Design and Losses Analysis of a High Power Density Machine for Flooded Pump Applications

Ahmed Al-Timimy, Paolo Giangrande, Michele Degano, Zeyuan Xu, Michael Galea, Chris Gerada, Giovanni Lo Calzo, He Zhang, Liqun Xia

Research output: Journal PublicationArticlepeer-review

71 Citations (Scopus)


This paper describes the design process of a 10 kW 19 000 r/min high power density surface mounted permanent magnet synchronous machine for a directly coupled pump application. In order to meet the required specifications, a compact machine with cooling channels inside the slots and flooded airgap has been designed through finite element (FE) optimization. For high power density, high-speed machines, an accurate evaluation of the power losses, and the electromechanical performance is always extremely challenging. In this case, the completely flooded application adds to the general complexity. Therefore, this paper deals with a detailed losses analysis (copper, core, eddy current, and mechanical losses) considering several operating conditions. The experimental measurements of ac copper losses, as well as the material properties (BH curve and specific core losses) including the manufacturing process effect on the stator core, are presented. Accurate 3-D FE models and computational fluid dynamics analysis have been used to determine the eddy current losses in the rotor and windage losses, respectively. Based on these detailed analysis, the no-load and full-load performance are evaluated. The experimental results on the manufactured prototype are finally presented to validate the machine design.

Original languageEnglish
Pages (from-to)3260-3270
Number of pages11
JournalIEEE Transactions on Industry Applications
Issue number4
Publication statusPublished - 1 Jul 2018


  • High power density
  • high speed
  • losses calculation
  • performance analysis
  • permanent magnet (PM) motors

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering
  • Electrical and Electronic Engineering


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