Loss Modelling of Soft Magnetic Composite Components in 3-D Flux Electrical Machines
by Dr Mehmet Kulan of School of Engineering, Newcastle University

Soft magnetic composites (SMCs) are an alternative to silicon steel laminations, yet the electromagnetic material properties are less well-documented and include uncertainties which can lead to inaccurate iron and Joule loss computations In traditional laminated electrical machines, the magnetic field is assumed to be alternating and along an axis. The nature of magnetic fields in soft magnetic composites is 3-dimensional and rotational. Soft magnetic composites differ from laminated steels in terms of magnetic field distribution within material. Electrical resistivity measurements in different grades of SMC indicate that these magnetic materials usually do not have a unique value of electrical resistivity at a given temperature. This causes discrepancy in loss computations through finite element simulations. Therefore, this presentation explores the opportunities, characterization and manufacturing challenges of soft magnetic composites in 3-D flux electrical machine topologies including axial and transverse flux machines.

James McKenzie of Hirst Magnetics

Ensuring quality of magnets, PM rotors and magnet assemblies with magnetic field camera technology and deep data analysis
by Koen Vervaeke of Magcam

With e-mobility on the rise, permanent magnet electric motor development and production are more important than ever before. Besides radial-flux motors, axial-flux motors are increasingly gaining importance. Supplies of permanent magnets and rare earth materials are becoming of strategic importance. In order to make optimal use of these valuable resources and create efficient and high-performing permanent magnet motors, magnetic quality inspection is of critical importance in both the R&D and production stages. Over more than a decade, Magcam has been developing and supplying superior magnet inspection systems to the world’s leading companies in automotive, medical, consumer electronics, magnet production and other industries and research institutes. In this presentation, you will discover how Magcam helps its customers develop and produce top quality magnets, motors and magnet assemblies, by identifying and solving magnet quality issues.

CoFe and Stator Segments – a Perfect Match
by Niklas Volbers of VACUUMSCHMELZE GmbH & Co. KG

Cobalt-Iron alloys (CoFe) such as VACODUR® and VACOFLUX® offer a significant technical advantage over standard iron-silicon materials (FeSi) when used as stator material for electrical machines. This improvement relates to both a substantial increase in power density due to the very high saturation magnetization and a better efficiency due to the low core loss. However, there are also challenges involved when using the material, such as the higher cost due to the cobalt content and the limited strip width. Considering these circumstances, segmentation is an attractive method for the production of CoFe stator stacks. By using segments instead of a full stator, a high material utilization and lower tool costs can be achieved. In addition, it allows the fabrication of stators with large diameters. This presentation outlines some possibilities for segmentation and discusses implications for subsequent production processes. A special focus will be on single tooth solutions, especially interlocked parts. This production method is cost-efficient for small to high volumes and is applicable even down to 0.20 mm thin strip material. To ensure a consistent quality, Vacuumschmelze® has designed and implemented an innovative Single Tooth Tester, which can be used to verify the magnetic properties of individual stator teeth made from CoFe.

Lamination technologies for thin sheets
by Frederic Baecker of VACUUMSCHMELZE GmbH & Co. KG

SecREETs - Secure European Critical Rare Earth Elements
by Dominik Ohmer of VACUUMSCHMELZE GmbH & Co. KG