Magnetic properties measurement of silicon steel by a high frequency 2-D magnetization structure

Abstract

Accurate magnetic properties measurement of the silicon steel plays an increasingly important role in electromagnetic devices design and optimization. However, with the 2D circular and elliptical magnetization, which usually exist in the corner joint of three-phase transformer and behind the teeth of AC rotating machines, there is lack of experimental data result in the difficulty of reaching high frequency induction at kilohertz range. In this paper, a novel two-dimensional (2-D) magnetic tester with ultra-thin silicon steel sheets is designed and analyzed. In order to improve the measurement precision, a combined B-H sensing structure is designed to avoid the local inhomogeneity of magnetic field distribution caused by drilling holes. Both the alternating and 2D rotating magnetic properties of non-oriented silicon steel M210-35A are systematically measured at a wide range of frequency and magnetic flux density.

Keywords

Ultra-thin silicon steel 2-D magnetic properties high frequency composite magnetic sensor

1. Introduction

The concept of rotational power loss and the measurement method was first presented in end of 19th century. Since then, a number of various approaches has been taken to study this phenomenon. The rotational power loss is usually generated in the magnetic field of the rotating machine and of the T joints of the three-phase transformers. The measurement of high frequency magnetic properties is important in design and performance optimization of the electrical apparatus, not only in the application of traditional motors and transformers, but also in emerging power electronics and special motors [1]. With the improvement of the processing technology of silicon steel materials, the thickness of the silicon steel gradually becomes thinner and thinner, making the high-frequency performance of electrical steel sheets greatly improved, and gradually applied to the field of high-frequency transformers. The optimal design of these electromagnetic devices is inseparable from the accurate magnetic properties measurement. Therefore, it is necessary to study magnetic properties of magnetic materials at high frequency rotation [2]. 2-D measurements are generally performed using either vertical (or horizontal) magnetizers with square samples [3,4], or circular magnetizers with circular samples [5–7]. However, the test frequency of above magnetizers is limited within a few hundreds Hz for the huge power consumed and power dissipation by the core material, especially at high frequency.

In this paper, a novel 2-D magnetic tester with ultra-thin steel sheet (0.05 mm), which permits one to conduct the 2D rotating measurement up to 2 kHz for 0.35 mm non-oriented (NO) steel sheet, is designed and constructed. Comprehensive magnetic properties of NO steel M210-35A are systematically measured and analyzed under both alternating and 2-D rotating excitations, especially in term of hysteresis loops and loss features.

2. 2-D magnetic testing system

2.1. Modeling of the 2-D magnetization structure

The novel 2-D magnetic testing structure consists of four “C-type” cores, B-H sensing box and four multi-layer excitation windings, which are wound around the orthogonal core poles, as shown in Fig. 1. In order to magnetize the specimen to saturation at high frequency, a high-grain-oriented ultra-thin (0.05 mm) silicon steel is applied to the magnetic circuit, which allows to increase the excitation field and reduces the power loss, compared with the common silicon steels [8]. Two pairs of “C-type” cores are mounted in perpendicular. The testing specimen is placed in the center of the 2-D tester and jointed by four core poles, as illustrated in Fig. 1. The multi-layer excitation winding is composed of three layers with different turns, which can be connected in series or parallel to satisfy variable excitation frequency range, flexibly. To sense B signal, B needle method is adopted to avoid the local inhomogeneity of magnetic field distribution caused by drilling holes in B coil method. H signal is measured with traditiona cross H coil method. A combined B - H sensing structure is designed.

Fig. 1.

Structure of the novel 2-D magnetic properties tester.

