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A Study in Additive Manufacturing of Windings for Traction Machines

Estenlund, Samuel LU orcid ; Adolfsson, Erik and Hosseini, Seyed V (2024) p.1302-1308
Abstract
This work presents a literature study over how additive manufacturing can be used to improve the performance of windings for traction machines when it comes to materials, loss minimization and thermal management, especially for concentrated windings. It continues to present the additive manufacturing methods most suitable for additively manufacturing windings. The lessons from manufacturing coils with metal binder jetting are presented, concluding that some support structures are needed which can be chemically removed later in the process which means that the full detail capability of metal binder jetting can not be utilized fully. Finally different approaches to thermal management with additively manufactured coils are modelled. The... (More)
This work presents a literature study over how additive manufacturing can be used to improve the performance of windings for traction machines when it comes to materials, loss minimization and thermal management, especially for concentrated windings. It continues to present the additive manufacturing methods most suitable for additively manufacturing windings. The lessons from manufacturing coils with metal binder jetting are presented, concluding that some support structures are needed which can be chemically removed later in the process which means that the full detail capability of metal binder jetting can not be utilized fully. Finally different approaches to thermal management with additively manufactured coils are modelled. The results show that compared to direct air cooled windings, additively manufactured copper coils with direct cooling can increase the maximum current by 50 %. If aluminium (AlSiMg) windings are made with both additive manufacturing and improved end-turn cooling they can match the performance of non-AM direct air cooled copper windings. (Less)
Please use this url to cite or link to this publication:
author
; and
organization
publishing date
type
Chapter in Book/Report/Conference proceeding
publication status
published
subject
host publication
2024 International Symposium on Power Electronics, Electrical Drives, Automation and Motion (SPEEDAM)
article number
10609139
pages
7 pages
publisher
IEEE - Institute of Electrical and Electronics Engineers Inc.
external identifiers
  • scopus:85201730328
DOI
10.1109/SPEEDAM61530.2024.10609139
language
English
LU publication?
yes
id
6a4c457a-dee4-4f65-80e1-3d00ddba7e2c
date added to LUP
2024-09-26 10:33:02
date last changed
2025-04-04 15:31:02
@inproceedings{6a4c457a-dee4-4f65-80e1-3d00ddba7e2c,
  abstract     = {{This work presents a literature study over how additive manufacturing can be used to improve the performance of windings for traction machines when it comes to materials, loss minimization and thermal management, especially for concentrated windings. It continues to present the additive manufacturing methods most suitable for additively manufacturing windings. The lessons from manufacturing coils with metal binder jetting are presented, concluding that some support structures are needed which can be chemically removed later in the process which means that the full detail capability of metal binder jetting can not be utilized fully. Finally different approaches to thermal management with additively manufactured coils are modelled. The results show that compared to direct air cooled windings, additively manufactured copper coils with direct cooling can increase the maximum current by 50 %. If aluminium (AlSiMg) windings are made with both additive manufacturing and improved end-turn cooling they can match the performance of non-AM direct air cooled copper windings.}},
  author       = {{Estenlund, Samuel and Adolfsson, Erik and Hosseini, Seyed V}},
  booktitle    = {{2024 International Symposium on Power Electronics, Electrical Drives, Automation and Motion (SPEEDAM)}},
  language     = {{eng}},
  month        = {{08}},
  pages        = {{1302--1308}},
  publisher    = {{IEEE - Institute of Electrical and Electronics Engineers Inc.}},
  title        = {{A Study in Additive Manufacturing of Windings for Traction Machines}},
  url          = {{http://dx.doi.org/10.1109/SPEEDAM61530.2024.10609139}},
  doi          = {{10.1109/SPEEDAM61530.2024.10609139}},
  year         = {{2024}},
}