Core Loss Estimation in Electric Machines With Flux-Controlled Core Loss Tester

The complexity of core loss estimation is a serious challenge in the design of high-efficiency electric machines. Current estimation methods based on the Steinmetz equation and loss separation are not accurate enough, even at the rated conditions. This paper describes a loss estimation technique combining finite-element analysis (FEA) and actual core loss measurements. First, flux density waveforms in various parts of the electric machine are determined using FEA. Second, the same waveforms are generated in a wound toroidal core made of the same material as used in the machine. The loss is measured per unit mass, and then the total motor core loss is calculated by integrating the measured W/kg loss values for predefined sections of the motor. These estimation results are compared with those of the Bertotti method. The proposed procedure is shown to improve the accuracy of loss estimation.