Wire Wound Research Articles

Peningkatan Kinerja Motor Induksi Melalui Variasi Diameter Lilitan Kawat

Testing of 3 phase induction motors with a variety of wire diameters. First, find out the ideal wire size on an induction motor. Second, ratio of the power used on an induction motor with different winding wire sizes. Third, to find out the torque produced by an induction motor with different wire winding sizes. Then, The induction motor test was performed by taking the power data used on two motors with a diameter of 0.6 mm and 0.5 mm winding wire, RPM data and torque produced by an induction motor with a diameter of 0.6 mm and 0.5 mm. So, we can get the results the induction motor with a diameter of 0.6 mm wire uses as maximum power of 549.10 Watt or more than the induction motor with a diameter of a wire wound of 0.5 mm which only uses a maximum power of 345.95 Watt, the wire diameter induction motor winding 0.6 mm produces a maximum torque of 746.92 Nm or greater than an induction motor with a diameter of 0.5 mm winding wire which only produces a maximum torque of 383.97 Nm. So, It can be conclude that the more number of revolutions per minute (RPM), the torque produced will be smaller, then, the greater the torque produced, the more power is used.

Influence of the Preformed Coil Design on the Thermal Behavior of Electric Traction Machines

Preformed coils are used in electrical machines to improve the copper slot fill factor. A higher utilization of the machine can be realized. The improvement is a result of both, low copper losses due to the increased slot fill factor and an improved heat transition out of the slot. In this study, the influence of these two aspects on the operational improvement of the machine is studied. Detailed simulation models allow a separation of the two effects. A preform wound winding in comparison to a round wire winding is studied. Full machine prototypes as well as motorettes of the two designs are built up. Thermal finite element models of the stator slot are developed and parameterized with the help of motorette microsections. The resulting thermal lumped parameter model is enlarged to represent the entire electric machine. Electromagnetic finite element models for loss calculation and the thermal lumped parameter models are parameterized using test bench measurements. The developed models show very good agreement in comparison to the test bench evaluation. The study indicates that both, the improvements in the heat transition path and the advantages of the reduced losses in the slot contribute to the improved operational range in dependency of the studied operational point.

Pressure Sensor Embedded Inductive Coil Toward a Wireless Pressure Sensing Stent

This paper reports the development of a wireless pressure sensing coil system by embedding a capacitive micro sensor onto a wire. The coil system, consisting of an inductor (coil itself) and multiple capacitors (sensors), formed a passive LC telemetry configuration for wireless sensing. The capacitive sensor, utilizing the movements of a liquid in a sealed chamber for hydraulic amplification, enabled high capacitance changes and amplified signal outputs. The capacitive sensor also produced digitized signal outputs as the liquid movement crossed a finite number of the interdigitated electrodes. Such characteristics were modeled and confirmed by establishing an equivalent fluidic circuit. The capacitive sensor was fabricated by grafting and polishing a copper wire piece on a silicon wafer, then performing standard microfabrication on the polished wire surface and filling a liquid into a sensor chamber. The fabricated pressure sensing coil system demonstrated a pressure sensitivity of 11.8 kHz/mmHg under a clinical pressure range of 0~206.9 mmHg in an ex vivo test with a water flowing tube, meeting the requirements for wireless detection of vessel restenosis. The sensitivity corresponded to the capacitance changes of 0.052 fF/mmHg and liquid displacement of 0.39 μm/mmHg. The fabricated coil system held a dimension of 2.5 mm in diameter and 7.2 mm in length in the form of a wound wire (copper, 260 μm in diameter). The embedded capacitive sensor consisted of a hydraulic chamber of 400×100×1 2 μm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sup> and a microchannel of 500×20×1 2 μm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sup> . [2020-0364]

Thermopneumatic Soft Micro Bellows Actuator for Standalone Operation.

