Eddy Current Loss Minimization in Conducting
Sleeves of High Speed Machine Rotors by Optimal
Axial Segmentation and Copper Cladding
Manoj R. Shah
Electrical Machines and Drives Lab
GE Global Research Center
Niskayuna, NY, USA
shahmr@research.ge.com
Abstract When a non-magnetic, high-strength metallic
retaining sleeve offers advantages over a non-metallic (e.g.
carbon fiber) one, it is possible to consider the application of a
high conductivity shield coating on this sleeve to reduce the
surface eddy current losses due to non-synchronous fields. One
can start by using a Maxwells equations based analytical model
to screen for the optimal shield thickness and then employs a
2.5D FE method that accounts for periodic fields and finite
rotor length including axial segmentation and/or copper
cladding. These are quantified to help design a low loss rotor
sleeve for a high speed SPM machine with fractional-slot
concentrated armature winding. With this type of windings the
sleeve losses can be significant due to its rich asynchronous
harmonic armature reaction mmf content.
Keywords- axial segmentation; concentrated; copper cladding;
eddy-current; flux weakening; fractional-slot; high-speed;
permanent magnet; sleeve; synchronous machines; surface;
winding;
I. INTRODUCTION
In a high-speed machine, a high-strength retaining sleeve
is often used to support the contents of its rotor for its safe and
reliable operation across its load, speed and temperature
ranges. The sleeve can be either metallic i.e. electrically
conducting or non-metallic such as carbon fiber. If a critical
evaluation from the design, manufacturing and performance
perspectives deems the metallic sleeve to be the preferred
choice, it behooves the cognizant electrical engineer to
minimize the sleeve electromagnetic losses to mitigate the
associated thermal and mechanical risk levels. This paper
deals with this specific challenge. The principal sources of
sleeve electromagnetic heating are the non-synchronous mmf
components of the armature winding space harmonics
combined with generally non-sinusoidal and potentially
unbalanced armature currents. Slot/tooth related permeance
variation adds to these losses [1-4]. For a specific application,
one can envision employing axial segmentation of the sleeve
to cut off the eddy current axial paths thereby reducing the
level of induction. Another option is to provide a high
0197-2618/07/$25.00 2007 IEEE
Ayman M. EL-Refaie
Electrical Machines and Drives Lab
GE Global Research Center
Niskayuna, NY, USA
elrefaie@research.ge.com
conductivity shield coating on the surface of the sleeve for
reducing the surface eddy current losses. Since the design
process for determining the optimal number of axial segments
along with the optimal copper cladding thickness can be very
complicated and time-consuming, one can start with a simple
analytical model based on Maxwells equations [5] using it as
a screening tool for determining the optimal shield thickness
for minimizing rotor surface losses. The next step in the
design process would be to employ a special 2.5D finite
element method that simultaneously accounts for the periodic
fields and the impact of finite axial length of the rotor
including axial segmentation and copper cladding. Validation
of this step was reported in [6].
Fractional-slot concentrated windings have been gaining a
lot of attention over the past few years. This is mainly due to
their short non-overlapping end turns. This improves the
machine power density and efficiency. Also they have low
cogging torque [7]. Recently, it has been shown that the
conditions for optimal flux weakening can be achieved in an
SPM by using fractional-slot pitch concentrated windings
(FSPCW) [8,9]. It has also been shown that using FSPCW
along with a higher number of phases helps in making an SPM
machine more fault-tolerant [10].
One of the key challenges with these winding configurations
is the high eddy-current losses generated in the rotor. This is
mainly due to the presence of sub harmonics as the
synchronous mmf component is generally of a higher space
harmonic order than unity [8,11]. Most of the existing
literature has focused on reducing the losses generated in the
permanent magnets. Both circumferential as well as axial
segmentation of the magnets have been considered [11,12].
Very little attention has been given to reducing the eddy-
current losses in conductive sleeves for high-speed
applications.
In this paper, the impacts of axial segmentation and
cladding are rigorously quantified to help design a lower eddy
loss rotor sleeve for a high speed surface mounted permanent
magnet rotor machine with fractional slot pitch concentrated
armature winding, FSPCW-SPM. Figures (1a) and (1b)
544
schematically show the single-layer and double-layer armature air, copper and steel. Here, this analysis is extended to six
winding embodiments of the FSPCW-SPM. regions: 1) airgap (g), 2) copper layer (c), 3) high-strength,
For each number of phases, there are criteria to choose the non-magnetic metallic sleeve such as Inconel (i), 4) permanent
optimal slot/pole combination that can support FSPCW magnet (p), 5) magnetic steel rotor back iron (s), and 6) air
designs [13]. In this paper, the proposed analysis and design representing the borehole (a), shown in Figure (2). Regions 2,
process will be applied to sample optimal slot/pole 3, and 5 are considered electrically conducting in the axial
combinations of 3,4,5, and 6 phase designs to evaluate the direction while regions 4 and 5 are assigned constant relative
effect of sleeve axial segmentation and/or copper cladding on permeabilities. The forcing function is represented as a current
the sleeve eddy- current losses. The chosen slot/pole sheet for each possible combination of space and time
combinations support both single-layer and double-layer harmonic MMF component located at the top of region 1, the
windings. This will help highlight how effective the loss airgap (g), representing the stator bore (inner surface.) By
reduction techniques will be for both types of windings. deriving Laplaces equations for the non-conducting regions
and Poissons equations for the conducting regions, one can
The designs that will be analyzed satisfy the same set of
solve for the coefficients of the corresponding magnetic vector
specifications. They have the same electric loading, magnetic
potentials, Ag, Ac, Ai, Ap, As and Aa employing the
loading, rotor speed, air gap radius, sleeve thickness, magnet
tangential magnetic field and normal magnetic flux density
thickness, and axial length. This will also help highlight the
boundary conditions at the region interfaces. This results in a
effect of the number of phases on the eddy-current losses in
set of eleven simultaneous complex equations given in the
the segmented and/or shielded sleeve while producing the
matrix form as equation (1) below.
same active output power.
Source
y= g+c
Airgap (I)
y= c y
Copper (II)
x
y= 0
Sleeve (III)
y= -i
Magnet (IV)
Fig. 1: Surface PM machine with two types of concentrated stator windings:
y= -i-p
single-layer (left) and double-layer (right). Steel (V)
y= -i-p-s
Air (VI)
II. SUMMARY OF ANALYTICAL SOLUTION
Fig. 2: General purpose model for analyzing the effect of copper layer

