Characterization of an Axial Flux Machine With an Additively Manufactured Stator

Nishanth, FNU; Goodall, Alexander D.; Todd, Iain; Severson, Eric L.

doi:10.1109/tec.2023.3285539

Cited by 15 publications

(6 citation statements)

References 46 publications

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“…In addition to rotors, the motor stator can also be fabricated using additive manufacturing technology to achieve lightweighting. The study in [72] introduces a novel 3D-printed laminated stator to address the issue of 3D magnetic flux paths in axial flux machines during the manufacturing process of radial laminated stator cores, as depicted in Figure 12c. The proposed stator is fabricated using silicon steel powder and incorporates a novel Hilbert lamination technique to emulate geometric structures, thereby mitigating eddy current losses.…”

Section: Coresmentioning

confidence: 99%

State-of-the-Art Lightweight Implementation Methods in Electrical Machines

Zhao,

Li,

Zhang

et al. 2024

Machines

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The demand for high-power density motors has been increasing due to their remarkable output capability and compact construction. To achieve a significant improvement in motor power density, lightweight design methods have been recognized as an effective enabler. Therefore, extensive investigations have been conducted to reduce motor mass and achieve lightweight configurations through the exploration of lightweight materials, structures and manufacturing techniques. This article provides a comprehensive review and summary of state-of-the-art lightweight implementation methods for electrical machines, including the utilization of lightweight materials, structural lightweight design, and incorporation of advanced manufacturing technologies, such as additive manufacturing techniques. The advantages and limitations of each approach are also discussed in this paper. Furthermore, some comments and forecasts on potential future methodologies for motor lightweighting are also provided.

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Section: Coresmentioning

confidence: 99%

State-of-the-Art Lightweight Implementation Methods in Electrical Machines

Zhao,

Li,

Zhang

et al. 2024

Machines

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“…Although there are a large number of SFCs, only two SFCs, the Hilbert and Peano curves, were chosen for this investigation in which the magnetic performance will be compared against sheets. These two SFCs, and especially the Hilbert curve, are also the ones used in studies such as [7][8][9]13]. The main reasons for excluding other SFCs are either that they do not fill a unit square which can then be replicated and adjusted to fit any area, they are too similar to another SFC, such as the Moore curve to the Hilbert curve, or they cannot be manufactured with a finite width without simplifying them beyond recognition, for example the Lebesgue curve.…”

Section: Space-filling Curvesmentioning

confidence: 99%

“…Naturally, this also changes the equation for the fill factor of the AM-built sheets, as the connection between the number of sheets N and the order o changes according to (9). Thus, the fill factor of AM-built sheets may be calculated as…”

Section: Fill Factor Comparisonmentioning

confidence: 99%

“…The first application of this kind was the core of a transformer by Plotkowski et al in [7]. A more recent set of publications by Goodall et al presented an axial flux machine with an additively manufactured stator [8,9]. Both of these research groups already addressed one of the main issues with AM-built soft-magnetic components, namely eddy currents and their respective losses.…”

Section: Introductionmentioning

confidence: 99%

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Magnetic Performance of Eddy Current Suppressing Structures in Additive Manufacturing

Klein,

May,

Nienhaus

2024

Actuators

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Additively manufactured soft-magnetic components are inherently bulky leading to significant eddy current losses when applied to electrical machines. Prior works have addressed this issue by implementing structures based on the Hilbert space-filling curve which include eddy current suppressing gaps, thereby reducing the fill factor of the soft-magnetic component. The present research aims at investigating a number of space-filling curves in addition to sheets in order to find the optimal eddy current suppressing structure from an electromagnetic point of view. By means of both analysis and finite-element simulation, it was shown that sheets are superior at minimizing eddy current losses while space-filling curves excel at maximizing the fill factor.

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“…To enable their use in alternating current (AC) EMs, soft-magnetic material is normally rolled into thin sheets to reduce parasitic eddy current losses. Similarly with AM, processing large bulk sections should be avoided, and therefore some cross-sectional geometries have been explored which achieve this such as lamination style slots [4], Hilbert space filling curve based cross-sections [5,[12][13][14], and others [15][16][17]. In a recent work [18], the current author has shown that good magnetic performance can be achieved by utilising processing parameters to induce stochastic cracking of Fe-6.5 wt%Si, reducing eddy current losses and demonstrating improved performance when compared to designed geometries such as Hilbert space filling.…”

Section: Introductionmentioning

confidence: 99%