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Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this paper describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to a 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this paper are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior. INDEX TERMS Multi 3D additive manufacturing, hybrid additive manufacturing, wire embedding, hipot testing, heat treatment, heat dissipation.
Fabrication of parts exhibiting multi-functionality has recently been complemented by hybrid polymer extrusion additive manufacturing in combination with wire embedding technology. While much mechanical characterization has been performed on parts produced with fused deposition modeling, limited characterization has been performed when combined electrical and thermal loads are applied to 3D printed multi-material parts. As such, this paper describes the design, fabrication, and testing of 3D printed thermoplastic coupons containing embedded copper wires that carried current. An automated fabrication process was used employing a hybrid additive manufacturing machine that dispensed polycarbonate thermoplastic and embedded bare copper wires. Testing included AC and DC hipot testing as well as thermal testing on as-fabricated and heat treated coupons to determine the effect of porosity in the substrate. The heat-treated parts contained reduced amounts of porosity, as corroborated through scanning electron microscopy, which led to a 50 % increased breakdown strength and 30 to 40 % increased heat dissipation capabilities. The results of this paper are describing a set of design protocol that can be used as a guideline for 3D printed embedded electronics to predict the electrical and thermal behavior. INDEX TERMS Multi 3D additive manufacturing, hybrid additive manufacturing, wire embedding, hipot testing, heat treatment, heat dissipation.
Line-start synchronous reluctance motors (LSSynRM) combine the high efficiency of synchronous reluctance Motors (SynRM) with the self-starting capability of induction motors. They operate at synchronous speed in steady state and produce minor rotor losses, thereby providing higher efficiency than induction motors and a higher power density. Despite the simple structure of LSSynRM, its analysis, modeling, and optimal design pose several challenges. In particular, design trends aiming at higher starting capabilities and improved steady-state operation pose significant hurdles. In this study, three synchronous reluctance motors with line-start capability are designed to achieve maximum efficiency at steady-state operation with the optimum amount of copper for starting. The induction cage is constructed using rectangular bars installed in flux barriers to minimize the changes in performance under the steady-state condition. Although different rotor shapes offer similar steady-state performance, they achieve synchronism using different cage bar widths. The rotor with the lowest copper weight is selected for manufacturing. The prototype is constructed based on the optimal design. The experimental results are in good agreement with the simulation results. . INDEX TERMSInduction Cage, Line-Start Synchronous Reluctance Motor, Rectangular Bar, Synchronization NOMENCLATURE πΏ π π d-axis inductance πΏ π π q-axis inductance π Pole pairs πΏ π Current angle relative to q-axis πΌ Stator current π π d-axis reactance π π q-axis reactance π π Stator phase resistance πΏ π£ Voltage angle relative to q-axis π Voltage π Slip π Synchronous angular speed πΎ Phase of the pulsating torque components π π Stator Voltage π ππ Rotor d-axis resistance π ππRotor q-axis resistance πΏ ππ d-axis magnetization inductance πΏ ππ q-axis magnetization inductance π πRotor angular speed π ππ ith flux barrier width along q-axis π ππ ith flux barrier width along d-axis βπΌ π ith flux barrier angle along q-axis π π Number of rotor virtual slots per pole pairs π π Number of stator slots per pole pairs πΎ πππ π Insulation ratio along q-axis I.
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