In [5], an analytical model was derived employing Maxwells

equations for determination of the optimal copper layer
thickness for three semi-infinite plane regions consisting of

nk (c + g ) cq
e e nk (c + g ) 0 0 0 0 0 0 0 0 0 1
enkc e nkc eqc c e qc c 0 0 0 0 0 0 0 cq
q q c qc c 2 0 MMF pk
enkc e nkc c e qc c e 0 0 0 0 0 0 0 c
nk nk c1 0
0 0 1 1 1 1 0 0 0 0 0 c
0
q qi c
0 0 1 1 i 0 0 0 0 0 2

qc qc 0
ci
e qi i e qi i e nki e nki 1 0
0 0 0 0 0 0 0
* ci = 0
q i
e i e i
qi nk
e nki
nk
e nki 2
0 0 0 0 0 0 0
qi p qi p p 0
c
1
e nk (i + p) e nk (i + p) e q s (i + p ) e qs (i + p)
p 0
0 0 0 0 0 0 0
q s p q ( i + p) q s p q (i + p) c 0
0 0 0 0 0 0 e nk (i + p) e nk (i + p) e s e s 0 2
nk s nk s cs 0
(+ + ) (+ + ) 1
0 0 0 0 0 0 0 0 e qs i p s e qs i p s e nk (i + p + s)
cs
0
+ + nk s nk (i + p + s) 2
0 0 0 0 0 0 0 0 e q s (i p s ) e qs (i + p + s) e a
qs c1

..(1)

545
 where, k is the wave number (1/m), n and m are the space and time harmonic order, respectively. From the solutions of the
magnetic vector potential (A) coefficients (c1 and c2 for each region), it can be shown that analytical equations for the surface loss
density (W/m2) can be calculated from (2) for copper, sleeve and steel regions, respectively, and the total surface losses can be
calculated from (3).

