Finite element simulation of iron losses for an Active Magnetic Bearing–Rotor system constructed of Hiperco laminations

Iron losses appear in Active Magnetic Bearings (AMBs) mostly because of the rotor's movement, but also because of the fluctuation of the control current in the stator's coils. They can be divided into three categories: the hysteresis losses, the eddy current losses and the excess losses and while they depend significantly on the rotating speed and the magnetic flux density applied on the poles, the most contributing factor is the magnetic material used for the core. In this paper, a 2-D Finite Element Method transient model is used to simulate the rotational motion of the shaft inside the AMB and calculate the iron losses that occur due to the alternating magnetic flux inside the rotor, as well as the mechanical load capacity on the vertical direction of the AMB for each case. A simulation is carried out, at first, for a constant control current value and a speed range of 0–30,000 rpm, followed by a second one, for constant rotational speed and control current values 0–0.5 A. Geometry remains the same for all simulations. When it comes to the materials selected for the stator and the rotor, the cases of Hiperco 27, Hiperco 50 and Hiperco 50 HS laminations are tested. The iron losses of the three alloys are compared to the losses of 3 % silicon-iron. The results show that the three iron cobalt alloys have significantly lower losses than the silicon iron for the same AMB size and rotor's speeds. Hiperco 50 has the lowest loss among the three Hiperco alloys, while Hiperco 50 HS provides slightly higher mechanical load capacity under the same operating conditions.