Recently, hairpin windings (HWs) have been among the most studied and implemented winding topologies to enhance the torque and power density of electrical machines (EMs), especially in the automotive sector. The aim of this work is threefold. First, it proposes an asymmetrical configuration for HWs, which exploits the possibility of reducing ac losses through the implementation of conductors featuring variable cross section within the slot. Second, this asymmetrical winding is envisioned using additive manufacturing (AM), given the constraints imposed by the conventional manufacturing process of HWs. Third, a suitable aluminum (Al) alloy is selected as a winding material, thus replacing copper (Cu), with the aim of achieving a more sustainable design. These three objectives are achieved through extensive analytical and numerical analyses and comparisons between conventional and asymmetrical windings, as well as among different materials. A practical demonstrator is then built to validate analyses, methodologies, and concepts proposed in this article. Finally, an experimental campaign is carried out on the asymmetrical winding demonstrator, highlighting the loss reduction and sustainability potentials of the proposed layout.
An Asymmetrical Additively Manufactured Hairpin Winding for Increased Efficiency and Sustainability
IEEE Transactions on Transportation Electrification ; 10 , 4 ; 9529-9538
2024-12-01
2415883 byte
Article (Journal)
Electronic Resource
English
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