Bolted cores made of coated silicon steel sheets constitute a vital part of heavy electrical equipment for transformers, motors and turbogenerators. Bolted laminates are eminently suitable for facilitating smooth magnetic flux paths, but, unfortunately, they are unable to suppress interlaminate shearing caused by flexural vibration generating noise levels often exceeding 100 dB during operation. The resulting din and cacophony in the surrounding has become a major environmental concern. This thesis makes an attempt to develop theoretical, experimental and numerical models for evolving an effective stiffness approach enhancing the design and analysis underlying nonlinear flexure of bolted laminates. While large machine cores contain thousands of thin sheets bolted together along with end plates, this thesis reports the results obtained on two different assemblies. Two 375 mm long 60 mm wide and 10 mm thick plates assembled with 3, 4 or 5 bolts constitute the first configuration. The second one which is much more realistic comprises 80 coated 270 micron silicon steel sheets with end plates of 2 or 4 mm thickness held together by 3 or 5 bolts. Static 3 point bend tests on these bolted assemblies are followed by instrumented impact tests. Static bending tests highlight the role of frictional nonlinearity inducing a drop in the stiffness due to sliding between the plates. An experimentally determined effective modulus in the initial linear range is utilized for static and dynamic finite element simulations. Nonlinear response of bolted plates is simulated using contact elements in between the sliding plates, plates and the bolts heads. Since the first fundamental mode of vibration dominates the tribomechanical vibration induced noise, the primary focus is on the fundamental frequency in bending. There is generally a good overall agreement in all the results obtained through theory, experiment and FE simulation. Experiments, however, unveil quite complex nonlinear effects induced by friction and plasticity outside the scope of this thesis. However, the low amplitude response of bolted laminates which is reasonably well captured in this thesis represents the starting point for initiating a more elaborate effort for addressing large amplitude nonlinear flexure in bolted laminates. These findings shed light on estimating and controlling noise and vibration levels in heavy electric machines.

As the major electricity consumer, electrical machines play a key role for global energy savings. Machine manufacturers put considerable efforts into the development of more efficient electrical machines for loss reduction and higher power density achievements. A consolidated knowledge of the occurring losses in electrical machines is a basic requirement for efficiency improvements. This thesis deals with iron losses in electrical machines. The major focus is on the influences of the stator core magnetic material due to the machine manufacturing process, temperature influences, and the impact of inverter operation. The first part of the thesis gives an overview of typical losses in electrical machines, with focus put on iron losses. Typical models for predicting iron losses in magnetic materials are presented in a comprehensive literature study. A broad comparison of magnetic materials and the introduction of a new material selection tool conclude this part. Next to the typically used silicon-iron lamination alloys for electrical machines, this thesis investigates also cobalt-iron and nickel-iron lamination sheets. These materials have superior magnetic properties in terms of saturation magnetization and hysteresis losses compared to silicon-iron alloys. The second and major part of the thesis introduces the developed measurement system of this project and presents experimental iron loss investigations. Influences due to machine manufacturing changes are studied, including punching, stacking and welding effects. Furthermore, the effect of pulse-width modulation schemes on the iron losses and machine performance is examined experimentally and with finite-element method simulations. For nickel-iron lamination sheets, a special focus is put on the temperature dependency, since the magnetic characteristics and iron losses change considerably with increasing temperature. Furthermore, thermal stress-relief processes (annealing) are examined for cobalt-iron and nickel-iron alloys by magnetic measurements and microscopic analysis. A thermal method for local iron loss measurements is presented in the last part of the thesis, together with experimental validation on an outer-rotor permanent magnet synchronous machine. / <p>QC 20140516</p>