Development of High-Efficiency PMSG With Extremely Thin Stator Lamination Materials for Electric-Propulsion UAV

Permanent magnet synchronous generator (PMSG) is gradually becoming popular in the aeroelectric propulsion system due to its high efficiency and high power density. The selection of stator lamination materials usually requires multiple considerations, including high magnetic performance, low losses, lightweight, and so on. In order to achieve higher efficiency and power density, the electromagnetic structure of the PMSG is optimized, and the electromagnetic performance and weight of various stator lamination materials and thicknesses are also taken into consideration in this article. The magnetic material properties, including <inline-formula> <tex-math notation="LaTeX">${B}$ </tex-math></inline-formula>–<inline-formula> <tex-math notation="LaTeX">${H}$ </tex-math></inline-formula> characteristics and losses at different frequencies, are obtained by the test and used to accurately predict the performance of machines. Finally, a 10 kW and 20-pole and 45-slot prototype with 0.1 mm thick 1J22 material is manufactured for the electric propulsion system of Unmanned Aerial Vehicle (UAV). The simulation and experiment results show that the efficiency of the generator system can reach 92.5%, and the power density of the generator is about 2 kW/kg.