Typical pneumatic soft micro actuators can be manufactured without using heavy driving components such as pumps and power supplies by adopting an independent battery-powered mechanism. In this study, a thermopneumatically operated soft micro bellows actuator was manufactured, and the standalone operation of the actuator was experimentally validated. Thermopneumatic actuation is based on heating a sealed cavity inside the elastomer of the actuator to raise the pressure, leading to deflection of the elastomer. The bellows actuator was fabricated by casting polydimethylsiloxane (PDMS) using the 3D-printed soluble mold technique to prevent leakage, which is inherent in conventional soft lithography due to the bonding of individual layers. The heater, manufactured separately using winding copper wire, was inserted into the cavity of the bellows actuator, which together formed the thermopneumatic actuator. The 3D coil heater and bellows allowed immediate heat transfer and free movement in the intended direction, which is unachievable for conventional microfabrication. The fabricated actuator produced a stroke of 2184 μm, equivalent to 62% of the body, and exerted a force of 90.2 mN at a voltage of 0.55 V. A system in which the thermopneumatic actuator was driven by alkaline batteries and a control circuit also demonstrated a repetitive standalone operation.

Fabrication and torsional strength evaluation of a glass fiber epoxy composite shaft

Drive shaft plays a significant role in automotive power transmission. The weight of the drive shaft should be optimum to get better outcome. The selection of drive shaft is done based on the designed torsional strength. It means that torsional strength should be same irrespective of the material. In this present work the effort has been taken to evaluate the torsional strength of composite material drive shaft keeping the dimensions unaltered. Here drive shaft is manufactured using wire wound method. The materials chosen are glass fiber and epoxy as a main constituent. The efforts show the possible replacement of exiting drive shaft with composite one keeping all design parameters as constants.

Оптимизация тихоходного синхронного генератора модульного типа и принцип реализации системы управления напряжением генератора на основе нейронной сети

A method for optimizing the parameters of a modular half-speed synchronous generator with permanent magnets (PMSG) and the generator voltage control system with a neural network-based algorithm are proposed. The basic design scheme of the modular half-speed PMSG is considered, which features a compact layout of the generator main parts, thereby ensuring the optimal use of the working volume, smaller sizes of the magnetic system, and smaller mass of the active materials used in manufacturing the machine. Owing to the simple and reliable design of the generator, its output parameters can be varied in a wide range with using standard electrical circuits for voltage stabilization and current rectification along with an additional voltage regulation unit. Owing to this feature, the design scheme of the considered generator has essential advantages over the existing analogs with a common cylindrical magnetic core. In view of these circumstances, the development of a high-efficient modular half-speed PMSG as an autonomous DC power source is of both scientific and practical interest; this generator can be used to supply power to a large range of electricity consumers located in rural areas, low-rise residential areas, military communities, allotments etc. In solving the problem of optimizing the generator’s magnetic system, the main electrical machine analysis equation is obtained. The optimal ratios of the winding wire mass to the mass of permanent magnets and of the PM height to the air gap value for achieving the maximum specific useful power output have been determined. An analytical correlation between the optimal design parameters of a half-speed modular PMSG and its power performance parameters has been established. The expediency to develop a neural network-based control system is shown. The number of load-bearing modules of the half-speed PMSG is determined depending on the wind velocity, load factor and the required output voltage. The neural network was trained on the examples of a training sample using a laboratory test bench. The neural network was implemented in the MatLab 2019b environment by constructing a synchronous generator simulation model in the Simulink software extension. The possibility of using the voltage control system of a half-speed modular PMSG with a microcontroller for operation of the neural network platform of the Arduino family (ArduinoDue) independently of the PC is shown.

Synthetic Inductance Standards Made Up of Capacitances and Gyrators

Inductance standards currently available are made up of toroidal inductors, i.e., coils of wire wound around a toroidal nonmagnetic core. The maximum inductance achievable is 10 H, while modern LCR meters offer measurement ranges up to more than 10 kH. Due to their winding capacitance and wire resistance, toroidal inductors exhibit quite large parasitic elements that restrict the operating frequency due to resonances. Using a gyrator in conjunction with a capacitance standard creates a synthesized inductance, which can exhibit values up to hundreds of kilohenries. Optimizing the gyrator's parameters leads to much lower parasitics and thus an extended usable frequency range even for inductances available as toroidal inductors. Furthermore, the physical size of a gyrator circuit is much smaller than that of a toroid, which simplifies thermoregulation and transportation.