(m ) 2 c c (m ) 2 i 0 (m ) 2 s i p
qcu =
2 0
Ac Ac*dy , qi =
2 i
Ai Ai*dy , q fe =
2 i p s
As As* dy (2)

q surface = q cu + qi + q fe (3)

IV. SIMULATION RESULTS

III. 2.5D FINITE ELEMENT METHOD
(EVP+MSP, HE- , FORMULATION)
For this FEM [6], the geometry is considered axi-symmetric
while the electromagnetic fields are considered axi-periodic
The Electric Vector Potential + Magnetic Scalar Potential
(EVP + MSP) formulation of Maxwells equations is briefly
given next.
Let
H = He (4)
Where, H is magnetic field intensity resulting from i) the
eddy currents, He, and ii) the geometry of the problem and
material properties represented by the gradient of magnetic
scalar potential, . It should be noted that a discontinuity in
the scalar potential represents the source.
Also, from Maxwells equation representing Amperes Law,
E = Je / = xHe / (5)
where, E is the electric field intensity, Je is the eddy current
density and is the electrical conductivity.
Then using Maxwells equation representing Faradays Law,
xE = B / t
yields
x(1 / (xHe)) + j He = j
In addition, the constitutive relation
B = 0
yields
= He (9)
By imposing He, tangential = 0 on conducting region surfaces,
Je = 0 is exactly enforced. Equations (7) and (9) are
solved iteratively and alternatively starting with equation (9)
and the initial assumption of no eddy currents. This approach
slows down the convergence process but yields robust results
as both B = 0 and Je = 0 are satisfied in a strong
way unlike the standard FEM approaches where only one of
the two is strongly satisfied while the other is satisfied in a
least square or weak sense.
In this section, the analytical model discussed in section II
is used to evaluate the effect of copper cladding on sleeve
losses for various designs under consideration. The 2.5
Finite Element Analysis method discussed in section III is
then used to evaluate the effect of axial segmentation and
copper cladding on the sleeve losses. Table I summarizes the
phase/slot/pole combinations that are analyzed. As previously
mentioned, these combinations have been chosen based on the
criteria previously identified in literature [7,13]. Also all these
combinations support both single-layer and double-layer
winding configurations that help highlight the effect of the
proposed sleeve loss-reduction techniques for both types of
windings.
Table I: Phase/Slot/Pole combinations
Number of Phases 3 4 4 5 5 6
Number of Slots 24 16 16 20 20 24
Number of Poles 20 14 18 18 22 22
(6) Tables II-VII contain the 15 most significant mmf harmonic
components with their respective space order, associated
electrical frequencies with respect to the rotor in multiples of
(7) the synchronous frequency and relative amplitudes with
respect to the useful or synchronous component for the 3-
(8) phase 24slot/20pole single layer (SL) armature winding
configuration (Highlighted in red) for the designs under (8)
consideration as given in Table (I).
All the mmf harmonic components have been scaled such
that all the designs would have the same peak value of the
synchronous current sheet (same electric loading). Also all
designs have the same magnetic loading, airgap radius, sleeve
thickness, magnet thickness, rotor mechanical speed, and axial
length.
Here the losses due to the slotting effect (no-load losses) are
ignored [14] as in the case of FSPCW, the armature winding
asynchronous space mmf harmonic components dominates the
rotor losses. On the other hand, ignoring the slotting effects
leads to slightly overestimating the rotor losses as partial
filtering of armature mmf components in the slot
opening/tooth tip area is ignored. In general, these
approximations have no significant effect on the relative
trends of the results.

