Analysis and simplified hybrid analytical calculation of AC copper loss in YASA motor windings

In the YASA motor investigated in this study, additively manufactured windings are adopted to enhance torque density. During the optimization process, the computation of AC copper losses proves time-consuming and computationally intensive. To address this challenge, a simplified hybrid analytical method is proposed for calculating these losses. The process begins with extracting the winding magnetic flux density distribution through finite element methods (FEM), followed by necessary data processing. Subsequently, an analytical model is utilized to compute the winding eddy current losses. This paper details the derivation of analytical eddy current loss models applicable to conventional flat wire windings and three types of profil ed conductor windings. The accuracy of the model is rigorously validated through comparative analysis with 3D FEM results. This approach reduces the computation time to one-sixth of that required by a full 3D FEM simulation while maintaining computational accuracy, thereby significantly enhancing design and optimization efficiency.