Numerical performance analysis of a novel shell-and-tube oil cooler with wire-wound and crescent baffles

Shell-and-tube oil coolers (STOC) are widely used in heat transfer of power systems. However, high-viscosity lubricants cause their oil-side heat transfer coefficients to be one order for magnitude lower than their water-side counterparts. Given this, a STOC with wire-wound (STOC-W) was designed to enhance the heat transfer of the oil cooler shell-side. The thermo-hydraulic performance of STOC-W is investigated by the numericalsimulation. According to the numerical calculation results of STOC-W, the STOC with wire-wound and crescent baffles (STOC-W-CB) was further proposed. The three factors (wire-winding angle, winding section shape, and baffles angle) that affect the heat transfer coefficient (HTC) of the STOC-W-CB were furtherly simulated and analyzed. The thermo-hydraulic performance of the STOC-W-CB and STOC with helical baffles (STOC-HB) were also compared. The results show that the structure of wire-wound and crescent baffles can effectively improve the shell-side heat transfer of the oil cooler. When Re is 201, the Performance Evaluation Criteria (PEC) of the STOC-W-CB is 2.2 times that of the bare tube cooler. The shell-side heat transfer coefficient of the STOC-W-CB are dramatically decreased with the increasing of the wire-winding angle. The best combination of the novel oil cooler is 30°-square wire winding with 10°-crescent baffles. When the Reynolds number is in the range of 100–350, the average heat transfer coefficient of STOC-W-CB is about 44% higher than that of STOC-HB.

An Overview of Methods and a New Three-Dimensional FEA and Analytical Hybrid Technique for Calculating AC Winding Losses in PM Machines

This article proposes a new hybrid analytical and numerical finite element (FE) based method for calculating ac eddy current losses in wire windings and demonstrates its applicability for axial flux permanent magnet electric machines. The method takes into account three-dimensional (3-D) field effects in order to achieve accurate results and yet greatly reduce computational efforts. The new 3-D FE-based method is advantageous as it employs minimum simplifications and considers the end turns in the eddy current path, the magnetic flux density variation along the effective length of coils, and the field fringing and leakage, which ultimately increases the accuracy of simulations. This study is one of the first ones to compare meticulous 3-D finite element analysis (FEA) models with more approximate, but faster solution methods, which can be employed in the optimization process. The accuracy of the 3-D FEA calculations has been confirmed through tests on a prototype axial flux permanent magnet machine. The proposed method is applicable for cases with majority of ac copper losses induced due to external magnetic flux sources, such as permanent magnets. Examples of such machines designs are coreless or open slot PM machines with conductors sizes smaller than skin depth.

Experimental and Numerical Investigation of the Internal Temperature of an Oil-Immersed Power Transformer with DOFS

To accurately detect and monitor the internal temperature of an operating power transformer, the distributed optical fiber sensor (DOFS) was creatively applied inside an oil-immersed 35 kV transformer through high integration with the winding wire. On the former basis, the power transformer prototype with a completely global internal temperature sensing capability was successfully developed and it was also qualified for power grid operation through the ex-factory type tests. The internal spatially continuous temperature distribution of the operating transformer was then revealed through a heat-run test and the numerical simulation was also applied for further analysis. Hotspots of windings were continuously located and monitored (emerging at about 89%/90% height of low/high voltage winding), which were furtherly compared with the IEC calculation results. This new nondestructive internal sensing method shows a broad application prospect in the electrical equipment field. Also, the revelation of transformer internal distributed temperature can offer a solid reference for both researchers and field operation staff.

