Analysis and Optimization of the Winding Loss of Flat-Wire Motors

The flat-wire motor has the characteristics of small size, low noise, high slot fill factor and good thermal conductivity in the slot. It can significantly improve the power density of the motor and is widely used in electric vehicles. The skin effect and proximity effect of the flat wire under high-speed conditions lead to high loss. Based on the established finite element model of a two-dimensional flat-wire motor, this paper first studies the high-frequency loss of different winding layers and the conductor sizes of each layer. Secondly, the influence of the magnetic field on AC loss is reduced by optimizing the tooth-tip height and tooth-tip width. Finally, it is verified that the high-frequency loss is reduced by 16% with the optimized layers, conductor sizes and tooth-tip sizes under the drive condition of the CLTC-P (China Light-duty Test Cycle—Passenger).