Design and Construction of a Foil Winding Permanent Magnet Machine

Rios, Michael; Venkataramanan, G.

doi:10.1109/ecce44975.2020.9235741

Cited by 4 publications

(7 citation statements)

References 8 publications

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“…This was already shown experimentally for a winding material sample in [24] and in a simulation study for an automotive solenoid actuator in [30]. Moreover, a foil winding allows a high fill factor and exhibits superior thermal properties as was reported for copper foil windings in [31], [32]. Hence, both the use of aluminium oxide insulated aluminium conductors and the foil winding topology promise to improve the specific torque.…”

Section: Introductionmentioning

confidence: 52%

“…Its inherent segmented structure allows winding of the coils prior to assembly into the stator [6]. This simplifies the foil winding process and allows to avoid open slots or a segmented stator which are required in the case of a radial flux machine [32], [40]. It also allows to eliminate the free space in a slot as found between two adjacent winding phases in foil wound radial flux machines [32].…”

Section: Requirement Motivationmentioning

confidence: 99%

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Anodized Aluminum Foil Winding Axial Flux Machine for Direct-Drive Robotic Applications

Vansompel

Crevecoeur

2023

IEEE Trans. Ind. Electron.

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There is a need for higher specific torque electric actuators in novel direct-drive robotic applications. Since the specific torque is inherently limited by material properties, designers have to look at novel materials to push the specific torque limit further. In this article, anodised aluminium foil is considered as an alternative to enamelled copper wire in a yokeless and segmented armature axial flux machine. This machine topology has a high specific torque and is particularly suited for an anodised aluminium foil winding. The DC resistance, thermal properties and eventually the specific torque of a prototype test case machine are compared for both winding materials. A 3D thermal finite element model is used to analyse the influence of the thermal interface between winding body and housing, and the influence of the cooling performance on the specific torque. To conclude, anodised aluminium foil winding offers a higher specific torque in direct-drive yokeless and segmented armature axial flux actuators where the winding body thermal resistance is dominant in the thermal path from heat source to heat sink. It is experimentally shown that for the prototype machine, the torque per kg active stator mass increases 13% through the use of anodised aluminium foil.

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Section: Introductionmentioning

confidence: 52%

Section: Requirement Motivationmentioning

confidence: 99%

Anodized Aluminum Foil Winding Axial Flux Machine for Direct-Drive Robotic Applications

Vansompel

Crevecoeur

2023

IEEE Trans. Ind. Electron.

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“…Preformed coils exhibit a high fill factor and a good thermal conductivity which are both attractive features when designing high torque density motors [39], [43]- [45]. A limitation of the use of preformed coils is the requirement to use either a segmented or separated teeth stator [46], or stator teeth with open slots [44], [47]. Additionally, existing electric motors with aluminium conductors typically use organic insulation [30], [33], [39], [42].…”

Section: Concentrated Winding Tooth Coilmentioning

confidence: 99%

“…A very high fill factor can be obtained in a YASA Axial Flux machine topology with anodised aluminium foil, since: • The YASA Axial Flux machine topology is particularly suited for a foil winding: the inherent segmented structure allows winding of the coils prior to assembly, this allows to use (semi-)closed slots. In radial flux machines, either open slot [47] or a segmented stator [46] are required if a foil winding is used. • Foil windings allow a high fill factor [47], [55].…”

Section: Concentrated Winding Tooth Coilmentioning

confidence: 99%

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Anodised Aluminium Foil Winding Axial Flux Machine for (Quasi-)Direct-Drive Robotic Applications: Preliminary Design and Manufacturing

Vansompel

Crevecoeur

Faes

et al. 2022

2022 12th International Electric Drives Production Conference (EDPC)

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Motivated by the need for higher torque density actuators in novel (quasi-)direct-drive robotics applications, a Yokeless and Segmented Armature Axial Flux Permanent Magnet Synchronous machine with anodised aluminium foil conductors instead of enamelled copper wire is considered in this work. Based on a requirements analysis of (quasi-)direct-drive actuators, a prototype axial flux machine is designed. Several design aspects are discussed keeping the application requirements in mind. It could be concluded that the combination of the machine topology and conductor material results in a high fill factor and excellent thermal properties, making it particularly promising for high torque density, low speed applications. A prototype was manufactured to demonstrate the feasibility of the design. The interconnection of aluminium foil to copper wire appeared to be challenging, two interconnection methods were tested and compared qualitatively.

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A Stabilized Circuit-Consistent Foil Conductor Model

Paakkunainen,

Bundschuh,

Garcia

et al. 2024

IEEE Access

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The magnetoquasistatic simulation of large power converters, in particular transformers, requires efficient models for their foils windings by means of homogenization techniques. Using the standard solid and stranded conductor models is not computationally feasible for a foil winding. In this article, the classical foil conductor model is derived and, for the first time, an inconsistency in terms of circuit theory is reported, which may lead to time-stepping instability. The inconsistency can be related to the differential-algebraic nature of the resulting system of equations. A new modified definition of the turnby-turn conductance matrix of the foil conductor model is shown to mitigate this problem. The different structure of the systems using the alternative turn-by-turn conductance matrix definitions is examined in detail. Numerical results are presented to demonstrate the instability of the original foil conductor model and to verify the effectiveness of the new proposed model.INDEX TERMS Foil conductor model, foil winding, differential algebraic equation, differential index, finite element method.

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Design and Construction of a Foil Winding Permanent Magnet Machine

Cited by 4 publications

References 8 publications

Anodized Aluminum Foil Winding Axial Flux Machine for Direct-Drive Robotic Applications

Anodized Aluminum Foil Winding Axial Flux Machine for Direct-Drive Robotic Applications

Anodised Aluminium Foil Winding Axial Flux Machine for (Quasi-)Direct-Drive Robotic Applications: Preliminary Design and Manufacturing

A Stabilized Circuit-Consistent Foil Conductor Model

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