Abstract
The continuous development in the field of industrial automation and electric mobility has led to the need for more efficient electrical machines with a high power density. The improvement of electrical machines’ slot filling factors is one of the measures to satisfy these requirements. In recent years, this topic has aroused greater interest in the industrial sector, since the evolution of the winding technological manufacturing processes allows an economically sustainable realization of ordered winding arrangements, rather than random ones. Moreover, the manufacture of electrical machines’ windings must be preceded by an accurate design phase in which it is possible to evaluate the maximum slot filling factor obtainable for a given wire shape and for its dimensions. For this purpose, this paper presents an algorithmic approach for the evaluation of maximum slot filling factors in electrical machines under an ideal geometric premise. In particular, this algorithm has a greater degree of flexibility with respect to the algorithm approaches found in the literature, since the study has been extended to round, rectangular and hexagonal wire sections. Furthermore, the slot filling factor calculation was carried out both for standard and non-standard slots. The algorithmic approach proposed can be considered as an additional useful tool for the fast design of electrical machine windings.
Highlights
The development of more and more efficient electrical machines has become a topic of interest for various industrial sectors, such as automation or electric traction
High filling factors make it possible to improve electrical machines’ performances, meeting the design requirements of several application fields. This improvement requires an optimal arrangement of the wires inside the slots and a careful evaluation of the maximum slot filling factor obtainable in the design phase
An algorithm approach is proposed to perform the calculation of slot filling factors in electrical machines
Summary
The development of more and more efficient electrical machines has become a topic of interest for various industrial sectors, such as automation or electric traction. The orthocyclic winding process requires very high manufacturing requirements to obtain an ordered wire positioning within each slot Another possible winding pattern is the “layer winding”, where the wires are uniformly arranged in layers [12]. In [12], a new and innovative needle winding method that allows shifted layer winding structures for distributed round wire applications is described, significantly increasing the copper filling factor In this regard, it is of considerable interest to accurately evaluate the slot filling factor obtainable during the design phase of electrical machines. The algorithm procedure is designed in order to systematically investigate a large number of cases defined for several values of the coordinates of the first wire in order to optimize the computation time and find the best arrangement inside the slot, with an improved accuracy. This paper is structured as follows: Section 2 describes the state-of-the-art optimization algorithms of the slot filling factors, Section 3 describes the algorithmic approach proposed and Section 4 illustrates several cases of studies that have been carried out and the relevant obtained results
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