AC losses reduction in Hairpin Windings produced via Additive Manufacturing

One of the key challenges of hairpin windings is the reduction of their high losses at high-frequency operations. Hairpin layouts comprising conductors with variable cross sections have proven good loss performance in previous studies. However, they come at the cost of significant manufacturing complications. The aim of this work is to design hairpin layouts featuring reduced losses compared to classical configurations, exploiting the flexibility enabled by additive manufacturing. In this context, the choice of a proper material with relatively high conductivity and low ecological impact plays an important role. Hence, this article first presents an overview of materials that can be used for the winding additive manufacturing, aiming to select the most suitable one for the application at hand. Then, the loss performance is evaluated and compared against classical copper hairpins. The results demonstrate that opportunely selected alloys featuring asymmetric configurations can compete against classical hairpin windings. © 20XX IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other worksThis paper reflects only the author's view. JU is not responsible for any use that may be made of the information it contains

Sensitivity analysis on the voltage distribution within windings of electrical machines fed by wide band gap converters

In the last years, Wide Band Gap devices are seeing a significant widespread in electric drives, due to their higher performance compared to conventional semiconductors. However, they also produce higher electric stress due to over-voltages and uneven voltage distributions among winding turns of electrical machines fed by them, which can lead to premature failures and/or reduced lifetimes.This paper presents a sensitivity analysis on the voltage distribution across stator winding turns of an electric motor intended for aerospace applications. The effects of the surge voltage characteristic parameters, such as dv/dt, voltage magnitude and parasitic impedances, are investigated. An equivalent circuit approach, based on the multi-transmission line theory, is developed and implemented in MatLab-Simulink environment, while the relevant circuital parameters are estimated through finite element analysis performed with MagNet and ElecNet software