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Com
pact
Ele
ctric
al M
achi
ne D
esig
nw
ith s
ubst
antia
l Cop
per s
avin
gs
XXXX
CC
CC
CC
,Hög
anäs
AB
,XXX
XX C
CC
CC
C,H
ögan
äsA
B
Gör
an N
ord
Hög
anäs
AB
2007
Mag
netic
Con
fere
nce
Apr
il 4-
5, C
hica
go, I
ll
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
2
Intro
duct
ion
8
Out
line
Cas
e S
tudy
: 28
-Com
pact
Ele
ctric
al M
achi
ne D
esig
n w
ith s
ubst
antia
l cop
per s
avin
gs
Cas
e S
tudy
Con
clus
ions
1
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
3
•Fou
nded
in 1
797
•Tod
ay a
lead
er w
ithin
the
iron
and
met
al p
owde
r ind
ustry
•End
pro
duct
s ar
e m
ainl
y us
ed b
y th
e au
tom
otiv
e in
dust
ry a
nd
hom
e ap
plia
nces
, law
n an
d ga
rden
and
han
d-to
ols
•160
0 em
ploy
ees
in 1
4 co
untri
es (2
005)
•Tur
nove
r 200
5 w
as 6
21M
US
D (1
US
D=7
.4S
EK
ave
rage
200
5-20
07)
•Mag
netic
:Sof
t Mag
netic
Com
pone
nts
-Som
aloy
®
Iron
Pow
der P
lant
in H
Iron
Pow
der P
lant
in H
öö gangan ää
s, S
wed
ens,
Sw
eden
US
US
––N
orth
Am
eric
an H
Nor
th A
mer
ican
Höö g
angan ää
s In
c.s
Inc.
Bra
zil
Bel
gium
Japa
n
Indi
aU
K
Chi
na
Hög
anäs
AB
Introd
uctio
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
4
Ele
ctric
ally
insu
late
d Fe
-pow
der p
artic
les
0,1m
m
Som
aloy
®M
ater
ials
Introd
uctio
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
5
Mag
netic
Mat
eria
ls A
pplic
atio
n A
reas
110
100
1k10
k10
0k1M
10M
0.0
0,5
1,0
1,5
2,0
Ferri
tes
Som
aloy
®
Hig
h fre
quen
cy
Si-s
teel
she
et
Gra
in-o
rient
ed S
i-ste
el s
heet
Non
-orie
nted
S
i-ste
el s
heet
Sin
tere
d P
/M-M
ater
ials
Sta
inle
ss
Ste
el
Ope
ratin
g fr
eque
ncy
(Hz)
Flux density (T)Int
roduc
tion
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
6
3D-M
agne
tic p
rope
rties
N
et-s
hape
d 3D
geo
met
ries
Com
pone
nts
mad
e ou
t of S
omal
oy®
Introd
uctio
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
7
Pow
der M
etal
lurg
y (P
/M)
•Net
sha
pe•L
ow c
ost
•Lar
ge s
cale
pro
duct
ion
•Glo
bally
wel
l est
ablis
hed
sinc
e 60
yea
rs•G
ood
tole
ranc
es•S
moo
th s
urfa
ces
•Low
mat
eria
l was
te•C
ompl
ex s
hape
s (3
D)
Som
aloy
®C
ompo
nent
Pro
duct
ion
Introd
uctio
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
8
Des
ign
Usi
ng S
omal
oy®
SMC
Lam
s
A. 3
D
B. F
lux
conc
entr
atio
nLo
wer
per
form
ance
mag
nets
ca
n be
use
d
3D m
agne
tic p
rope
rties
3D g
eom
etry
⇒
flux
path
s in
3 d
irect
ions
Introd
uctio
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
9
Som
aloy
®te
chno
logy
:•r
ound
s of
f stru
ctur
es e
asily
•win
ding
with
redu
ced
perip
hera
l len
gth
C. C
oppe
r sav
ings
=> L
ess
copp
er⇒
Less
tota
l los
s⇒
Red
uced
cos
ts
ALA
M=
AS
MC
Lam
inat
ion
SM
C c
ore
body
Circ
ular
cro
ss s
ectio
n=>
sm
alle
st ra
tio b
etw
een
perip
hera
l len
gth
and
cros
s-se
ctio
n ar
ea
ALA
MA S
MC
Des
ign
Usi
ng S
omal
oy®
Exa
mpl
e of
a s
hort
coil
on a
roun
ded
core
bod
y
Prof
. Ala
n Ja
ck, N
ewca
stle
Uni
vers
ity
Introd
uctio
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
10
Som
aloy
®C
omm
erci
al E
xam
ples
325
1
6
4
Introd
uctio
n
1.A
ctua
tor
–LY
NG
Mot
or A
/S, N
orw
ay2.
