the most important case of sinusoidal induction B of 50 Hz, this would correspond to an instantaneous magnetization power function p(t) that is sinusoidal as well, however, with 100 Hz (or 120 Hz). On the other hand, from complex, non-linear mechanisms of hysteresis, it is obvious that p(t) should be strongly non-sinusoidal, even for exactly sinusoidal B(t). So far, almost all corresponding instantaneous investigations were restricted to calculated modelling of loss portions and transient modelling. On the other hand, for the first time, the present study was focussed on functions p(t) as measured at IEC-standardized samples of industrially relevant steel. Practical evaluations are discussed with respect to the revealed "history" of magnetization processes, as well as for product characterization. For these tasks, a novel digitized "Low-mass Single Sheet Tester" was developed that was applied for both non-oriented steel (NO) and grain-oriented steel (GO), for 50 Hz. Interpretations proved to be favoured by relating p(t) to total P, according to an instantaneous power ratio. As a result, both steel types revealed strongly non-sinusoidal power functions, with short durations of negative p. Negative p proved to be most pronounced for NO steel, as a measure for the onset of reversible turns of atomic moments. As a consequence, p(t) comprises strong upper harmonics of 200 Hz and even 300 Hz. Based on theoretical considerations, we split p(t) in a dissipative loss power function p L(t) and in a potential energy power function p P(t). Finally, we used p(t) to determine the corresponding power resistance R M(t) that proves to be a distinctly nonlinear function as well. It resembles a rectified co-sinus, also exhibiting short negative spikes that reflect the crystallographic dis-orientation of the polycrystalline material.

Calculated versus measured iron losses and instantaneous magnetization power functions of electrical steel.

Magnetic energy loss P of soft magnetic laminations like SiFe sheets tends to be expressed through an integral over the power product H · dB/dt. Already in earlier papers, we stressed that distinctions are needed for the quantities H and B. However, they are not considered in practically consistent ways, in the so far literature. Here, we discuss these distinctions in closer ways, comparing loss determination by calculation and measurement, respectively. A physically consistent procedure is described for the determination of loss and magnetization power functions through measurement of bi-located quantities H S and B C (S surface, C cross section). On the other hand, it is concluded that corresponding quantitative calculations-based on co-located quantities H and B-are impeded by the high amount of technological parameters of modern steel products. For example, they result from chemical additions, and-in particular-also from specific technologies of rolling, annealing, coating or scribing.

3D-Printed Detector Band for Magnetic Off-Plane Flux Measurements in Laminated Machine Cores.

Laminated soft magnetic cores of transformers, rotating machines etc. may exhibit complex 3D flux distributions with pronounced normal fluxes (off-plane fluxes), perpendicular to the plane of magnetization. As recent research activities have shown, detections of off-plane fluxes tend to be essential for the optimization of core performances aiming at a reduction of core losses and of audible noise. Conventional sensors for off-plane flux measurements tend to be either of high thickness, influencing the measured fluxes significantly, or require laborious preparations. In the current work, thin novel detector bands for effective and simple off-plane flux detections in laminated machine cores were manufactured. They are printed in an automatic way by an in-house developed 3D/2D assembler. The latter enables a unique combination of conductive and non-conductive materials. The detector bands were effectively tested in the interior of a two-package, three-phase model transformer core. They proved to be mechanically resilient, even for strong clamping of the core.