This work addresses an alternative approach to electrical insulation of the winding by using ceramic materials such as aluminum oxide, which in addition to good insulation strength also have relatively high thermal conductivity. This can be applied to copper by thermal spray processes, which also allow the use of profiled conductors. In the present work, the determined values for insulation strength and insulation resistance are presented depending on different layer thicknesses and manufacturing parameters, as well as the influence of posttreatments. For this purpose, a special measurement setup is used which records the corresponding data with a large number of contact points and thus takes into account weak points caused by manufacturing variations.
This paper proposes a winding head support design with a thin film surface metallization for edge rounding to avoid high electric field strengths and thereby winding insulation failures. Base materials of the winding head support are high performance plastics like polyetheretherketone (PEEK) or high temperature resins with good heat resistance capabilities and a low electrical conductivity to minimize eddy current losses. The metallization layer of the support is manufactured in thin film technology for the same purpose. The main focus of the work lies on investigating the improvement of dielectric strength of the insulation system. Electrostatic FEM-calculations are being conducted to estimate the distribution of the electric field strength in the area of the stator edges. Within this work eddy current losses inside the metallization layer are also considered. Although the conductive film of the support is with a thickness fewer than 100 microns [1] very thin, heating, especially in the area of the winding head, may cause structural and lifetime issues. On this account, FEM-simulations regarding eddy current losses and thermal distributions are being progressed.
With additive manufacturing, copper windings and even whole coils can be manufactured in a new, totally different approach than with common manufacturing methods. The coil design is no longer bound to the limitations given by the wires bend radius or the geometric capabilities of winding machines. Therefore, additive manufacturing offers new degrees of freedom for the design of copper windings and thus the design of electric machines. However, the electric properties of printed copper material must be known exactly and should be comparable to solid copper wire. This paper examines the impedance characteristics of additive manufactured copper conductors of two different copper alloys with varying print density and two different cross-section areas. Additionally, copper conductors consisting of multiple twisted subprofiles are examined, emulating stranded conductors. The measurement results are set in relation to an extruded copper profile to ensure comparability. The influence of the skin effect is examined by performing the investigations over a wide frequency range. Furthermore, the effect of different print densities on the effective resistance can be shown clearly. Besides the measurement results, an evaluation of the possible field of application and the limitations is given.
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