546
 (A) Effect of Copper Cladding:
Each of the designs is considered to have an Inconel
sleeve. The losses for all designs are evaluated first using the
analytical method via a MATLAB simulation (using the mmf
harmonic components and the corresponding frequencies in
Tables II-VII) to determine the optimal copper layer. The
results of the analytical method (total rotor losses) for both
single-layer (SL) as well as double-layer (DL) winding
configurations are shown in Figures 3, and 4 respectively.
The copper thickness is varied from 0 to 10 mm. 100% loss
value represents the losses for the case of the 3-
phase/24slot/20pole SL design. Several points can be made by
examining Figures 3, and 4:
As expected, the rotor loss decreases rapidly and
essentially flattens out around 2 mm for all the cases
under evaluation. Additional copper thickness can
only reduce the design power density as to maintain
a minimum physical gap, the magnetic gap would
increase.
The DL windings reduce rotor losses from zero to 2
mm copper cladding. This is consistent with the fact
that the most dominant lower order sub-harmonic
component is significantly lower for the DL
compared to SL windings for all the cases. Above
copper thickness of 2 mm, both SL and DL windings
almost generate the same rotor losses.
The 4-Phase 16slot/18pole and 5-Phase
20slot/22poledesigns have the two highest losses.
From Tables IV and VI, it can be seen that the key
reason for this is that both designs have two
dominant sub-harmonic components as against only
one for other cases. In general, whenever the number
of slots is lower than the number of poles, the rotor
losses are expected to be higher.
The two 4-phase designs have comparable losses.
This is because they have similar mmf harmonic
spectrum. The only difference is in the order of the
synchronous component in each case (the 7th vs the
9th).
The 6-phase design has the lowest loss values. This
is mainly due to the lower mmf values of the most
dominant subharmonic component compared to the
rest of the designs.
In addition to the rotor loss values, other factors have
to be taken into account that might favor a particular
design. For example cost, size, mass, volume, the
complexity of the power converter (and the
associated controls), and the number connections.
Another important factor is the maximum allowable
synchronous frequency. This is determined based on
the maximum allowable switching frequency and
maintaining enough separation relative to the
machine synchronous frequency. As a rule of thumb,
a separation of ~10:1 may be needed in order to
maintain high quality of the current and voltage
waveforms. This constraint could push the design to
have a lower number of poles (depending on the
rotor speed), and reduce the machine power density
due to the thicker back iron.

Table II: Space Harmonic order, pu frequency and % mmf for Table III: Space Harmonic order, pu frequency and % mmf for
The 3-Phase 24Slot/20Pole Single-layer (SL) and Double-Layer The 4-Phase 16Slot/14Pole Single-layer (SL) and Double-Layer
(DL) windings (DL) windings

Harmonic Order Frequency[pu] MMF_SL [%] MMF_DL [%] Harmonic Order Frequency[pu] MMF_SL [%] MMF_DL [%]
1 1.2 134.0 35.9 1 0.8 198.9 39.6
5 0 100.0 100.0 7 0 142.9 142.9
7 2.4 71.4 71.4 9 1.6 111.1 111.1
11 1.2 12.2 3.3 15 0.8 13.3 2.6
13 3.6 10.3 2.8 17 2.4 11.7 2.3
17 2.4 29.4 29.4 23 1.6 43.5 43.5
19 4.8 26.3 26.3 25 3.2 40.0 40.0
23 3.6 5.8 1.6 31 2.4 6.4 1.3
25 6 5.4 1.4 33 4 6.0 1.2
29 4.8 17.2 17.2 39 3.2 25.6 25.6
31 7.2 16.1 16.1 41 4.8 24.4 24.4
35 6 3.8 1.0 47 4 4.2 0.8
37 8.4 3.6 1.0 49 5.6 4.1 0.8
41 7.2 12.2 12.2 55 4.8 18.2 18.2
43 9.6 11.6 11.6 59 6.4 17.5 17.5

547
Table IV: Space Harmonic order, pu frequency and % mmf for Table V: Space Harmonic order, pu frequency and % mmf for
the 4-Phase 16Slot/18Pole Single-layer (SL) and Double-Layer The 5-Phase 20Slot/18Pole Single-layer (SL) and Double-Layer
(DL) windings (DL) windings

Harmonic Order Frequency[pu] MMF_SL [%] MMF_DL [%] Harmonic Order Frequency[pu] MMF_SL [%] MMF_DL [%]
1 0.8 198.9 39.6 1 1 158.4 25.1
7 1.6 142.9 142.9 9 0 111.1 111.1
9 0 111.1 111.1 11 2 90.9 90.9
15 2.4 13.3 2.6 19 1 8.3 1.3
17 0.8 11.7 2.3 21 3 7.5 1.2
23 3.2 43.5 43.5 29 2 34.5 34.5
25 1.6 40.0 40.0 31 4 32.3 32.2
31 4 6.4 1.3 39 3 4.1 0.6
33 2.4 6.0 1.2 41 5 3.9 0.6
39 4.8 25.6 25.6 49 4 20.4 20.4
41 3.2 24.4 24.4 51 6 19.6 19.6
47 5.6 4.2 0.8 59 5 2.7 0.4
49 4 4.1 0.8 61 7 2.6 0.4
55 6.4 18.2 18.2 69 6 14.5 14.5
59 4.8 17.5 17.5 71 8 14.1 14.1

