Performance and manufacturability tradeoffs of different electrical machine designs

Fyhr, Pontus; Domingues, Gabriel; Reinap, Avo; Andersson, Mats; Alaküla, Mats

doi:10.1109/iemdc.2017.8002181

Cited by 12 publications

(4 citation statements)

References 23 publications

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“…The constant terms 𝐴 , 𝐴 are found through the boundary conditions ( 9) and (10), where h is the height of the considered layer. The current density in the k-th layer is finally obtained as in (11), whereas the associated losses are determined as in (12).…”

Section: Amentioning

confidence: 99%

“…The stress on insulation and conductive materials can be excessive when bending and twisting operations are not properly performed [9], [10]. Therefore, only a few configurations are feasible and can be manufactured [11], [12]. However, hairpin windings achieve a higher fill factor compared to the winding types mentioned above, thus obtaining higher current density and peak torque.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Hairpin Windings: Sensitivity Analysis and Guidelines to Reduce AC Losses

Preci

Gerada

Buticchi

et al. 2021

2021 IEEE Workshop on Electrical Machines Design, Control and Diagnosis (WEMDCD)

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Nowadays, electrification in the transportation sector is one of the most viable solutions to reduce CO2 emissions and meet fuel economy requirements. Being the electrical machine one of the most important players in this electrification trend, extensive research is currently being dedicated to the improvement of their efficiency and power density. In automotive applications, hairpin technologies are widely spreading due to their potential in reducing costs and life cycles in a mass production perspective, as well as in increasing the torque capabilities of machines. However, several challenges need to be addressed before the complete replacement of random windings with hairpins can take place. Of these challenges, the loss produced during high frequency operations is one of the most limiting. This paper aims at studying and investigating high frequency (AC) losses for different slot geometries and conductor cross sections, which in turn involve the analysis of different slots-per-pole-per-phase / layers-perslot combinations. In addition, the effects on the AC losses of reducing the slot fill factor are studied, either by removing the closest conductors to the slot opening or by reducing the hairpin legs' height. Analytical and numerical models are employed to investigate these concepts.

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Section: Amentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Hairpin Windings: Sensitivity Analysis and Guidelines to Reduce AC Losses

Preci

Gerada

Buticchi

et al. 2021

2021 IEEE Workshop on Electrical Machines Design, Control and Diagnosis (WEMDCD)

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“…The upfront cost of the electrical machine is determined by the cost of the materials used and the cost of the major manufacturing operations required to generate and assemble the physical parts, as described in [18,19]. This results in production volumes affecting the upfront cost of the machines, and thus lower costs may be obtained by sharing either complete 3D machine designs or even 2D geometries, due to economies of scale.…”

Section: Models 41 Electrical Machinesmentioning

confidence: 99%

Electric Drivetrain Optimization for a Commercial Fleet with Different Degrees of Electrical Machine Commonality

Domingues-Olavarría

Márquez-Fernández

et al. 2021

Energies

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At present, the prevalence of electric vehicles is increasing continuously. In particular, there are promising applications for commercial vehicles transfering from conventional to full electric, due to lower operating costs and stricter emission regulations. Thus, cost analysis from the fleet perspective becomes important. The study of cost competitiveness of different drivetrain designs is necessary to evaluate the fleet cost variance for different degrees of electrical machine commonality. This paper presents a methodology to find a preliminary powertrain design that minimizes the Total Cost of Ownership (TCO) for an entire fleet of electric commercial vehicles while fulfilling the performance requirements of each vehicle type. This methodology is based on scalable electric machine models, and particle swarm is used as the main optimization algorithm. The results show that the total cost penalty incurred when sharing the same electrical machine is small, therefore, there is a cost saving potential in higher degrees of electrical machine commonality.

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“…In particular, high efficiency, high power density and cost-effective manufacturing are required in the automotive industry [1][2][3]. One possible solution to meet these requirements is to optimize the copper filling factor of stator winding [4][5][6][7][8][9][10][11]. In particular, a high copper filling factor involves a more rational and efficient use of copper with economic benefits and improved energy savings.…”

Section: Introductionmentioning

confidence: 99%

Enhanced Flexible Algorithm for the Optimization of Slot Filling Factors in Electrical Machines

et al. 2020

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The continuous development in the field of industrial automation and electric mobility has led to the need for more efficient electrical machines with a high power density. The improvement of electrical machines’ slot filling factors is one of the measures to satisfy these requirements. In recent years, this topic has aroused greater interest in the industrial sector, since the evolution of the winding technological manufacturing processes allows an economically sustainable realization of ordered winding arrangements, rather than random ones. Moreover, the manufacture of electrical machines’ windings must be preceded by an accurate design phase in which it is possible to evaluate the maximum slot filling factor obtainable for a given wire shape and for its dimensions. For this purpose, this paper presents an algorithmic approach for the evaluation of maximum slot filling factors in electrical machines under an ideal geometric premise. In particular, this algorithm has a greater degree of flexibility with respect to the algorithm approaches found in the literature, since the study has been extended to round, rectangular and hexagonal wire sections. Furthermore, the slot filling factor calculation was carried out both for standard and non-standard slots. The algorithmic approach proposed can be considered as an additional useful tool for the fast design of electrical machine windings.

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Performance and manufacturability tradeoffs of different electrical machine designs

Cited by 12 publications

References 23 publications

Hairpin Windings: Sensitivity Analysis and Guidelines to Reduce AC Losses

Hairpin Windings: Sensitivity Analysis and Guidelines to Reduce AC Losses

Electric Drivetrain Optimization for a Commercial Fleet with Different Degrees of Electrical Machine Commonality

Enhanced Flexible Algorithm for the Optimization of Slot Filling Factors in Electrical Machines

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