Permanent magnet synchronous motor (PMSM) for electric vehicles is developing higher frequency and speed but triggering a significant increase of eddy current loss. To resolve the eddy current loss issue, a novel flat wire transposed winding composed of double-row multiple parallel strands is proposed. Transposed winding techniques have been proved to be efficient in reducing eddy current loss by preventing the uneven leakage magnetic field induced by high frequency. The proposed transposition further improved this technique in reducing circulating current loss. Taking a 60-kW PMSM as an example, the novel flat wire transposed winding arrangement is carried out. The 3-D field-circuit coupled finite-element models of 360° complete transposed and incomplete transposed winding PMSM are established, and circulating current losses are compared. The analysis results show that incomplete transposed winding has a better performance in reducing the circulating current loss. The transposition method suitable for novel flat wire transposed winding is obtained, and the feasibility of PMSM with novel flat wire transposed winding to reduce winding losses is proven.

The stator winding acts as a carrier for the electrical load, and its loss accounts for about 50% of the total loss in AC machines. So how to design the stator winding for reducing winding loss is extremely crucial. Some traditional transposition methods are adopted in the winding design for large AC machines. Although they have a certain effect on reducing winding loss, there is still room for the improvement in the winding design and manufacturing technology. In this paper, a new global transposition method of stator winding is proposed. Then a megawatt driving motor is taken as the research object, and the eddy current losses, circulating current losses and total losses of winding strands are calculated by the three dimensional (3-D) finite element method (FEM) which has been validated by the experiment. In addition, by comparison with the two original transposition methods, it is proved that the proposed global transposition method is more effective in further reducing the winding loss, and the winding loss distribution is more uniform. This global transposition method proposed in this paper provides a reference for the optimal deign of the stator winding in AC machines.

In recent years, the hairpin winding flat wire motor has received more and more attention because of its high power density and high torque, but the problem of increased AC copper loss caused by the increase of its wire diameter has restricted the use of the motor. Aiming at the problem of large AC copper loss in hairpin winding flat wire motors, this paper introduces the use of formed transposition windings into permanent magnet synchronous motors. Through analysis and comparison, the transposition bar suitable for permanent magnet synchronous motor is determined, and a method of inter-turn transposition that can improve the slot full rate of the motor is proposed. Taking a 223kW permanent magnet synchronous motor as an example, the transient field of the stator bar under 360° transposition was calculated by using the field-circuit combined three-dimensional(3-D) finite element method. By calculating the data, combined with the AC copper loss calculation method of the formed transposition winding given in the article, the distribution of the DC copper loss, eddy current copper loss and circulating copper loss of the motor is obtained. Compared with hairpin windings, the use of formed transposition windings can reduce the AC copper loss of the motor to a certain extent, the feasibility of using the formed transposition winding in the permanent magnet synchronous motor is verified.

Calculation of circulating current in transposition bars is the key problem in the design of stator windings, which will determine the transposition type of stator windings. The circuit equation method, in which the calculation of strand end leakage reactance in transposition bars is the premise, is widely used in engineering to calculate circulating current. This paper describes an analytical algorithm for the calculation of strand end leakage reactance in transposition bars, which is based on mirror image principle. The end leakage reactance of strands in transposition bar is calculated by the integral of transposition path discretized into many key points. Contrary to the existing calculation method, the analytical algorithm proposed in this paper is a general method for calculating the end leakage reactance, which can simulate the transposition path of strands in the end region for different transposition types. In order to validate the proposed method, the end coil self and mutual leakage reactance are calculated by proposed analytical algorithm and finite element method.

Aiming at the problem of torque ripple caused by cogging torque in the external rotor permanent magnet synchronous motor, this study proposes a method for reducing the cogging torque by the eccentric structure of stator teeth. Taking a 3 kW external rotor permanent magnet synchronous motor as an example, the validity of the method proposed is verified by theoretical analysis and finite element calculation. Finally, the other performances of the models with different teeth eccentricities are compared, and a prototype is manufactured to verify the correctness of the simulation results. The research shows that the eccentric structure of stator teeth does not affect the other performances of the motor greatly while reducing the cogging torque of external rotor permanent magnet synchronous motor effectively.