2.2. The measurement bench

Figure 2 shows a block diagram of the multi-channel digital signal measurement system. Arbitrary waveforms were generated in a computer through the data acquisition card (DAQ) NI PXIe-6368 and excited the specimen so as to get sinusoidal condition for the flux density components by iterative feedback control. The 2-D magnetic properties measurement system consists of B-H composite sensing structure, data acquisition card, differential amplifier circuit and two power amplifiers, which are used to amplify the excitation signal. In order to obtain reliable measurement results, a frequency domain feedback method is proposed to control the B locus as a pure circular, which greatly diminishes the adverse effects of harmonics and increase the accuracy of the measurement [9]. By using the new designed 2-D tester and control method, alternating B-H loops, various experimental circular B loci, corresponding H loci and power losses are obtained for non-oriented silicon steel sheet (M210-35A) and the loops and the losses were obtained [10].

Fig. 2.

Magnetic properties measurement system.

3. Magnetic properties measurement and analysis

3.1. Alternating magnetic properties

The alternating magnetic properties measurement of laminated silicon steel specimen is progressed when the B signal is controlled to be sinusoidal alternating waveform by the digital feedback method. In order to examine the measurement accuracy, taking the NO steel M210-35A as an example, the alternating core loss along both RD and TD are measured by the newly constructed measurement system and compared with the results from a Epstein frame of 200 turns, which is used as a reference, as shown in Fig. 3(a) and (b). It can be seen that this system can provide an acceptable measurement accuracy up to 400 Hz. Since the experimental device square is not a high frequency Epstein frame, the experiment has only been carried out to 400 Hz. In Fig. 3(c), the alternating power loss along two directions are compared at 1000 Hz. It can be observed that the alternating power loss of rolling direction is less than that of the transverse direction.

Fig. 3.

Comparison of alternating core losses measured from this measurement system and standard Epstein frame. (a) Rolling direction. (b) Transverse direction. (c) Alternating power loss in the rolling and transverse directions at 1000 Hz.

Fig. 4.

B loci and corresponding H loci under rotating magnetic measurements with harmonic compensation under different excitation currents in clockwise at 1000 Hz: (a) and (d) under small excitation currents, (b) and (e) under middle excitation currents; (c) and (f) under large excitation currents.

3.2. Rotational magnetic properties

For the NO silicon steel M210-35A specimen, the circular rotation excitation is applied to the xoy plane parallel to the whole rolling surface. Figure 4 shows B loci and corresponding H loci under rotational magnetic measurements with harmonic compensation under different excitation currents. It can be seen that the B loci can be well controlled to be circular with a total harmonic distortion (THD) less than 0.8%.

When the excitation current is small, as shown in Fig. 4(a) and (d), the component values of the H vector in the x and y directions are slightly different and the anisotropic magnetic characteristics are insignificant. Note that rolling direction is along y axis, which is relatively easy direction to magnetize; When the excitation current is large, as shown in Fig. 4(c) and (f), the difference between the H _x and H _y components increases during the increase of the excitation current [11].

The reason for the magnetic anisotropy generated under the rotating magnetization conditions is as follows: When the excitation current is small, the anisotropy caused by the rolling stress of the silicon steel sheet plays a leading role; when the excitation current increases, especially when the saturation magnetization approaches, the grain anisotropy of the material plays a dominant role. This is also the reason why the H loci evolves from an ellipse to a saddle-shaped quadrilateral [12].

3.3. Power loss measurement and analysis

Under the condition of rotating flux density, the measurement method of rotational power loss P is based on the orthogonal component of B and H : B _X, B _Y, H _X, and H _Y, respectively. $\begin{eqnarray}\displaystyle P_{rot}=P_{X}+P_{Y}. & & \displaystyle\end{eqnarray}$ (1) Because: $\begin{eqnarray}\displaystyle & \displaystyle P_{X}=\frac{1}{{\rho}T}\int _{0}^{T}\left(H_{X}\cdot \frac{dB_{X}}{dt}\right)dt & \displaystyle\end{eqnarray}$ (2) $\begin{eqnarray}\displaystyle & \displaystyle P_{Y}=\frac{1}{{\rho}T}\int _{0}^{T}\left(H_{Y}\cdot \frac{dB_{Y}}{dt}\right)dt & \displaystyle\end{eqnarray}$ (3) Where 𝜌 is the density of the specimen, f is the magnetizing frequency, and T = 1∕f.

