Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

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

“…The conductors are initially distributed uniformly along the slot, assuming a single fullwidth column, as illustrated in Fig. 8a, which eases the manufacturing and electrical insulation process, [19], Section IV. The winding height, k wh , is a design variable normalised to the slot dimensions, in this case k wh = 0.8 or 80%.…”

“…The asymmetric conductor profiles must be merged in the end winding to form a complete concentrated winding as illustrated in Fig. 15 where the end-windings are semi-square rather than semi-circular, [19], to minimise the end-winding length, reduce losses and improve power-density.…”

“…1. Example of a shaped profile copper winding manufactured using Direct Metal Laser Sintering for a filter inductor application, [19].…”

Additive Manufacturing in Construction of Electrical Machines – A Review

“…Fig. 8a) presents a coil example designed for a filter inductor, where the individual coil turns have different profile [38]. This is to provide a low-loss winding design, where both dc and ac winding loss components are well balanced.…”

“…8. Examples of electrical windings/coils fabricated using AM, a) 'variable' profile copper coil for concentrated windings -University of Bristol [38], b) MM copper coil with ceramic insulation for SRM -Chemnitz University of Technology [40], c) liquid cooled induction coil for metal hardening process -GKN [41] early feasibility study used DMLS and a copper alloy to fabricate the coil. However, the electrical material properties of the AM coil were found to be significantly poorer than the equivalent copper commonly used in fabricating coils.…”