Alternative motor windings and drive schemes

[Clugh]

Investigation of Electromagnetic Losses Considering Current Harmonics in High-Speed Permanent Magnet Synchronous Motor
MDPI energies:

In the peer reviewed research what they found is:

When sinusoidal and harmonic currents were applied to the HPMSM, the DC copper losses remained the same in both cases. However, the AC copper losses increased significantly under PWM excitation due to the presence of high-order current harmonics. At low operating speeds, the difference in core losses between sinusoidal and harmonic current operation was relatively small, at approximately 11%. As motor speed increased, however, the core losses associated with PWM current became substantially higher, reaching a 30% increase compared to sinusoidal operation. Furthermore, rotor eddy current losses were particularly affected by the PWM current; across all operating points, the rotor eddy current loss increased by approximately 70% compared to the losses observed under sinusoidal current excitation.

You cant forget the rotor as part of the iron losses and Dr Okon knows all about it as he has had returned plenty of motor where the magnets were permanently damaged. That's why magnovol slot wedges to protect them can broaden the efficiency band significantly.

[Clugh]

They are wrong to claim that everyone can wind the machines. If that were true, why have Dr. Okon and the so-called superior mind of Audiosmith only produced 1- and 2-layer machines in the last 20 years, with no wye-delta hybrids and no 3- or 4-layer machines? These are the cleanest-running FSCW machines on factory stators. They stick to outdated windings and keep creating silly threads to justify to pilots why they haven’t offered any new winding designs in over 20 years, accepting seasonal failures in flight and countless reworks. They refuse to wind modern designs because it would expose that they aren’t leading anything with antiquated windings that “anyone” can supposedly do.

It’s incredibly difficult for someone to explain how it works when they’ve never wound and shown a functioning example. The medical doctor who winds for a hobby has plenty to say to electrical engineering doctors who validated this years ago. To this day, they haven’t produced a working hybrid or anything beyond a 2-layer wind, since their basic Kv calculations don’t align with these designs. Some of these windings can halve AC iron rotor and PM losses, with winding and power factors surpassing the 2-layer machines. The routing and termination are too advanced for the so-called winding “guru” in Gotha. I wound my first hybrid scorpion years ago.

Since they thrive in Germans only sites and Germans only conversations this is clearly a Germans only problem for the goofy forum. The real German EE's and GURUS at the University of Bundeswehr in Munich Germany are fully aware or these advanced winds and are the ones that developed many of them. That's how from reality the Dr is. These are the facts and the only reason id report new winding tech into a forum.

I've even left a video numerous times that show idle currents never achieved by a conventional 1 or 2 layer. They opened numerous threads on the subject matter that never produced a working example and they fall right to the bottom. They can only blame themselves because I sent several people there the winding diagrams and they never produced a thing that works.


Even when It comes to maximum copper fill a serially wound coil is truly not the way.😳

Same turn same direction windings like a servo motor maximizes fill. Additionally it is easier to wind.

[Clugh]

Scorpions Hong Kong 5020

Im not going to waste my time dragging a hard head horse to water but semi magnetic slot wedges is one way to get more out of the rotor and magnets.

[Clugh]

Hallo Ralph, ich habe gelesen, was Sebastian schreibt – ich habe keine Ahnung, wovon er da redet. Ein Pyro 600 liefert weit über 1000 Watt; da liegt er völlig daneben. Ich kann dir nicht viel über ihn sagen, außer dass er in Wirklichkeit gar keine Wicklungen vornimmt. Es scheint, als würde er sich heutzutage darauf beschränken, nur noch zu provozieren. Ich halte nicht viel von ihm; ich habe ihm sogar selbst die Wickelschemata geschickt, aber von ihm sieht man immer nur nackte Statoren. Er hat außerdem einen völlig falschen Bericht über Stern- und Dreieckschaltungen veröffentlicht – mehr als heiße Luft hat er hinter seiner Tastatur noch nie produziert. Viel Erfolg dabei, 11 Windungen eines 1,18-mm-Drahts dort unterzubringen – der Kv-Wert ist für meine Piloten jedenfalls absolut unbrauchbar. In ihren Fluggeräten wird der Motor sehr zahm laufen; bei hohen Drehzahlen macht dieser „Draht“ ohnehin keinen großen Unterschied beim Wirkungsgrad. Der Motor sitzt in einem Getriebe – er kann also, anders als bei einem Direktantrieb, frei drehen. Ich verstehe, worauf du hinauswillst – das ist schon ziemlich amüsant. Ich hoffe, die Lektionen haben dir gefallen.

The motors peak around 4000 watts @ 10s lipo. But motor and drive weight are also very important to them.

[Clugh]

For pilots in North America, there’s no 1.18 mm bare wire available. That size is larger than 17 AWG in our standards, so 11 turns will be interesting to see under the hammers, and not positioned right in the middle of the slot opening near the tooth tips where leakage occurs, resulting in elevated AC losses in the wire. High power density is great, but sometimes it makes more sense to choose a larger machine for more power, especially when pushing them to the limits of their performance.


Thanks,
Hubert

[Clugh]

Die 8 Windungen – im Vergleich zu den vorgeschlagenen 11 – könnten für einen 14-poligen Motor sinnvoll sein. 😏

Gute Nacht...
Hubert