It is well known that in the fieldmetric method, the value of rotational power loss measured in the clockwise (CW) and anticlockwise (ACW) directions can differ significantly. This discrepancy is caused mostly by angular misalignment of the B and H sensors. Therefore, in the fieldmetric method each total value of rotational power loss is typically calculated as an average of the clockwise (P _{rot, CW}) and anticlockwise (P _{rot, ACW}) values: $\begin{eqnarray}\displaystyle P_{rot,avg}=\frac{1}{2}(P_{rot,CW}+P_{rot,ACW}) & & \displaystyle\end{eqnarray}$ (4) Where P _{rot, CW} and P _{rot, ACW} are separately calculated from Eq. ((1)), for measurements under that respective direction of rotation.

Fig. 5.

Rotational power loss components measured for M210-35A at 2000 Hz, under controlled circular B , plotted as: (a) P = f (B) in clockwise and anticlockwise, (b) P = f (B) in clockwise, (c) P = f (B) in anticlockwise.

The results for M210-35A measured at 2000 Hz under controlled circular B are shown in Fig. 5. The material has low anisotropy, so the P _X and P _Y components have comparable numerical values for all exciation levels. They both reach their peak values and then start decreasing at about 1.5 T, as shown in Fig. 5(a). Figure 5b and Fig. 5c show the same data, but plotted separately for x- and y-direction and as P _{rot, CW} = f (B) and P _{rot, ACW} = f (B), respectively.

A series of rotational power loss curves with different magnetic flux density magnitudes and frequencies in average are plotted, as shown in Fig. 6. The rotational power loss rises rapidly with the increasing frequency, owing to intense motions of magnetic domain walls. However, the increasing tendency is slightly different under different magnetization conditions. Besides, it can be observed that the rotational power losses increase to peak value until the magnitude of B reaches about 1.3–1.5 T and then decrease afterwards. When reaching the saturation state, the magnetic domain walls gradually disappear, the classical eddy current loss increases but the hysteresis loss and abnormal loss decrease, so the total rotational power loss also decreases. Thus, in the region close to saturation, the rotational power loss is slightly smaller than the alternating power loss.

Fig. 6.

Rotational power loss curves with different flux density magnitudes and frequencies in average, measured for M210-35A.

Fig. 7.

Comparison of power loss characteristics for M210-35A for alternating and rotational circular magnetization. (a) 50 Hz and 100 Hz. (b) 1000 Hz and 2000 Hz.

Alternating and rotational power losses are compared in 50 Hz, 100 Hz, 1000 Hz, and 2000 Hz, as shown in Fig. 7. When the magnetic flux density is low, the rotational power loss is approximately twice of the alternating loss in the rolling direction. When the magnetic flux density is large, the rotation loss will be drastically reduced and becomes even lower than the alternating loss [13].

4. Conclusions

This paper presents a new type of tester for measuring the alternating and 2-D magnetic properties of silicon steels. Comprehensive magnetic properties including B and H loci and rotational power loss of a non-grain oriented silicon steel M210-35A are measured and analyzed, and the magnetization frequency was extended to 2 kHz by using ultra-thin silicon steel as the core. Besides, a complete testing system was built, a feedback control algorithm and a harmonics compensation were established, which achieve accurately simulation of rotating magnetic field. The alternating and rotating power losses in the test process are analyzed, which is very useful to develop high-frequency and high-power density electrical machines.

Footnotes

Acknowledgements

This work was supported in part by the National Key R & D Program of China (2017YFB0903904), the National Natural Science Foundation of China, (No. 51777055, 51690181), Hebei Province Science Foundation for Distinguished Young Scholars (No. E2018202284), and Program for Hundred Excellent Innovative Talents of Hebei Province (No. SRLC2017031).

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