Hybrid Layer Modeling Method With Dual-Leakage Flux Paths for Heavily Saturated Iron-Cored Linear Permanent Magnet Synchronous Motors

This paper presents the dual-leakage hybrid layer modeling (DL-HLM) method for the linear permanent-magnet synchronous motors (LPMSMs) in a heavily saturated state. The proposed hybrid model consists of the nonlinear dual-leakage flux-tube model for the iron-cored armature where the geometric saliency exists, the Maxwell model for the PM track with uniform layers, and the hybrid input-output conversion method for the iteration between two models. As the minimum number of leakage flux paths, the dual-leakage flux-tube network is selected, considering the opposite-direction leakage fluxes generated by the flux-steering effect in heavily saturated iron-core teeth. The novel reluctance adaptation methods are also proposed, which allow the DL-HLM to accurately capture significant nonlinearities even with the minimum number of leakage flux paths, thereby correctly estimating motor forces in high-performance LPMSMs. The proposed DL-HLM is validated comparing to the equivalent finite element method (FEM) in terms of the magnetic fields in the working air-gap and motor force performances. The proposed modeling method estimates the magnetic fields and forces with an accuracy of higher than 95% even at significantly high saturation levels while simultaneously achieving multiple-orders-of-magnitude faster computation time as compared to the FEM.