AB
S P
ump
Mot
or–
AIS
IN S
EIK
I, Ja
pan
3.S
ervo
Mot
or–
Pha
se M
otio
n C
ontro
l S.r.
l., It
aly
4.Li
near
mot
or–
Twin
bird
, Jap
an5.
Wat
er p
ump
–LA
ING
Gm
bH, G
erm
any
6.D
iese
l act
uato
r–
Rob
ert B
osch
Gm
bH, G
erm
any
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
11
to
Pro
fess
or A
lan
Jack
an
d pr
ojec
t lea
der G
lynn
Atk
inso
n
Pow
er E
lect
roni
cs, D
rives
& M
achi
nes
Gro
upU
nive
rsity
of N
ewca
stle
upo
n Ty
ne, U
K
for t
he c
oope
ratio
n an
d ex
celle
nt d
esig
n w
ork
in th
is s
tudy
!
Case S
tudy
Ack
now
ledg
men
t
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
12
•D
rivin
g fo
rces
•C
ase
stud
yre
fere
nce
and
targ
et•
Mat
eria
ls c
ompa
rison
•R
edes
ign
Phi
loso
phy
•S
omal
oy®
Com
pone
ntD
esig
n•
Res
ults
•C
oncl
usio
ns
Out
line
Cas
e S
tudy
Case S
tudy
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
13
Savi
ngs
in1.
Spac
e2.
Cop
per
Pro
ject
Driv
ing
Forc
esCas
e Stud
y
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
14
Ref
eren
ce:
•H
ome
appl
ianc
e S
plit-
syst
em a
ir co
nditi
oner
en
ergy
ratin
g “A
”•
‘Sta
te-o
f-art’
varia
ble
spee
d B
LDC
driv
e •
Low
-noi
se S
crol
l com
pres
sor
•R
epre
sent
ing
top
leve
l effi
cien
cy o
n th
e m
arke
t
Targ
et:
•Fo
cus
on c
ompr
esso
r driv
e•
Mai
ntai
n or
impr
ove
high
effi
cien
cy
•R
edes
ign
stat
or fo
r Som
aloy
®
•Eq
ual o
r sm
alle
r mot
or s
ize
•An
alyz
e co
st d
rivin
g fa
ctor
s
Case S
tudy
Cas
e S
tudy
Ref
eren
ce
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
15
Lam
inat
ed m
otor
per
form
ance
:•
Out
er d
iam
eter
112
.2 m
m
•A
xial
leng
th95
mm
•S
peed
336
0 rp
m
•To
rque
2,5
Nm
•
Ope
ratin
g fre
quen
cy 1
12 H
z•
Inpu
t pow
er m
ax. 9
56 W
•E
ffici
ency
at m
ax. p
ower
91.
