Fast Computation Method for Stator Winding Skin-Effect Additional Losses in Synchronous Machines with Open Slots and Arbitrary Rotor Geometry

Large medium-voltage electric machine stators are usually equipped with form wound coils made of flat conductors (strands) and embedded in open (rectangular) slots. Air-gap magnetic flux lines can enter the slot and, sweeping the strands placed nearest the slot opening, induce eddy currents in them. Such eddy currents cause additional losses which can be much higher than usual skin-effect and proximity losses. In order to avoid dangerous overheating and hot spots, the additional losses in question need to be carefully predicted in the design stage. Time-stepping finite-element analysis (TSFEA) can be used for the purpose, which however implies a large computational burden and requires the machine geometry to be modeled in detail. This article proposes alternative methods based on time-harmonic finite-element analysis (THFEA) simulations performed on highly simplified machine models and with no need to take rotor motion into account. The proposed methods are shown to produce very accurate results, compared to TSFEA, but with very significant time and computational savings.