Enhanced Electric Motors Using Multi-Functional 3D Printed Winding With Integrated Heat Sinks

Thabuis, Adrien; Ren, Xiaotao; Perriard, Yves

doi:10.1109/tec.2022.3221189

Cited by 8 publications

(5 citation statements)

References 30 publications

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“…13d. Coils with similar design features (thin turns and varying cross-sections) and of similar size have been successfully additively manufactured in metal [21]. This comforts further the feasibility of fabricating the new topologyoptimized winding in metal.…”

Section: Discussionmentioning

confidence: 67%

“…Finally, the presented framework is focused on magnetostatics but future work could investigate the integration of AC phenomena modeling to possibly generate topology-optimized windings for reduced AC losses. Additional physics could be incorporated to investigate new designs of multi-functional windings integrating thermal management as recently proposed in [21], [22].…”

Section: Discussionmentioning

confidence: 99%

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Topology Optimization of Motor Windings for Coreless Electrical Machines

Thabuis¹,

Ren²,

Perriard³

2023

Preprint

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<p>Coreless electric motors are gaining interest from the community as they have a larger power-to-weight ratio and higher efficiency. The absence of iron slots leaves the winding space unobstructed. It enables the geometry of the coils to be skewed to overlap with their neighbors. This work proposes a topology optimization method to design 3D-printed motor windings aiming for coreless electrical machines with higher motor-constant. A multi-coil interpolation scheme is proposed to design a single coil while accounting for packing with the other ones constituting the winding, without requiring assumptions on the shape or position of the coil. The standard 2-D topology optimization is extended to a 2.5-D one so as to provide more freedom on the achievable geometries while keeping a reasonable computational time. The developed computational design tool generated a novel motor winding with high performance.</p>

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Section: Discussionmentioning

confidence: 67%

Section: Discussionmentioning

confidence: 99%

Topology Optimization of Motor Windings for Coreless Electrical Machines

Thabuis¹,

Ren²,

Perriard³

2023

Preprint

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“…Conductor designs with varying thicknesses in the groove/slot are also achievable, which shift the thermal limits through reduced thermal resistances (higher fill factors). Simultaneously, hollow conductors can be designed more effectively both electrically (using the skin effect) and thermally (using a larger heat transfer surface area and direct connection between heat sink and source) [39]. Different literature-based winding cooling methods are shown in Figure 5.…”

Section: Windingsmentioning

confidence: 99%

“…By designing the typically unused part of the end winding in such a way that it protrudes further into the heat sink, a better coupling with the cooling system is achieved. The coupling can be implemented using 3D printed fins considering current technology levels and in future using lattices or topology-optimised structures [39].…”

Section: End Windingsmentioning

confidence: 99%

“…Cold Plates [32] Water [32] Cooling Jacket [6,12,[18][19][20][21][22][23][24]40,43] Water [19][20][21]23,24,39,43] Water Glycol [22] WEG [6,18] Oil [18,24,43] Hollow Shaft [6,24] Heat Pipe (Rotor Iron) [6] PCM (Rotor Iron) [6] Lamination Cooling (Rotor Iron) [6] Ventilation Cooling (Air Gap) [6] Flooded Cooling (EW) [6] Ventilation Cooling (Rotor Iron) [12] Flooded Cooling (EW) [43] Flooded Cooling [25][26][27] Oil [25][26][27] Ventilation Cooling [13][14][15][16] Air [13] Cooling Channel (Stator) [14] Heat Pipe [30,…”

Section: Statormentioning

confidence: 99%

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Comprehensive Review on Cooling of Permanent Magnet Synchronous Motors and Their Qualitative Assessment for Aerospace Applications

König,

Sharma,

Konda

et al. 2023

Energies

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The permanent magnet synchronous motor (PMSM) can be a suitable candidate for electrified propulsion in aviation. Despite the very high efficiency, heat dissipation during operation leads to performance limitations. Elevated temperatures in the electrical insulations and the magnets pose a potential safety risk that must be reduced by selective cooling. A comprehensive review is conducted to capture current research interests in cooling methods in PMSM. Cooling methods are described according to their heat transfer mechanism, grouped, and assigned to the components within the motor. Key findings of the literature reviewed are described in the context of PMSM cooling. Information on cooling media and potential combinations of cooling methods in components is gathered. Assessment parameters such as safety, weight, effectiveness, integrability, complexity and cost are defined to enable a subsequent qualitative analysis for six selected cooling methods. A point-weighted evaluation approach, according to VDI 2225, was applied to identify the most promising cooling approach for successful implementation in aviation.

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Temperature rise characteristics of permanent magnet synchronous motor considering boiling heat transfer

He,

Feng,

Zhang

et al. 2023

Electr Eng

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The temperature rise characteristics of PMSM (permanent magnet synchronous motor) during operation were studied under the condition of BHT (boiling heat transfer) in cooling water. The subcooling boiling heat transfer model, RPI (Rensselaer polytechnic institute), was used to calculate and improve the computational accuracy of simulation results. The experiments have shown that, when the motor was tested and simulated after preheating, the temperature rise characteristics were similar to test data because the boiling heat transfer phenomenon of the motor was taken into account, with an error of 1.7 %, which was more accurate than the error of 7.5 % without boiling. Therefore, from the results obtained from the experiments, the phenomenon of boiling heat transfer in cooling system has a significant effect on the temperature rise characteristic of the motor, which should be regarded as an important factor. Due to the influence of two-phase flow boiling heat transfer, the temperature rise of the motor in the plain areas is 4-5 ℃ higher than that in the high altitude areas, Consequently, if the motor is operated in high altitude areas, its temperature rise characteristic has better effect compared with plain area. Additionally, when BHT in cooling water is considered, the temperature of the motor drops as the rate of flow increases. In the meantime, the temperature difference between the minimum flow rate and the maximum flow rate is about 1 ℃, which means that the increase of rate of flow can enhance the boiling heat transfer effect. KeywordsPermanent magnet • Synchronous motor • Temperature field • Boiling heat transfer • Two-phase flow • Plateau environment

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Enhanced Electric Motors Using Multi-Functional 3D Printed Winding With Integrated Heat Sinks

Cited by 8 publications

References 30 publications

Topology Optimization of Motor Windings for Coreless Electrical Machines

Topology Optimization of Motor Windings for Coreless Electrical Machines

Comprehensive Review on Cooling of Permanent Magnet Synchronous Motors and Their Qualitative Assessment for Aerospace Applications

Temperature rise characteristics of permanent magnet synchronous motor considering boiling heat transfer

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