Design and analysis of a high-speed claw pole motor with soft magnetic composite core

Soft magnetic composite (SMC) material is formed by surface-insulated iron powder particles, generating unique properties like magnetic and thermal isotropy, and very low eddy currents. This paper presents the design and analysis of a high-speed claw pole motor with an SMC stator core for reducing core losses and cost. The analyses of magnetic and thermal fields are conducted based on a comprehensive understanding of the property of SMC materials. The 3-D finite-element analysis (FEA) is performed for accurate parameter calculation, design optimization, and thermal calculation. Because of the importance of core loss in high-speed motors, rotational core loss model is employed, and the core losses are coupled directly into thermal calculation by keeping the same hexahedral mesh structure between magnetic field analysis and thermal analysis. Since the rotor modal analysis is very important to high-speed motors, the natural frequencies and mode of the rotor are studied. Index Terms--Core losses, finite-element field analysis, high-speed motors, modal analysis, soft magnetic composite (SMC) materials, thermal analysis.