Utilizing residual stresses in electrical sheet metal to increase energy efficiency

用常规方法提高电机效率的方法已基本用尽。因此，需要新的方法来释放更多的潜力。一种可能的解决方案是使用目标残余应力来局部地调整磁性材料特性并替换传统的磁通屏障。因此，未来电力驱动的新设计可能性是可以实现的。无切口的电工钢板由于具有更高的机械稳定性，可以提高电驱动的角速度，从而提高效率。在第一个项目期间，我们验证了创建磁通屏障的基本原理，并量化了残余应力对电工钢板的影响。我们已经表明，具有压花磁通屏障的电工钢板具有更高的机械稳定性，并允许更高的角速度。我们还分析了，在压花过程中的标准不精确度只会导致磁性能的微小变化。我们验证了我们的模拟模型（机械和磁性）使用中子光栅干涉测量，单片测试和纳米压痕。将第一阶段的结果与我们的模拟和测量相结合，我们验证了残余应力测量。在第三个项目期间，我们将利用前两个阶段的成果，开发我们的研究成果，用于工业应用。我们将优化和简化我们的磁力学和微磁模型来分析材料性能的改善。使用优化的仿真模型，我们将继续提高磁通屏障的有效性，并考虑典型操作条件（温度、静态和循环负载）的影响。基于这些结果，我们将在演示器中对磁通量进行建模和优化。结果将在数值上进行比较，在一个传统的演示磁通。基于优化的演示器，我们将展示成功的磁通量引导。在这些过程中，我们将进一步改进我们的测量方法，并进行验证测量。最后，将制定一个指导方针，为发展的压花转子几何形状。

Increasing the efficiency of electric machines by conventional means has been mostly exhausted. Hence, novel approaches to unlock additional potential are needed. One possible solution is using targeted residual stress to locally tune the magnetic material properties and replace conventional flux barriers. Thus, new design possibilities for future electric drives are achievable. Electrical steel sheets without cutouts allow to increase the angular velocity of electric drives due to higher mechanical stability, resulting in an increased efficiency.Based on the validation of the fundamental principles for the creation of flux barriers during the first project period, we quantified the influence of residual stress on the electrical steel sheets. We have shown that electrical steel sheets with embossed flux barriers have an increased mechanical stability and allow higher angular velocities. We have furthermore analyzed that standard imprecisions in the embossing process only cause minimal changes in the magnetic properties. We validated our simulation models (mechanic and magnetic) using measurements with neutron grating interferometry, single sheet testing and nanoindentation. Connecting the results from the first phase with our simulations and measurements, we validated the residual stress measurements. In the third project period, we will use the results of the previous two periods to develop our research results for industrial applications. We will optimize and simplify our magneto-mechanic and micromagnetic models to analyze the material property improvement. Using the optimized simulation models we will continue to increase the effectiveness of our flux barriers as well as consider the influence of typical operating conditions (temperature and static and cyclic loads). Based on these results, we will model and optimize the magnetic flux in a demonstrator. The results will be compared numerically to the magnetic flux in a conventional demonstrator. Based on the optimized demonstrator, we will show the successful magnetic flux guidance. During these processes, we will further improve our measurement methods as well as perform validation measurements. Finally, a guideline for the development of embossed rotor geometries will be developed.