Table VI: Space Harmonic order, pu frequency and % mmf for Table VII: Space Harmonic order, pu frequency and % mmf for
the 5-Phase 16Slot/18Pole Single-layer (SL) and Double-Layer The 6-Phase 24Slot/22Pole Single-layer (SL) and Double-Layer
(DL) windings (DL) windings

Harmonic Order Frequency[pu] MMF_SL [%] MMF_DL [%] Harmonic Order Frequency[pu] MMF_SL [%] MMF_DL [%]
1 1 158.4 25.1 1 1.2 131.7 17.3
9 2 111.1 111.1 11 0 90.9 90.9
11 0 90.9 90.9 13 2.4 76.9 76.9
19 3 8.3 1.3 23 1.2 5.7 0.8
21 1 7.5 1.2 25 3.6 5.3 0.7
29 4 34.5 34.5 35 2.4 28.6 28.6
31 2 32.3 32.3 37 4.8 27.0 27.0
47 3.6 2.8 0.4
39 5 4.1 0.6
49 6 2.7 0.4
41 3 3.9 0.6
59 4.8 16.9 16.9
49 6 20.4 20.4
61 7.2 16.4 16.4
51 4 19.6 19.6 71 6 1.9 0.2
59 7 2.7 0.4 73 8.4 1.8 0.2
61 5 2.6 1.0 83 7.2 12.0 12.0

130.00% 130.00%

110.00% 110.00%
Sleeve Losses [%]
Sleeve Losses [%]

90.00% 90.00%

70.00% 70.00%

50.00% 50.00%

30.00% 30.00%
0 0.5 1 1.5 2 2.5 3 0 0.5 1 1.5 2 2.5 3
Copper Cladding Thickness [mm] Copper Cladding Thickness [mm]

24S/20P_3Ph_SL 16S/14P_4Ph_SL 16S/18P_4Ph_SL 24S/20P_3Ph_DL 16S_14P_4Ph_DL 16S/18P_4Ph_DL

20S/18P_5Ph_SL 20S/22P_5Ph_SL 24S/22P_6Ph_SL 20S/18P_5Ph_DL 20S/22P_5Ph_DL 24S/22P_6Ph_DL

Fig.3: Relative surface sleeve loss (%) vs. Copper Layer Fig.4: Relative surface sleeve loss (%) vs. Copper Layer
thickness for the various SL combinations thickness for the various DL combinations

548
 number of sleeve axial segment increases.
(B) Effect of Sleeve Axial Segmentation (with and without
Copper Cladding): Two general inferences can be made at this point:

A finite element model (Figure 5) was constructed next to
evaluate the effectiveness of the above determined optimal
copper layer as well as that of axial segmentation of the rotor
sleeve with and without copper layer.
The finite element model has been used to evaluate the
sleeve losses for each slot/pole combination for various
number of sleeve segments. For each number of segments four
cases are evaluated: SL without copper cladding (SNC), DL
without copper cladding (DNC), SL with 2mm copper
cladding (SC), and DL with 2mm copper cladding (DC), In
this analysis, only the 4 most dominant mmf harmonic
components have been included. It is expected that if higher
number of harmonic components are included, the loss results
will slightly vary but the trend of the results will not change.
Figure 6 shows the current density distributions for a whole
and a six-segment sleeve over half the axial length for the
fundamental space harmonic component for the reference 3-
phase machine. It is clear that the eddy-current paths are
interrupted by segmentation and hence reducing the sleeve
losses.
The results for the six winding configurations, under
consideration are show in Figures 7-12. The losses in all these
figures are normalized based on the losses of the 3-phase
24slot/20pole SL winding configuration, shown as 1 [pu] in
Figure 7. Z
(1) The most effective way of reducing the losses is to
use a whole sleeve with optional copper cladding.
(2) If one chooses to segment the sleeve without copper
cladding, it has to be kept in mind that this would
complicate the assembling process. Also it is expected
that there will be some penalty in the machine power
density due to the need to either increase the machine
axial length or reduce the machine tip speed. There has
to be a compromise between reducing the sleeve losses
and maintaining a high machine power density.
Shaft
Inconel Cu
Sleeve Layer
PM Stator
Rotor back Iron
Airgap

