Influence Of Stator Segmentation On Iron Losses In PMSMs

Ever wondered how the intricacies of stator design can significantly impact the efficiency of electric motors, especially in the context of traction applications? The journey into the world of motor optimization brings us to a pivotal question: How does stator segmentation influence iron losses in Permanent-Magnet Synchronous Motors (PMSMs) designed for traction applications?

In this paper, we investigate and discuss the realm of stator segmentation, conducting a detailed analysis of its influence on total iron losses. 

We aim to unravel the complexities and nuances of this crucial aspect of motor design, comparing various segmentation methods under equal excitation conditions.

Whether you’re an institute engineer, a seasoned professional in science or university, or simply curious about the inner workings of electric motors.

As we embark on this journey, the significance of achieving the optimal balance between efficiency and performance becomes apparent, paving the way for advancements in sustainable and energy-efficient electric propulsion systems. 

Understanding Stator Segmentation

Silicon Steel Segmented Laminations Bonding And Stacking

Stator segmentation is a design technique that involves dividing the stator winding into distinct segments.

Segmented stators are usually made of electrical steel. These segments can be achieved through various methods such as full-pitched windings, fractional slot windings, and concentrated windings.

A variety of motor topologies including laminated-core surface-mounted or interior permanent magnets with distributed or concentrated winding are studied and considered.

Each technique has its unique advantages and disadvantages, influencing the motor’s overall efficiency and performance.

Full-pitched windings, for instance, involve winding coils that span the full pitch of the stator. Fractional slot windings, on the other hand, divide the stator into fractional slots, providing more design flexibility.

Concentrated windings concentrate the coil turns in specific slots, enhancing certain motor characteristics. The choice of segmentation technique depends on the specific requirements of the application.

Iron losses in the stator core for PMSMs

In the realm of permanent magnet synchronous machines, the intricate interplay of factors contributes to the phenomenon of iron loss terms, a critical consideration for motor efficiency. 

Key variables such as copper fill factors, cut edge precision, homogenized airgap length, magnetic flux density, and segmented stator winding fill factors are integral components in the pursuit of optimizing motor performance.

Copper fill factors, defining the volume of copper within stator slots, effect the motor’s conductive efficiency. A careful balance is crucial to prevent unnecessary energy losses.

The cut edge precision, a geometric parameter, shapes the magnetic flux distribution, directly impacting iron losses. Precise engineering of the cut edge is fundamental for minimizing energy dissipation.

The segmentation of the stators creates additional air gaps and changes the soft magnetic material’s material properties due to the cut edge effect. 

Obtaining a homogenized airgap length is essential to control variations in magnetic circuits. Consistent airgap lengths contribute to the reduction of iron-loss, enhancing overall motor efficiency.

The winding fill factor, representing the ratio of actual copper area to total slot area, plays a pivotal role in optimizing the motor’s winding efficiency. Striking the right balance in winding fill factors is key to minimizing energy losses and maximizing motor efficiency.

In the intricate dance of these factors, fine-tuning copper fill factors, cut edge precision, homogenized airgap length, magnetic flux density, and winding fill factors is the art of mitigating iron core losses, ensuring permanent magnet synchronous machines operate at their peak efficiency.

spliced stator lamination stacks

The Relationship Between Stator Segmentation and Iron Losses

The interaction between stator spliced tooth and iron losses is a key factor in motor design. Segmentation changes the distribution of magnetic flux within the stator, influencing the magnitude and distribution of iron losses.  

Research indicates that combined hysteresis model design, finite element analysis, and IMs per pole magnetic flux calculate can help mitigate iron losses, improving overall motor efficiency.

Comparative studies reveal that motors with segmented stators experience lower iron losses compared to their non-segmented counterparts.

The segmentation optimizes the magnetic field, reducing energy dissipation as heat. This optimization is particularly significant in traction applications where energy efficiency is paramount.

Optimization Techniques for Minimizing Iron Losses

To minimize iron losses, motor designers employ various optimization techniques. Stator segmentation emerges as a crucial tool in this process.

By strategically implementing segmentation, motor designers can achieve a balance between reduced iron losses and other performance metrics.

Stator segmentation not only contributes to lower iron losses but also increases motor performance in terms of power density and torque characteristics.

Therefore, this optimization is vital for traction applications, where the demand for efficient energy utilization is high.

Applications in Traction Systems

Using stator core segmentation is most evident in traction systems, such as electric vehicles. The reduction in iron losses achieved through segmentation directly impacts the vehicle’s range, hub rotational speed, and overall efficiency.

Real-world examples showcase the successful implementation of segmented stators, resulting in tangible improvements in traction system performance.

In these applications, the influence of stator segmentation goes beyond theoretical advantages.

It translates into measurable benefits, including extended battery life, reduced heat generation, and enhanced overall drivetrain efficiency.

Our Segmented Stator Lamination Capabilities

At Motorneo, our commitment to innovation developed our cutting-edge capabilities in segmented stator laminations. With a focus on precision engineering, we excel in crafting stator laminations that incorporate leading segmentation techniques.

Our expertise source lies in various segmentation methods, namely full-pitched windings, fractional slot windings, and concentrated windings.

This allows us to tailor our products to meet the unique requirements of diverse applications, ensuring final motor optimal efficiency and performance.

The meticulous design, manufacture, and measure test processes employed by our skilled team guarantee stator laminations that not only adhere to the highest quality standards but also contribute to the reduction of iron losses in permanent magnet synchronous machines. 

Partner with us for a seamless integration of technology and craftsmanship, redefining the benchmarks for segmented stator laminations in the realm of single or three phase electric motor design.

our segmented stator lamination stacks capabilities


In conclusion, the influence of stator segmentation on iron losses in PMSM is a critical aspect of motor design, especially in traction applications.

By understanding the relationship between stator segmentation and iron losses, motor designers can optimize performance, improve efficiency, and contribute to the advancement of sustainable technologies.

The segmentation in most cases slightly decreases the iron losses in the stator because of the overall reduced magnetic flux density B due to the additional air gaps in the magnetic circuit. 

An increase in the individual components, as well as total power loss, was observed in the Pole Chain segmentation design. In general, segmentation did not change the total iron losses significantly.

This exploration underscores the pivotal role of stator segmentation in shaping the future of sustainable electric propulsion systems.

The quest for enhanced efficiency in traction applications finds a reliable ally in the precision of stator segmentation, ushering in a new era of energy-conscious and high-performance electric motors.


In what ways does stator segmentation improve the efficiency of electric motors used in traction applications?

Stator segmentation improves efficiency by minimizing iron losses, optimizing magnetic flux distribution, and enhancing overall motor performance in traction-driven systems.

How does the iron loss reduction achieved through stator segmentation translate into benefits for electric vehicles?

The reduction in iron losses directly contributes to improved energy efficiency, extended battery life, and enhanced overall performance in electric vehicles.

What is the purpose of segmenting stator laminations in electric motor design?

Segmenting stator laminations in electric motor design serves the purpose of optimizing magnetic flux distribution and minimizing energy losses.

This precision engineering technique involves dividing the stator into distinct segments, allowing for more efficient control of the magnetization and demagnetization processes.

By strategically managing the distribution of magnetic flux, segmented stator laminations contribute to reduced iron losses and enhanced overall motor efficiency, making them a vital element in the quest for high-performance and energy-efficient electric motors.

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