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A directly enhanced cooled winding in an electrical traction machine has the potential to extend the operation range, which is in particular attractive for a traction application when operating near peak power for extended periods of time. This paper presents the heat transfer analysis of a modular machine segment with a laminated winding. The laminated winding has a great potential when it comes to production of the winding and the thermal management of the excessive power losses in the winding. The prototype is built and assessed based on experimental measurements and finite element analysis. The results indicate some practical challenges of integrating the combined heat exchanger and winding and controlling the coolant flow through the machine construction. The prototype machine shows a limited enhanced cooling capability mostly due to flow leakage while the results from the simulation models indicate the great potential of direct cooled windings.

A design model development for electrical machines with laminated windings is presented. The focus is to provide manufacturable solutions for commercial vehicle traction applications. The machine is designed with axially distributed single-layer wave-winding segments with a core that builds a modular three-phase machine. The phase segment, whose central part is a wave-winding made as a laminated winding, form a semi-claw pole structure. A conventional permanent magnet synchronous machine is used as a reference. The result indicates that comparable torque and power can be reached with the suggested alternative design.

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