2%
Case S
tudy
Cas
e S
tudy
Ref
eren
ce
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
16
Rot
or c
hara
cter
istic
s•
0.35
mm
lam
inat
ion
•4
pole
•
Bur
ied
sint
ered
NdF
eBm
agne
ts•
OD
60
mm
•
Leng
th 4
8 m
m
•M
aint
ain
the
high
effi
cien
cy•
Red
uctio
nof
mot
or s
ize
•R
edes
ign
stat
or c
ore
for S
omal
oy®
•K
eep
orig
inal
roto
r des
ign
Case S
tudy
Cas
e S
tudy
Per
form
ance
Tar
get
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
17
0,0
0,4
0,8
1,2
1,6
2,0
020
0040
0060
0080
0010
000
H (A
/m)
B (T)
3% S
ilicon
ste
elSo
mal
oy®
3P
Som
aloy
® 5
00
Lam
inat
ion
: typ
ical
sing
lesh
eetd
ata
from
cat
alog
ueS
omal
oy 3
P (0
.3%
lubr
ican
t), 8
00M
Pa
: com
pone
ntda
taS
omal
oy 5
00 (0
.5%
Ken
olub
e), 8
00M
Pa
: com
pone
ntda
ta
Mat
eria
l Com
paris
on –
BH
-cur
veCas
e Stud
y
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
18
0510152025
0,35
mm
3%
Silic
onla
min
atio
nSo
mal
oy 5
00 +
0,5%
Keno
lube
(800
MPa
)
Som
aloy
3P
(800
MPa
)
(W/kg)
Mot
or o
pera
ting
cond
ition
;•
1,3T
•11
2Hz
Mat
eria
ls C
ompa
rison
-Lo
ssCas
e Stud
y
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
19
SMC
Cha
lleng
e:•
Som
ewha
t low
er s
atur
atio
n in
duct
ion
than
lam
inat
ions
•Lo
wer
iron
loss
than
lam
inat
ion
at h
igh
frequ
ency
•H
ighe
r iro
n lo
ss th
an la
min
atio
n at
low
freq
uenc
y
Mat
chin
g pe
rfor
man
ce b
y re
desi
gn
Com
pone
nts
mad
e ou
t of S
omal
oy®
SMC
Opp
ortu
nitie
s:•
3D p
rope
rties
•D
esig
n fre
edom
•
Com
plex
, net
sha
ped
parts
with
tigh
t tol
eran
ces
Case S
tudy
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
20
Win
ding
loss
es
Iron
loss
es
Win
ding
loss
es
Iron
loss
es
Win
ding
loss
es
Iron
loss
es
Lam
inat
ion
Dire
ct re
plac
emen
t<
Som
aloy
®>
Opt
imiz
ed re
-des
ign
Rou
nded
str
uctu
reM
ore
circ
ular
cro
ss-s
ectio
nTi
ghte
r win
ding
Incr
ease
d iro
n cr
oss-
sect
ion
area
Equ
alG
eom
etry
Com
pact
Geo
met
ry
Case S
tudy
Red
esig
n P
hilo
soph
y
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
21
Ref
eren
ceSo
mal
oy®
base
d de
signCas
e Stud
yS
omal
oy®
Com
pone
nt D
esig
n
Red
uced
w
indi
ng
leng
th
Red
uced
leng
th
26m
19m
Winding configuration
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
22
Ref
eren
ceSo
mal
oy®
base
d de
signCas
e Stud
yS
omal
oy®
Com
pone
nt D
esig
n
Diff
eren
t cro
ss
sect
ion
area
768m
m2
827m
m2
(Min
imum
)(C
onst
ant)
Stator tooth shape
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
23
Win
ding
con
figur
atio
n
142
132
No.
turn
s:
65 m
m92
mm
Axi
al le
ngth
:
22.3
W29
.8 W
Win
ding
loss
:
533
g76
2 g
Wei
ght:
19 m
26 m
Wire
leng
th:
66%
44%
Slot
fill
fact
or:
Ref
eren
ceSo
mal
oy®
base
d de
signCas
e Stud
yS
omal
oy®
Com
pone
nt D
esig
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
24
Ref
eren
ceSo
mal
oy®
base
d de
sign
Sta
tor I
ron
conf
igur
atio
nCas
e Stud
yS
omal
oy®
Com
pone
nt D
esig
n
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
25
Ref
eren
ceSo
mal
oy®
base
d de
sign
Sta
tor I
ron
conf
igur
atio
n
Som
aloy
®3P
0.35
mm
Si-l
am.
