基于非晶合金材料的新型高速高频永磁电机损耗-散热模型与电磁综合设计研究

As a new type of soft magnetic material, amorphous alloy has excellent electromagnetic properties such as high permeability, low hysteresis losses and eddy current losses. It particularly suits for iron core material of high-speed high-frequency motor. However, due to the characteristics of thin, brittle, hard, limited physical size and sensitive to mechanical stress, amorphous alloy used in electrical machines is restricted. The new type of topologies of high-speed high-frequency permanent magnet machine will be presented in this subject according to the mechanical and electromagnetic properties of amorphous material firstly. Sencondly, a calculation model of iron losses for high-speed high-frequency amorphous alloy permanent magnet machine is established. In order to give full play to the advantages of low iron losses of amorphous alloy machines, the influence law of iron losses under different topologies and processes is revealed. Thirdly,the heat-conducting property and its influencing factors of amorphous alloy iron core is investigated. Furthermore, the conjugate heat transfer model of high-speed high-frequency amorphous alloy permanent magnet machine is established based on fluid-solid coupling method. On this basis, an effective cooling system is proposed. Finally, to realize the purpose of high efficency and high power density, the electromagnetic integration design model of high-speed high-frequency amorphous alloy machine is established by taking frequency as a free varible. To investigate solutions of the above desciribed scientific issues of high-speed high-frequency amorphous alloy permanent magnet machine can achieve innovative results with independent intellectual property rights. These results have important theoretical significance.

非晶合金是一种新型软磁材料，具有高磁导率、低磁滞、涡流损耗的优异电磁性能，特别适合用作高速高频电机的铁心材料。然而，由于非晶带材薄、脆、硬，外形尺寸受限，损耗性能对应力敏感，且现有设计计算方法不能充分发挥非晶电机优越性等因素，制约了其在电机中的应用。本课题首先通过分析计算和实验研究，提出与材料机械特性和电磁特性相适应的高速高频永磁电机新型拓扑结构；其次，建立高速高频非晶合金永磁电机铁耗计算模型，揭示不同结构工艺对铁耗的影响规律，以充分发挥非晶电机铁耗小的优点；然后，探明非晶合金铁心的导热性能及其影响因素，建立基于流固耦合的高速高频非晶合金电机共轭传热模型，在此基础上提出高效的散热系统；最后，建立高速高频非晶合金电机以频率为自由变量的电磁综合设计模型，以实现高效和高功率密度目标。研究解决上述非晶合金高速高频永磁电机的相关科学问题，形成具有自主知识产权的创新成果,具有重要理论意义。

非晶合金是一种新型软磁材料，具有高磁导率、低磁滞、涡流损耗的优异电磁性能，特别适合用作高速高频电机的铁心材料。然而，由于非晶带材薄、脆、硬，外形尺寸受限，损耗性能对应力敏感，且现有设计计算方法不能充分发挥非晶电机优越性等因素，制约了其在电机中的应用。本课题针对非晶合金高速高频永磁电机的相关科学问题进行研究，取得如下研究成果：.(1)基于实验方法研究了不同拓扑结构非晶合金铁心的磁化、损耗和振动噪声性能差异，同时，采用解析计算与有限元软件相结合的方法研究了适合于高速旋转的分段式轴向磁通永磁电机转子结构和内置式径向磁通永磁电机转子结构。该研究成果为非晶合金铁心和非晶合金高速高频永磁电机的定转子拓扑结构设计提供重要参考。.(2)基于理论分析和实验研究，建立了基于实测非晶合金铁心损耗曲线的非晶合金永磁电机空载铁耗和谐波损耗的精细化计算模型，总结了非晶合金永磁电机的损耗规律；通过所搭建的实验平台测试了过盈配合、卷绕、退火、浸漆固化等工艺对铁心性能的影响规律。相关工作为非晶合金永磁电机损耗的精确计算和设计极低损耗非晶合金永磁电机奠定坚实基础。.(3)基于无限大平板层法测试了不同叠压系数下非晶合金叠片铁心轴向导热系数；同时，基于流固耦合计算方法研究了全封闭式高速非晶合金永磁电机机内空气的流动状态及其对散热的影响；进而提出转子结构变化（包括转子有无风刺、风刺尺寸与数量、转子通风孔等）对转子温升的抑制作用，相关研究成果对于这一类全封闭式高速永磁电机的转子散热提供一种有效途径。.(4)通过对一台15kW、30000r/min内置式非晶合金高速高频永磁电机的优化设计、制造与实验，得到该电机在15kW、20000r/min时效率高达96.5%，高于硅钢片电机4-6个百分点。.上述研究成果对推进高速高频非晶合金永磁电机的产业化应用具有重要的理论意义和实用价值。