Electrical Machines Winding Technology: Latest Advancements for Transportation Electrification

Selema, Ahmed; Ibrahim, Mohamed N.; Sergeant, Peter

doi:10.3390/machines10070563

Cited by 43 publications

(25 citation statements)

References 89 publications

(90 reference statements)

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“…Recently, AM has been used to fabricate bridges for the construction industry [ 197 ]. Moreover, the components of electrical machines, such as shape profile windings, multi material coils, heating coils and hollow conductors were made by AM [ 198 ]. In automotive applications, AM is utilized for the fabrication of frames/chassis, suspensions, transfer cases, cross car beams, doors, and engine cradles [ 199 ].…”

Section: Critical Analysis and Challenges In Intelligent Manufacturingmentioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

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Section: Critical Analysis and Challenges In Intelligent Manufacturingmentioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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“…The amount of welding points n welding,hp is calculated with the number of hairpins n hairpins and the number of phases n Phases to: Thus, the cycle time is: 3.2.4.3 Formed-Litz wire Formed-Litz wire is a form-pressed round wire, which increases the copper density in the wire and consequently the fill factor to between 60 and 70%. These wires are often produced with thermal bonding wire, meaning that through heating the wire gets stiff, comparably to a hairpin bar [40]. It is therefore assumed in this model, that windings using Formed-Litz wire are produced with the same production processes than hairpin windings.…”

Section: Hairpinsmentioning

confidence: 99%

Production cost modeling for permanent magnet synchronous machines for electric vehicles

Hemsen

Nowak

Eckstein

2023

Automot. Engine Technol.

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A cost model for the estimation of production costs of permanent magnet synchronous machines (PMSM) is presented, which allows to alter design choices such as wire technology, winding layout, cooling system, materials and more. With the goal to make results reproducible by others, the methods are explained in detail and used data and assumptions are given. The developed model helps to understand the interaction between the design of PMSM, manufacturing methods and the resulting costs. With it, different PMSM technologies and materials can be evaluated regarding its influence on the production costs, which is a perquisite to find the best compromise between performance and costs. Production volume is shown to be the most decisive factor for the resulting production costs. Between minimum and maximum assumed volumes, an average cost per unit reduction of 67% could be observed. Furthermore, the results imply that the winding production is responsible for the greatest part of the overall costs, followed by the rotor assembly (including rare earth magnets). When using the model to compare different wire types, it can be stated that up to a production volume of roughly 150,000 units/year, hairpin wires are more expensive to produce. Above this volume, hairpin windings will get cheaper than round wire windings due to its higher grade of automation of the production process. Through the conducted investigations and the presented results, it is demonstrated that the cost model can serve to evaluate technologies with regards to costs in the early development stage. This way a more holistic assessment of technologies for PMSM is possible, helping to find the ideal compromises between costs and performance and to increase the attractiveness of sustainable mobility.

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“…These wires are often produced with thermal bonding wire, meaning that through heating the wire gets stiff, comparably to a hairpin bar. (Selema et al 2022) It is therefore assumed in this model, that windings using Formed-Litz wire are produced with the same production processes than hairpin windings. This has been described in section 3.2.4.2 before.…”

Section: Formed-litz Wirementioning

confidence: 99%

A Flexible Production Cost Model for Permanent Magnet Synchronous Machines for Electric Vehicles

Hemsen

Nowak

Eckstein

2023

Preprint

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A cost model for the estimation of production costs of permanent magnet synchronous machines (PMSM) is presented, which allows to alter design choices such as wire technology, winding layout, cooling system, materials and more. With the goal to make results reproducible by others, the methods are explained in detail and used data and assumptions are given. The developed model helps to understand the interaction between the design of PMSMs, manufacturing methods and the resulting costs. With it, different PMSM technologies and materials can be evaluated regarding its influence on the production costs, which is a perquisite to find the best compromise between performance and costs. Production volume is shown to be the most decisive factor for the resulting production costs. Between minimum and maximum assumed volumes, an average cost per unit reduction of 67% could be observed. Furthermore, it is shown that the winding production is responsible for the greatest part of the overall costs, followed by the rotor assembly (including rare earth magnets). When using the model to compare different wire types, it can be stated that up to a production volume of roughly 150,000 units/year, hairpin wires are more expensive to produce. Above this volume, hairpin windings will get cheaper than round wire windings due to its higher grade of automation of the production process. Through the conducted investigations and the presented results, it is demonstrated that the cost model can serve to evaluate technologies with regards to costs in the early development stage. This way a more holistic assessment of technologies for PMSM is possible, helping to find the ideal compromises between costs and performance and to increase the attractiveness of sustainable mobility.

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Electrical Machines Winding Technology: Latest Advancements for Transportation Electrification

Cited by 43 publications

References 89 publications

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

Production cost modeling for permanent magnet synchronous machines for electric vehicles

A Flexible Production Cost Model for Permanent Magnet Synchronous Machines for Electric Vehicles

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