Round and rectangular winding loss analysis and optimisation for a 22,000 rpm 150 kW switched reluctance Machine

Under research is a switched reluctance Machine for the powertrain of an electric vehicle. The research focuses on accurate estimation and optimisation of winding losses in switched reluctance Machines. These losses result from both AC and DC resistance. An FEA-based procedure is described which computes both components of loss. Round and rectangular conductors are both analysed for a number of cases. Ultimately, rectangular conductors are chosen for more thorough analysis. Here, a number of winding geometries are simulated. Plotting conductor geometry versus conductor loss confirms a loss trend with a global minimum. For the motor design under consideration, this represents up to 4 kW reduction in loss over the initially simulated round conductors.