Performance Analysis and Temperature-Corrected Core Loss Modeling of Soft Magnetic Materials for Hybrid Stepper Motors in Cryogenic Environments

Hybrid stepper (HB) motors are widely used in precision actuation systems such as cryogenic refrigerator robotic arms. Under cryogenic working conditions, the core loss characteristics of magnetic materials change significantly, while conventional core loss models calibrated at room temperature can hardly provide reliable prediction accuracy. In this work, the electromagnetic properties of 35SW1900 non-oriented silicon steel were measured from 25 °C − 100 °C using a BROCKHAUS Epstein frame system. Variations in permeability, core loss and coercivity with magnetic flux density, temperature and frequency were obtained. An improved core loss model was developed by introducing a flux-dependent exponent and dual temperature correction coefficients for hysteresis and eddy current losses. Experiments place the prediction error of the proposed model within 4% under cryogenic conditions. Compared with the classical Bertotti model, the proposed model effectively reduces high-frequency deviation caused by the temperature-dependent material properties and skin effect. The core loss of silicon steel increases by 15–30% at −100 °C compared with room temperature, which is mainly attributed to the decrease in resistivity and the strengthening of domain wall pinning. This paper provides an accurate loss prediction method and design references for HB motors applied in ultralow temperature working conditions.