Metal additive manufacturing enables production of copper and aluminium parts exhibiting unmatched geometric freedom, giving rise to new possibilities in the winding design of electrical machines and wound passive components. Early adopters of additive manufacturing are primarily concerned with improving power-density or efficiency by increasing slot fill-factor, optimizing end-winding topology or incorporating cooling channels into the conductors. In this article, a method of minimizing the elevated ac loss present in open slot electrical machine topologies is presented, in which individual conductor profiles are shaped according to their magnetic environment. Such shaped profile windings are shown to exhibit operating mode dependent loss behavior giving them potential for efficiency improvement in applications with a dominant operating mode such as electric vehicle traction, aerospace propulsion fans, and generators. For the first time, the conductor shaping method and associated benefits are demonstrated by the retrospective design, additive manufacture, and experimental test of a three-phase set of shaped profile windings for a concentrated wound, open slot, permanent magnet electrical machine.

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Additive Manufacturing of Shaped Profile Windings for Minimal AC Loss in Electrical Machines

Concentrated wound, open slot, permanent magnet electrical machines are an attractive topology for automotive and aerospace applications as they exhibit compact end-windings, resulting in high power-density, facilitate fault tolerant operation through, physical, thermal, magnetic and electrical isolation of phase windings, and the open slot structure eases manufacture. However, a significant disadvantage of this topology is the interaction between the armature reaction field and winding conductors leading to elevated AC losses. A common mitigation technique is to reduce the height of the winding in the slot to minimise this interaction, however, the conductor cross-sectional area is consequently reduced which compromises low-speed performance. This paper investigates the use of additive manufacturing to produce shaped profile windings which exhibit minimal AC loss whilst maximising the utilisation of the slot area, thereby improving low-speed performance while maintaining high-speed performance.

/pdf/additive-manufacturing-of-shaped-profile-windings-for-337v2jj5nw.pdf

Current carrying windings are a fundamental feature of electrical machines, inductors and transformers, and are typically the dominant source of losses, arising from DC Joule and AC skin and proximity effect loss mechanisms. The minimum physical volume occupied by a winding is ultimately limited by the ability to dissipate these internally generated losses, manifesting as heat, and in turn by the temperature rating of the electrical insulation system or Permanent Magnets (PMs), if present. Hence, a combination of loss reduction and improved heat extraction can yield system level performance improvement. This paper investigates the use of metal additive manufacturing to form electrical windings in place of conventional methods affording unparalleled freedom in the conductor geometry and the potential to incorporate complementary features such as endwinding cooling. Two conductor shaping algorithms capable of exploiting such geometric freedom are developed and applied to the design of an 80 µH, 200 A RMS , 400 Hz E-core line filter inductor. The resulting performance of each winding and design for additive manufacture considerations are discussed.

Design of High Performance Shaped Profile Windings for Additive Manufacture

This study reduced winding eddy current losses by optimizing the shapes of air gaps in inductors. Finite element method software was used for inductor simulations. A special script was made to implement an optimization algorithm to reach a minimum of an objective function. The objective function consisted of two weighted parts. The first part was the total losses of an inductor, and the second was the average flux density of a central leg's core around a gap. A relationship between these parts was used to determine how deeply the inductor could be saturated to minimize the total loss of the inductor. Simulation results and experimental data were noted, and the total loss and temperature reductions of the inductor were demonstrated.

An Air-Gap Shape Optimization for Fringing Field Eddy Current Loss Reductions in Power Magnetics

Air gap reluctance and the effective cross-sectional area strongly depend on size, shape and position of the air gap. This paper introduces a novel approach to quickly predict the effective cross-sectional area as a function of these influencing factors. Special attention is paid to the reluctance of large air gaps.

The reluctance of large air gaps in ferrite cores

AC-loss analysis in gapped-core inductor windings can be performed using finite element analysis (FEM) software with good results. The process however becomes very time consuming especially if the winding is shaped in the vicinity of the air gap. The lack of closed form solutions for optimization of shaped windings emphasizes the need for alternative techniques offering solutions quicker than running FEM-simulations for all the possible conductor arrangements. A novel technique for optimisation of shaped planar inductor windings is proposed in this work but should be applicable to larger low frequency power system components with minor adjustments. The flux density as a function of the distance from the air gap is estimated using a very simple model and the subsequent losses calculated using a first-principle method with good results. The simulated results are verified experimentally.

Novel Technique for Shaped Planar Inductor Winding Optimization in Gapped Core Applications

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Novel Technique for Shaped Planar Inductor Winding Optimization in Gapped Core Applications