Toroidal Ferrite Transformers With Conformal Laser Direct Structured Windings

Many applications in communications and power electronics demand inductive components that operate at high frequency or a broad range of frequencies. For applications requiring miniature devices with large inductance values, most often the components are manufactured imprecisely in the traditional method where magnetic cores are wound with a fine gauge wire. To achieve the best high-frequency performance, there is a desire to use a practical manufacturing method that removes the imprecision of wire winding. In this article, a unique 3-D laser exposure system is used to direct-write conformal winding patterns on the surface of MnZn ferrite toroids. The toroidal helix windings were fabricated by both an additive laser direct structuring (LDS) process and a subtractive laser-written mask-and-etch process. Both methods were performed on both enamel-coated ferrites and bare ferrites. The performance and equivalent circuit model parameters of the transformers were measured up to 1.5 GHz and will be presented. The transformers fabricated on the enamel-coated cores were found to have comparable or better inductances and broadband coupling than wire-wound transformers of matching construction.

Pengaruh medan elektromagnetik pada prestasi mesin motor bakar empat langkah dengan bahan bakar gas

The high level of fuel oil consumption in Indonesia caused by increases number of vehicles. Fuel oil consumption has switched into gas fuel as one of the secure alternative fuels and obtained more little gas emissions if compared with fuel oil. LPG (Liquified Petroleum Gas) is one of the alternative fuel was environmentally friendly. This research is purposed for compared performance of four-step engine with premium fuel and LPG fuel with a variety of additional electromagnetic field 600, 800, and 1000 total of copper wire windings. Using LPG fuel can increase torque generated by engine, but the result of engine power to be lower. Based on research data 800 copper wire windings can increase the number of torque and generated power compared to LPG fuel standard. LPG fuel can save fuel consumption compared to premium fuel. The most optimum decrease in fuel consumption is generated by using 1000 copper wire windings. Using LPG fuel can also reduce CO, CO2, and HC emissions levels. The best CO, CO2, and HC emissions levels are obtained from 1000 copper wire windings.Keywords: torque, power, fuel consumption, emissions, and LPG.

Mechanical System and Template-Matching-Based Position-Measuring Method for Automatic Spool Positioning and Loading in Welding Wire Winding

Welding wire is a major type of welding consumable, which needs to be winded onto spools for sale. Currently, the winding process is accomplished manually due to obstacles such as automatic spool loading and clamping. When loading the spool, the angular position of the spool is a prerequisite for matching the drive rod on the spindle and drive bore on the spool. Therefore, this paper proposes a template-matching method combined with area-based matching and feature-point detection to measure the angular position of the spool, and presents a mechanical system that can rotate the spool to match the drive rod and push the spool onto the spindle. A novel feature-point distribution density (FPDD) method was developed to accelerate the matching process and improve matching reliability by pre-locating the searching area. The robustness and accuracy of the template-matching-based measuring method were validated using a built prototype of the mechanical system. The comparison result shows that the proposed method was superior in robustness, accuracy, and speed, and it was efficient for automatic spool loading in the welding wire winding process.

3-D Analytical Model and Direct Measurement Method of Ultra-Thin Open-Circuit Air-Gap Field of Interior Permanent Magnet Synchronous Motor With Multi-Segmented Skew Poles and Multi-Layered Flat Wire Windings for Electric Vehicle

3-D analytical model and direct measurement method (DMM) of ultra-thin open-circuit air-gap field (OCAGF) of interior permanent magnet synchronous motor (IPMSM) with multi-segmented skew poles (MSP) and multi-layered flat wire windings (MFWW) for electric vehicles (EV) are proposed. Basis functions of slotless OCAGF are derived through field reconstruction method (FRM). In order to consider MSP and slotting effects, a complex relative permeance function is extended from 2-D to 3-D. Based on the magnetic potential and permeance method, 3-D analytical model of OCAGF is obtained. Then the back electromotive force (BEF) is calculated through Faraday's Law and the cogging torque is obtained through Maxwell stress tensor method. Furthermore, spatial order and amplitude-frequency characteristics of OCAGF are revealed. Additionally, influence of local inhomogeneous saturation caused by PM materials on analytical accuracy is discussed. Finally, the proposed analytical model is verified through both the traditional indirect measurement methods (BEF measurement and cogging torque measurement) and a novel direct measurement method, in which ultra-thin OCAGF of 10−1 mm order of magnitude can be measured directly. Local microscopic characteristics of OCAGF in some important locations, such as tooth top and magnetic bridge, can be accurately detected by using of the direct measurement method.

