Additive Manufacturing and Testing of a Soft Magnetic Rotor for a Switched Reluctance Motor

Gargalis, Leonidas; Madonna, Vincenzo; Giangrande, Paolo; Rocca, Roberto; Hardy, Mark; Ashcroft, Ian; Galea, Michael; Hague, Richard

doi:10.1109/access.2020.3037190

Cited by 33 publications

(10 citation statements)

References 23 publications

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“…After printing, the components are postprocessed before assembling the full machine: printing supports cut, cleaning and polishing necessary surfaces and typically annealing the furnace for material homogenization and grain recrystallization. All the necessary individual components for assembling an EM (except the bearings) have successfully been printed with SLM; e.g., solid soft magnetic rotor [7] and stator designs [8], gapped electromagnetic coils [9,10], hairpin windings for traction motors [11] and partitioned (various geometries) soft magnetic cores [12]. Even some upgrades for the existing designs have been presented, such as printed heat guides for supplementary heat evacuation paths for machine areas particularly susceptible to high power loss [13,14].…”

Section: Introductionmentioning

confidence: 99%

AC Magnetic Loss Reduction of SLM Processed Fe-Si for Additive Manufacturing of Electrical Machines

et al. 2021

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Additively manufactured soft magnetic Fe-3.7%w.t.Si toroidal samples with solid and novel partitioned cross-sectional geometries are characterized through magnetic measurements. This study focuses on the effect of air gaps and annealing temperature on AC core losses at the 50 Hz frequency. In addition, DC electromagnetic material properties are presented, showing comparable results to conventional and other 3D-printed, high-grade, soft magnetic materials. The magnetization of 1.5 T was achieved at 1800 A/m, exhibiting a maximum relative permeability of 28,900 and hysteresis losses of 0.61 (1 T) and 1.7 (1.5 T) W/kg. A clear trend of total core loss reduction at 50 Hz was observed in relation to the segregation of the specimen cross-sectional topology. The lowest 50 Hz total core losses were measured for the toroidal specimen with four internal air gaps annealed at 1200 °C, exhibiting a total core loss of 1.2 (1 T) and 5.5 (1.5 T) W/kg. This is equal to an 860% total core loss reduction at 1 T and a 510% loss reduction at 1.5 T magnetization compared to solid bulk-printed material. Based on the findings, the advantages and disadvantages of printed air-gapped material internal structures are discussed in detail.

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Section: Introductionmentioning

confidence: 99%

AC Magnetic Loss Reduction of SLM Processed Fe-Si for Additive Manufacturing of Electrical Machines

et al. 2021

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“…Away from the scattered field of semiconductors-driven micro-/nano-fabrication technologies and techniques, falls the emerging scenarios of AM and 3D printing. These terms unroll a widely scattered ground of technical solutions and materials employment, like powder or polymer based, electrically conductive and insulating, which provide developers with a remarkably extended set of degrees of freedom [221]- [225].…”

Section: ) Additive Manufacturingmentioning

confidence: 99%

Review and Perspectives of Micro/Nano Technologies as Key-Enablers of 6G

Iannacci

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2022

IEEE Access

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“…The readiness of metal AM for manufacturing of soft magnetic rotor for SRMs is demonstrated in [96] by comparing an additively manufactured rotor (Fe-5.0% w.t. Si) with that of a conventional laminated, non-oriented silicon steel rotor.…”

Section: Switched Reluctance Machines (Srm)mentioning

confidence: 99%

A Review on Additive Manufacturing Possibilities for Electrical Machines

et al. 2021

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This paper presents current research trends and prospects of utilizing additive manufacturing (AM) techniques to manufacture electrical machines. Modern-day machine applications require extraordinary performance parameters such as high power-density, integrated functionalities, improved thermal, mechanical & electromagnetic properties. AM offers a higher degree of design flexibility to achieve these performance parameters, which is impossible to realize through conventional manufacturing techniques. AM has a lot to offer in every aspect of machine fabrication, such that from size/weight reduction to the realization of complex geometric designs. However, some practical limitations of existing AM techniques restrict their utilization in large scale production industry. The introduction of three-dimensional asymmetry in machine design is an aspect that can be exploited most with the prevalent level of research in AM. In order to take one step further towards the enablement of large-scale production of AM-built electrical machines, this paper also discusses some machine types which can best utilize existing developments in the field of AM.

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Additive Manufacturing and Testing of a Soft Magnetic Rotor for a Switched Reluctance Motor

Cited by 33 publications

References 23 publications

AC Magnetic Loss Reduction of SLM Processed Fe-Si for Additive Manufacturing of Electrical Machines

AC Magnetic Loss Reduction of SLM Processed Fe-Si for Additive Manufacturing of Electrical Machines

Review and Perspectives of Micro/Nano Technologies as Key-Enablers of 6G

A Review on Additive Manufacturing Possibilities for Electrical Machines

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