Soft
mag
netic
mat
eria
l:6
6To
oth
num
ber:
Yes
No
3D d
esig
n:
2220
g16
90 g
Wei
ght:
108
mm
215
0 m
m2
Slot
are
a:39
mm
48 m
mTo
oth
body
leng
th:
65 m
m48
mm
Tot.
axia
l len
gth:
Case S
tudy
Som
aloy
®C
ompo
nent
Des
ign
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
26
Sta
tor a
ssem
bly
Ref
eren
ceSo
mal
oy®
base
d de
signCas
e Stud
yS
omal
oy®
Com
pone
nt D
esig
n
Equal Fe length
Leng
th
savi
ng
Leng
th
savi
ng
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
27
Sta
tor a
ssem
bly
Exa
mpl
e of
Mod
ules
/Sec
tioni
ngSo
mal
oy®
base
d de
sign
Case S
tudy
Som
aloy
®C
ompo
nent
Des
ign
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
28
Sta
tor a
ssem
bly
Exa
mpl
e of
Mod
ules
/Sec
tioni
ngSo
mal
oy®
base
d de
sign
Case S
tudy
Som
aloy
®C
ompo
nent
Des
ign
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
29
Mat
eria
l -So
mal
oy®
3P
•0.
3% lu
bric
ant
•80
0 M
Pa
com
pact
ion
pres
sure
•D
ensi
ty:
–7.
45 g
/cm
3 ,To
oth
–7.
36 g
/cm
3 , C
ore-
back
•R
esis
tivity
–50
0 µO
hm m
Case S
tudy
Pro
toty
pe
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
30
Tool
edne
t-sha
ped
Som
aloy
®co
mpo
nent
Case S
tudy
Pro
toty
pe
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
31
Som
aloy
®R
efer
ence
Case S
tudy
Pro
toty
pe
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
32
Som
aloy
®R
efer
ence
Case S
tudy
Pro
toty
pe
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
33
Test
Sta
tus
•P
roto
type
Som
aloy
mot
or is
now
runn
ing
in
benc
h te
st•
The
lam
inat
ed re
f. st
ator
will
be
iden
tical
ly
test
ed•
Test
and
ver
ifica
tion
of th
e de
sign
in p
rogr
ess
Case S
tudy
Pro
toty
pe
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
34
Com
paris
on S
omal
oy®
desi
gn v
.s. r
ef. l
amin
ated
des
ign
Perf
orm
ance
0%25%
50%
75%
100%
125%
Effic
ienc
yM
ax T
orqu
e
Lam
inat
ion
Som
aloy
Case S
tudy
Res
ults
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
35
Com
paris
on S
omal
oy®
desi
gn v
.s. r
ef. l
amin
ated
des
ign
Des
ign
geom
etry
par
amet
ers
0%25%
50%
75%
100%
125%
Mot
or le
ngth
Mot
or d
iam
eter
Wei
ght,
stat
or a
ssem
bly
Lam
inat
ion
Som
aloy
Case S
tudy
Res
ults
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
36
•Com
pact
app
licat
ion
desi
gn•M
ater
ial s
avin
gs
Ref
eren
ceSo
mal
oy®
base
d de
signCas
e Stud
yR
esul
tsAutomotive example: Scroll compressor
Pot
entia
lre
duct
ion
~10
–20
%
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
37
Com
paris
on S
omal
oy®
desi
gn v
.s. r
ef. l
amin
ated
des
ign
Cos
t rel
ated
par
amet
ers
0%25%
50%
75%
100%
125%
150%
Cu-
wire
mas
sSh
aft l
engt
hH
erm
etic
hou
sing
leng
thIro
n m
ass
Lam
inat
ion
Som
aloy
Case S
tudy
Res
ults
2007
Mag
netic
s C
onfe
renc
e A
pril
4-5,
Chi
cago
, Ill
38
•C
aref
ul d
esig
n of
Som
aloy
®st
ator
com
pone
nts
is s
how
n to
com
pete
sta
te-o
f-art
effic
ienc
y in
H
VA
C c
ompr
esso
r driv
es
•Th
e co
mpa
ct S
omal
oy®
stat
or d
esig
n fe
atur
es:
–30
% s
horte
r axi
al m
otor
leng
th–
25%
redu
ctio
n of
cop
per-
win
ding
–U
p to
20-
30%
sho
rter s
haft
–U
p to
10-
20%
sho
rter h
ousi
ng
Case S
tudy
Con
clus
ions
XXXX
CC
CC
CC
,Hög
anäs
AB
,XXX
XX C
CC
CC
C,H
ögan
äsA
B