Frequency Response Modelling of Transformer Windings Connected in Parallel

This paper describes the approach to the frequency response modelling of transformer windings consisting of coils connected in parallel. At present, computer models are intensively developed with the aim of simulating the influence of faults on the frequency response of the active part of power transformers. Frequency response analysis (FRA) is one of the standard methods used for the assessment of the mechanical condition of a transformer’s windings and core. The interpretation of the FRA results is crucial in the diagnostics of the active part of the transformer. Proper simulations of the FRA results allow the improvement and simplification of the interpretation process of the windings’ faults. Usually only serial winding wires are simulated in computer modelling and parallel wires are simplified, leading to simulation inaccuracies. In this work, a combined electromagnetic field/network method, which includes parallel connections of the coils, is proposed. The method is based on lumped RLC elements. The results of the analysis conducted by the computer model are referred to as the real transformer measurement. The modelling was also performed for the case of a winding with a fault. The results of modelling were assessed with four numerical indices used for FRA interpretation.

Introduction of the next generation of CORC® wires with engineering current density exceeding 650 A mm−2 at 12 T based on SuperPower’s ReBCO tapes containing substrates of 25 μm thickness

Next generation particle accelerators and fusion machines will greatly benefit from the development of low-inductance magnets capable of generating magnetic fields in excess of 16 T. Such magnets require high-temperature superconductors capable of carrying very high currents exceeding 5 kA at current densities of 400–600 A mm−2, such as Conductor on Round Core (CORC®) cables and wires wound from RE-Ba2Ca3O7-δ (ReBCO, Re = rare earth) coated conductor tapes. CORC® wires containing ReBCO tapes with 30 μm thick Hastelloy® substrates have previously been demonstrated as a viable high-field magnet conductor that can be produced at long lengths. Further improvement of the performance and flexibility of CORC® wires would benefit from the development of ReBCO tapes with even thinner substrates. SuperPower Inc. recently demonstrated ReBCO tapes based on 25 μm thick Hastelloy® substrates that allow the development of thinner and more flexible CORC® wires that meet the stringent performance requirements of high-field magnets. Several tapes containing 25 μm thick substrates were produced and analyzed, exhibiting critical current and cabling performance in-line with the current production level tapes with 30–50 μm thick substrates. Tape critical current was measured at 4.2 K and applied magnetic fields up to 31.2 T. Several CORC® wires incorporating these tapes were manufactured by Advanced Conductor Technologies using similar winding procedures that previously resulted in high-quality magnet-grade CORC® wires based on tapes with 30 μm thick substrates. The CORC® wires were tested in an applied magnetic field up to 12 T after bending to a 63 mm diameter. A critical current as high as 6231 A (12 T, 4.2 K) was measured with an engineering current density (Je) of 678 A mm−2, which extrapolates to over 450 A mm−2 at 20 T and is the highest current density reported in a CORC® conductor to date. The combination of ReBCO tapes produced using 25 μm thick substrates and the ability to wind them into long-length, high-quality CORC® magnet wires brings the development of low-inductance accelerator and fusion magnets that operate at magnetic fields exceeding 20 T closer to fruition.

Thermal Analysis and Management for Doubly Salient Brushless DC Generator With Flat Wire Winding

The preformed flat wire winding is widely applied in doubly salient brushless DC generator with a rectangular slot structure due to the high slot filling factor and processing efficiency. The windings are commonly identified as the hottest component. The slot leakage is serious in the doubly salient structure machine, which increases the AC copper loss and thermal load of flat wire winding. Hence, predicting and lowering windings temperature are crucial tasks in the design of a doubly salient brushless DC generator with a flat wire winding. This article proposes the thermal modeling method of flat wire winding, where uneven AC copper loss distribution and thermal resistance between stator and winding are considered. Besides, the thermal model is simplified by canceling the local coordinate system. The characteristics of the temperature distribution of flat conductor winding under water-cooled and fan-cooled conditions are analyzed. Since the thermal resistance between stator and winding prevents the transfer of heat from the winding to the stator, the fan-cooled method is a better choice for the flat conductor winding. Finally, the thermal resistance measurement experiment is the design, and the fan-cooled brushless DC machine with flat conductor winding is developed. The analysis is verified through experiment.

