Additive Manufacturing of a lightweight rotor for a permanent magnet synchronous machine

Lammers, Stefan; Adam, Guido; Schmid, Hans‐Joachim; Mrozek, Rafael; Oberacker, R.; Hoffmann, Michael J.; Quattrone, Francesco; Ponick, Bernd

doi:10.1109/edpc.2016.7851312

Cited by 49 publications

(25 citation statements)

References 9 publications

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“…3. Lightweight rotor/shaft assemblies, a) inner-rotor/shaft with lattice structure for PM motor application (CAD and complete rotor assembly) -Paderborn University, Karlsruhe Institute for Technology and Leibniz University Hannover [12], b) outer-rotor/shaft for open-frame PM motor -Newcastle University fabricated using AM. Fig.…”

Section: A Mechanical Assembly and Thermal Managementmentioning

confidence: 99%

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Additive Manufacturing in Construction of Electrical Machines – A Review

Wróbel

Mecrow

2019

2019 IEEE Workshop on Electrical Machines Design, Control and Diagnosis (WEMDCD)

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Section: A Mechanical Assembly and Thermal Managementmentioning

confidence: 99%

“…Fig. 3a) presents a lightweight innerrotor/shaft assembly: CAD and practical implementation, together with permanent magnet (PM) array and damping coils [12]. The rotor/shaft was manufactured using tool steel (H13).…”

Section: A Mechanical Assembly and Thermal Managementmentioning

confidence: 99%

Additive Manufacturing in Construction of Electrical Machines – A Review

Wróbel

Mecrow

2019

2019 IEEE Workshop on Electrical Machines Design, Control and Diagnosis (WEMDCD)

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“…Furthermore, implementing lightweight lattice structures beyond the flux paths to increase the machine's power density and dynamics is possible. The latter improvement was successfully implemented in an additively manufactured rotor of a permanent magnet synchronous machine [48]. Figure 25a, shows another additively manufactured rotor and shaft, which was introduced from Lammers et al [48], and was made of a soft magnetic ferro-silicon alloy, assembled and implemented into a conventionally manufactured stator, and successfully tested under usual operating conditions.…”

Section: Metal Additive Manufacturingmentioning

confidence: 99%

“…The latter improvement was successfully implemented in an additively manufactured rotor of a permanent magnet synchronous machine [48]. Figure 25a, shows another additively manufactured rotor and shaft, which was introduced from Lammers et al [48], and was made of a soft magnetic ferro-silicon alloy, assembled and implemented into a conventionally manufactured stator, and successfully tested under usual operating conditions. Finally, handling of common three-dimensional machine features like skewing or machine end-effects becomes possible during the production process using metal additive manufacturing techniques [49].…”

Section: Metal Additive Manufacturingmentioning

confidence: 99%

Challenges and Opportunities of Very Light High-Performance Electric Drives for Aviation

et al. 2018

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Abstract:The demand for alternative fueling methods to reduce the need for fossil fuels is not limited to the electrification of ground vehicles. More-electric and all-electric aircraft pose challenges, with extensive requirements in terms of power density, efficiency, safety, and environmental sustainability. This paper focuses on electrical machines and their components, especially for high-power applications like the main propulsion. The electrical machine is evaluated from different aspects, followed by a closer look at the components and materials to determine the suitability of the current standard materials and advanced technologies. Furthermore, the mechanical and thermal aspects are reviewed, including new and innovative concepts for the cooling of windings and for the use of additive manufacturing. Aircraft have special demands regarding weight and installation space. Following recent developments and looking ahead to the future, the need and the possibilities for light and efficient electrical machines are addressed. All of the approaches and developments presented lead to a better understanding of the challenges to be expected and highlight the upcoming opportunities in electrical machine design for the use of electric motors and generators in future aircraft. Several prototypes of electrical machines for smaller aircraft already exist, such as the electric drive of the Siemens powered Extra 330LE. The focus of this paper is to provide an overview of current technical possibilities and technical interrelations of high performance electric drives for aviation. A 1 MW drive is exemplified to present the possibilities for future drives for airplanes carrying a larger number of passengers. All presented techniques can also be applied to other drive power classes.

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“…smart material utilization) [3]. AM technologies have only recently been utilised in the development of parts for electrical machines (EMs) [4][5][6], which can be attributed to the lack of AM processable materials with the necessary properties for such applications [7]. Among AM build strategies, the laser powder bed fusion (LPBF) method is the most suitable for producing highly detailed metallic parts [3] and it has been extensively applied in manufacturing structural materials.…”

Section: Introductionmentioning

confidence: 99%