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Development of novel semi-stranded windings for high speed electrical machines enabled by additive manufacturing

Ahmed Selema (UGent) , Mohamed Ibrahim (UGent) and Peter Sergeant (UGent)
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Abstract
Recent advances in electrical machines and energy storage technologies make electric vehicles (EVs) feasible replacements to conventional internal combustion engines. One of the main challenges of high speed electrical machines is providing maximum output power with minimum energy losses, weight, and volume. At high frequency operation, the conductors of AC electrical machines can suffer from skin and proximity effects. This results in high AC losses in the machine windings and can eventually lead to machine failure. In this paper, a novel design for a semi-stranded coil is proposed to limit these undesirable effects. Enabled by additive manufacturing (AM) technology, this sophisticated design is 3D printed using ultralight aluminum alloy. Finally, the AC performance of this coil is measured and compared with conventional single-strand copper coil at different frequency levels. It is found that the proposed design can effectively limit the eddy current losses in the high frequency domain.
Keywords
Electrical Machines, 3D Printing, Additive Manufacturing, Windings, electric machines, 3D printed windings, additive manufacturing eddy, currents, CONDUCTIVITY, LOSSES, INKJET

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MLA
Selema, Ahmed, et al. “Development of Novel Semi-Stranded Windings for High Speed Electrical Machines Enabled by Additive Manufacturing.” APPLIED SCIENCES-BASEL, vol. 13, no. 3, 2023, doi:10.3390/app13031653.
APA
Selema, A., Ibrahim, M., & Sergeant, P. (2023). Development of novel semi-stranded windings for high speed electrical machines enabled by additive manufacturing. APPLIED SCIENCES-BASEL, 13(3). https://doi.org/10.3390/app13031653
Chicago author-date
Selema, Ahmed, Mohamed Ibrahim, and Peter Sergeant. 2023. “Development of Novel Semi-Stranded Windings for High Speed Electrical Machines Enabled by Additive Manufacturing.” APPLIED SCIENCES-BASEL 13 (3). https://doi.org/10.3390/app13031653.
Chicago author-date (all authors)
Selema, Ahmed, Mohamed Ibrahim, and Peter Sergeant. 2023. “Development of Novel Semi-Stranded Windings for High Speed Electrical Machines Enabled by Additive Manufacturing.” APPLIED SCIENCES-BASEL 13 (3). doi:10.3390/app13031653.
Vancouver
1.
Selema A, Ibrahim M, Sergeant P. Development of novel semi-stranded windings for high speed electrical machines enabled by additive manufacturing. APPLIED SCIENCES-BASEL. 2023;13(3).
IEEE
[1]
A. Selema, M. Ibrahim, and P. Sergeant, “Development of novel semi-stranded windings for high speed electrical machines enabled by additive manufacturing,” APPLIED SCIENCES-BASEL, vol. 13, no. 3, 2023.
@article{01GR10XW01V3T6XQ7JYVZJFAE3,
  abstract     = {{Recent advances in electrical machines and energy storage technologies make electric vehicles (EVs) feasible replacements to conventional internal combustion engines. One of the main challenges of high speed electrical machines is providing maximum output power with minimum energy losses, weight, and volume. At high frequency operation, the conductors of AC electrical machines can suffer from skin and proximity effects. This results in high AC losses in the machine windings and can eventually lead to machine failure. In this paper, a novel design for a semi-stranded coil is proposed to limit these undesirable effects. Enabled by additive manufacturing (AM) technology, this sophisticated design is 3D printed using ultralight aluminum alloy. Finally, the AC performance of this coil is measured and compared with conventional single-strand copper coil at different frequency levels. It is found that the proposed design can effectively limit the eddy current losses in the high frequency domain.}},
  articleno    = {{1653}},
  author       = {{Selema, Ahmed and Ibrahim, Mohamed and Sergeant, Peter}},
  issn         = {{2076-3417}},
  journal      = {{APPLIED SCIENCES-BASEL}},
  keywords     = {{Electrical Machines,3D Printing,Additive Manufacturing,Windings,electric machines,3D printed windings,additive manufacturing eddy,currents,CONDUCTIVITY,LOSSES,INKJET}},
  language     = {{eng}},
  number       = {{3}},
  pages        = {{14}},
  title        = {{Development of novel semi-stranded windings for high speed electrical machines enabled by additive manufacturing}},
  url          = {{http://doi.org/10.3390/app13031653}},
  volume       = {{13}},
  year         = {{2023}},
}

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