3-D Analytical Model of Armature Reaction Field of IPMSM With Multi-Segmented Skewed Poles and Multi-Layered Flat Wire Winding Considering Current Harmonics

A 3-D analytical model of armature reaction field (ARF) of interior permanent magnet synchronous motor (IPMSM) with multi-segmented skewed poles (MSP) and multi-layered flat wire winding (MFWW) considering current harmonics is proposed in this paper. Firstly, based on the MFWW distribution analysis and the coil magnetic field vector superposition method, the ideal ARF functions of the MFWW considering low-order current harmonics and high-order sideband current harmonics are derived. Secondly, 3-D relative permeance functions caused by the stator slotting effect and the multi-segmented rotor magnetic barriers are presented. Thirdly, 3-D analytical expressions of ARF are obtained by multiplying the ideal ARF functions and the 3-D relative permeance functions. Additionally, the effects of low-order current harmonics, high order sideband current harmonics, MSP, and stator slotting on the spatial orders and frequencies of ARF are analyzed. Finally, the proposed model is verified by finite element method (FEM) and experiment.

Permeate flux enhancement with a helical wired concentric tube in air gap membrane distillation systems

Temperature polarization plays an important role in determining the permeate flux of the membrane distillation in an air gap membrane distillation (AGMD) module. This study aimed to increase the pure water productivity of saline water desalination by applying helical wire on the circumference of a concentric-tube AGMD module to reduce the temperature polarization occurring on the smooth annulus tube of an AGMD module with a normal concentric-tube. Modeling equations of heat and mass transfer in the new design of the AGMD device with helical wire winding on the annulus of a concentric tube have been investigated theoretically and experimentally. The mathematical model proposed in this study was used to correlate a simplified equation for estimating the heat transfer coefficient and to predict the permeate flux accordingly. The effects of various operation parameters, including the feed saline water temperature, feed volumetric flow rate, air gap thickness, and helical wire pitch, on the pure water productivity were also delineated. The permeate flux enhancement for helical wire in the AGMD module could provide the maximum relative increment of up to 31.1. The temperature polarization coefficient found in this study is ranging from 0.5527 to 0.5451 for different hot feed temperature and flow rate, respectively. An optimal helical wire module was assessed when considering both permeate flux enhancement and energy utilization effectiveness. © 2020 Desalination Publications. All rights reserved.

Characterization of Rectangular Copper Wire Forming Properties and Derivation of Control Concepts for the Kinematic Bending of Hairpin Coils

As a result of the continuously growing demand for electric vehicles, innovative production technologies must be developed to fulfill the high automotive requirements for productivity and quality in the manufacturing of electric drives. By providing advantages regarding the degree of automation, the productivity as well as the attainable filling factors in comparison to established round wire winding technologies, the hairpin technology shows a high potential for meeting the requested specifications but also technological weaknesses, especially concerning the process reliability. The referring production process of stators is normally based on the spatial forming of open, hairpin-shaped coils of enameled flat copper wire as well as subsequent joining and contacting processes. Consequently, the hairpin coils represent the elementary components of the process chain and can be either shaped by robust tool-bound or flexible kinematic bending processes that enable the shaping of different contours at moderate tool costs. In this paper, the essential mechanical forming and product properties of flat copper wires with different dimensions and insulation coatings are characterized by means of uniaxial tensile tests as well as metallographic analyses of the material structure, at first. Subsequently, the identified forming properties are correlated to the applied manufacturing processes drawing, rolling as well as continuous extruding and considered as limits of possible material variations. To evaluate the effect of fluctuating wire qualities on the robustness of kinematic hairpin bending processes, the fabrication tolerances are analyzed by finite element simulations, using the example of elementary kinematic bending operations and modeled changes of the material properties. Based on the knowledge of material-based process tolerances, different control concepts for the kinematic bending of hairpin coils are derived and compared based on technical as well as economic aspects.