AC Loss Analysis of Novel Hybrid Wire for High-Speed Machines

A hybrid wire with high bundle copper fill factor, enhanced thermal conductivity, and low AC losses is proposed for high-speed machines. Firstly, the topology of hybrid wire is presented, highlighting its advantages over conventional litz and solid wires in high-speed machine applications. Secondly, an analytical model for AC loss of the hybrid wire is developed based on the partial element equivalent circuit method. A loss-coupling iterative strategy is proposed to correct the cross-sectional impedance, enhancing the accuracy of AC losses calculations. Thirdly, comparison with finite element analysis results validates the analytical approach. Finally, experimental evaluation of different wire types, including solid, litz, and hybrid wires, demonstrates the superior AC loss suppression of hybrid wire and further confirms the validity of the analytical method for AC loss estimation.