Abstract
In the design of electrical machines, the increase in power density has become one of the main research themes. With most of the power loss in high power density electrical machines often being generated in the stator winding assembly, it is necessary to reduce these losses. The effects of strands and bundle positions in the slot on the ac losses in the winding are often overlooked. Taking as a case-study an existing high-frequency machine, this article analyzes and provides an in-depth insight into such effects. Exploiting the rapid advancements in precision three-dimensional printing, it is found and experimentally verified that by controlling the position of the conductors within the top of the slot the ac losses can be markedly reduced.
Highlights
Increasing demands and widespread adoption of electrical drives in aircraft, automobiles and machine tools have intensified efforts in the design and development of high performance electrical machines that combine high power density, light-weighting and high efficiency [1]
With the majority of the power loss within high power density electrical machines often being generated in the stator winding [2], it is necessary to reduce the copper losses and improve the heat transfer mechanisms for such losses
In [14], the authors investigated a variety of winding connections at different speeds and studied the proximity losses with circulating currents and strands in hand for rectangular conductors
Summary
Increasing demands and widespread adoption of electrical drives in aircraft, automobiles and machine tools have intensified efforts in the design and development of high performance electrical machines that combine high power density (kW/kg or kW/L), light-weighting and high efficiency [1]. While in [10], the influence of conductor shape on the proximity losses is investigated, vanDerGeest in [12], analysed the effect of varied number of parallel strands, partially filled slots, strand shape, fill factor and slot size on proximity loss and inferred that the AC losses in strands of different shapes (circular, hexagonal, square) but with same area are virtually identical. In [14], the authors investigated a variety of winding connections at different speeds and studied the proximity losses with circulating currents and strands in hand for rectangular conductors. For low-voltage machines with random windings the proximity losses caused by the flux leakage are sensitive to the positions of strands. The influence of such magnet wire arrangements both at the strand and bundle levels on the AC losses in the winding of the machine are investigated with the aim of achieving an improved layout of conductors with reduced losses.
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