Novel Optimized Shape and Topology for Slotless Windings in BLDC Machines

Burnand, Guillaume; Thabuis, Adrien; Araujo, Douglas Martins; Perriard, Yves

doi:10.1109/tia.2019.2956717

Cited by 19 publications

(5 citation statements)

References 27 publications

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“…Also, with no slotting harmonics, the rotor experiences less eddy current losses as well as zero cogging torque. In [74], a six-coil winding was manufactured for PM brushless DC machine (BLDC) using a 1-mm sheet of copper as shown in Figure 20a. Although the initial prototype is manufactured using laser cutting, the authors declared that the optimized shape of these windings will only be possible to produce using AM due to the high degree of freedom.…”

Section: Slotless Pcb Windings and Modular Electrical Machinesmentioning

confidence: 99%

Electrical Machines Winding Technology: Latest Advancements for Transportation Electrification

2022

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The ever-increasing demand for higher-power dense electrical machines has resulted in different electrical, mechanical, and thermal stresses, which can eventually cause machine failure. For this reason, the management of stresses and losses must be thoughtfully investigated to have a highly reliable electrical machine. The literature agrees that winding losses are the dominant loss mechanism in many electrical machines. However, statements vary on how to mitigate these losses along with the aforementioned stresses. To avoid winding failure, a study of the various winding topologies would allow for a better consideration of the challenges and limitations in the performance of different electrical machines. To this aim, this paper introduces a comprehensive review for different winding topologies. Many reported cases in the literature are summarized and compared. Moreover, the utilization of additive manufacturing (AM) in the production of the machine windings is presented, showing a high level of maturity of this emerging technology. Finally, different challenges facing the design of machine windings are introduced including the AC high frequency losses, thermal management, mechanical and acoustic problems, insulation aging, automated production, and winding manufacturability.

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Section: Slotless Pcb Windings and Modular Electrical Machinesmentioning

confidence: 99%

Electrical Machines Winding Technology: Latest Advancements for Transportation Electrification

2022

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“…As result, the cogging torque is theoretically zero. There are certain advantages of slotless motors over slot motors [22][23][24]:…”

Section: Proposed Slotless Motormentioning

confidence: 99%

“…If the winding angle is fixed, and the number of coil turns is increased, the vector diagram will be similar to the shape of an arc. Therefore, the winding factor can be expressed briefly by Equation (22). Consequently, as shown in Figure 11, there is a phase difference between the flux linkages in the TSLM, unlike in the CM in which the winding factor is constant regardless of the number of turns.…”

Section: Number Of Coil Turns Variationmentioning

confidence: 99%

A Study on a Slotless Brushless DC Motor with Toroidal Winding

et al. 2021

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In this study we developed a brushless DC (BLDC) slotless motor with toroidal winding. The proposed toroidal winding is a method of winding a coil around a ring-type stator yoke in the circumferential direction. As there is no need for a slot or tooth structure, it can be designed with a slotless motor structure that is advantageous for vibration and noise. The basic principle of operation and motor characteristics of a slotless motor with toroidal winding were explained using an analytical method and finite element analysis (FEA). Further, the air gap flux density, winding factor, and back electromotive force (EMF) for changes in the winding angle and number of coil turns were calculated using the analytical method and compared with the FEA results. Finally, the resistance, back EMF, cogging torque, and performance of the prototype were measured and compared with the FEA results. The results show that the air gap flux density and winding factor were approximately the same with an error of <2%, while the back EMF had an error of ~10% from the analysis result. Thus, the proposed slotless motor provides a basic design for conveniently manufacturing brushless DC (BLDC) slotless motors with toroidal windings.

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“…Their performance can be further improved by using more advanced manufacturing methods in order to have the width of coil tracks evolve along their path. This has been implemented with Printed Circuit Board (PCB) [2], or laser-cutting [3]. Additive manufacturing technologies have been recently demonstrated as great alternatives for fabricating novel electromagnetic devices [4], [5].…”

Section: Introductionmentioning

confidence: 99%

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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Novel Optimized Shape and Topology for Slotless Windings in BLDC Machines

Cited by 19 publications

References 27 publications

Electrical Machines Winding Technology: Latest Advancements for Transportation Electrification

Electrical Machines Winding Technology: Latest Advancements for Transportation Electrification

A Study on a Slotless Brushless DC Motor with Toroidal Winding

Topology Optimization of Motor Windings for Coreless Electrical Machines

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