From these six figures, several observations can be made:

R
For the whole sleeve, as previously discussed, DL
windings always have lower losses compared to Fig. 5: Finite Element Model Outline
SL windings. Copper cladding significantly
reduces the losses for both the SL, and DL
windings.
Axial segmentation of the sleeve (without copper
cladding) initially causes an increase in the sleeve
losses. However, as the number of segments
increase, the losses start to decrease.
In most cases, axial segmentation of the sleeve Fig. 6: Current density distribution: whole & segmented sleeve
(without copper cladding) initially has slight or no
effect on reducing the sleeve losses for DL
windings. Nonetheless, as the number of segments
increase, the reduction in losses becomes more
obvious.
In case of 2mm copper cladding, the sleeve losses
for both the SL, and DL windings increase as the

549
 3-Phase 24Slot/20Pole Design 4-Phase 16Slot/14Pole Design

1.400 1.600
1.200 1.400
Sleeve Losses [pu]

Sleeve Losses [pu]

1.000 SNC 1.200 SNC
0.800 DNC 1.000
DNC
0.800
0.600 SC SC
0.600
0.400 DC DC
0.400
0.200 0.200
0.000 0.000
Full Two Four Six Eight Full Two Four Six Eight
Sleeve Segments Sleeve Segments

Fig.7: Effect of axial segmentation on rotor losses with and Fig.8: Effect of axial segmentation on rotor losses with and
without copper cladding in case of the 3-phase 24slot/20pole without copper cladding in case of the 4-phase 16slot/14pole
designs designs

4-Phase 16Slot/18Pole Design 5-Phase 20Slot/18Pole Design

2.000 1.400
1.200
Sleeve Losses [pu]

Sleeve Losses [pu]

1.500 SNC 1.000 SNC
DNC 0.800 DNC
1.000
SC 0.600 SC
0.500 DC 0.400 DC
0.200
0.000 0.000
Full Two Four Six Eight Full Two Four Six Eight
Sleeve Segments Sleeve Segments

Fig.9: Effect of axial segmentation on rotor losses with and Fig.10: Effect of axial segmentation on rotor losses with and
without copper cladding in case of the 4-phase 16slot/18pole without copper cladding in case of the 5-phase 20slot/18pole
designs designs

5-Phase 20Slot/22Pole Design 6-Phase 24Slot/22Pole Design

1.600 1.200
1.400
Sleeve Losses [pu]

Sleeve Losses [pu]

1.000
1.200 SNC
0.800 SNC
1.000
DNC DNC
0.800 0.600
SC SC
0.600
DC 0.400
0.400 DC
0.200 0.200
0.000 0.000
Full Two Four Six Eight Full Two Four Six Eight
Sleeve Segments Sleeve Segments

Fig.11: Effect of axial segmentation on rotor losses with and Fig.12: Effect of axial segmentation on rotor losses with and
without copper cladding in case of the 5-phase 20slot/22pole without copper cladding in case of the 6-phase 24slot/22pole
designs designs

550

V. Conclusions
A simple and effective analytical model for
calculating the rotor surface losses for an electrical machine
is presented. The derived set of equations was applied to six
FSPCW-SPM machines having different number of phases
and different slot/pole combinations. A 2.5D finite
element simulation was employed to quantify the impact of
axial segmentation of the rotor sleeve with and without
copper cladding.
It is clear that copper layer does help reduce the rotor
surface losses significantly, but only for the whole sleeve.
Also, axial segmentation of the rotor sleeve without any
copper layer helps reduce rotor sleeve losses. Surprisingly,
if both these solutions are applied at the same time, the rotor
losses increase! Based on these findings, it is expected that
the proposed analytical and finite element tools would serve
as set of complementary tools to help determine which of
the two solutions to employ, especially for high-speed
machines operating in conjunction with power electronic
converters.
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