Direct thermal management of windings enabled by additive manufacturing

This is an accepted manuscript of an article published by IEEE in IEEE Transactions on Industry Applications on 27/09/2022, available online: https://doi.org/10.1109/TIA.2022.3209171 The accepted version of the publication may differ from the final published version.The electrification and hybridization of ground- and air-transport, in pursuit of Carbon Net Zero targets, is driving demand for high power-density electrical machines. The power-density and reliability of electrical machines is ultimately limited by their ability to dissipate internally generated losses within the temperature constraints of the electrical insulation system. As the electrical windings are typically the dominant source of loss, their enhanced design is in the critical path to improvements in power-density. Application of metal additive manufacturing has the potential to disrupt conventional winding design by removing restrictions on conductor profiles, topologies and embedded thermal management. In this paper, a modular end-winding heat exchanger concept is presented, which enables effective direct cooling without occupying valuable stator slot cross-section. In addition, this arrangement eliminates the need for a good stator-winding thermal interface, thereby allowing mechanical or other less permanent winding retention methods to be used, facilitating non-destructive disassembly and repair. A prototype winding is fabricated and experimentally tested to demonstrate the feasibility of the concept, yielding promising results.This work has been funded by EPSRC Grant Number EP/f02125X/1 and EP/S018034/1 as part of a Future Electrical Machines Manufacturing (FEMM) Hub feasibility study.Published versio

The Contribution of Urban Morphology to the Formation of the Microclimate in Compact Urban Cores: A Study in the City Center of Thessaloniki

The purpose of this paper is to investigate the contribution of urban morphology to the formation of microclimatic conditions prevailing within urban outdoor spaces. We studied the compact form of a city and examined, at a detailed, street plan level, elements related to air temperature, urban ventilation, and the individual’s thermal comfort. All elements examined are directly affected by both the urban form and the availability of open and green spaces. The field study took place in a typical compact urban fabric of an old city center, the city center of Thessaloniki, where we investigated the relationship between urban morphology and microclimate. Urban morphology was gauged by examining the detailed street plan, along with the local building patterns. We used a simulation method based on the ENVI-met© software. The findings of the field study highlight the fact that the street layout, the urban canyon, and the open and green spaces in a compact urban form contribute decisively both to the creation of the microclimatic conditions and to the influence of the bioclimatic parameters

MRI-guided coupling for a focused ultrasound system using a top-to-bottom propagation

Background: A novel magnetic resonance imaging (MRI)-conditional coupling system was developed that accommodates a focused ultrasound (FUS) transducer. With this coupling system, the transducer can access targets from top to bottom. The intended clinical application is treatment of fibroids using FUS with the patient placed in supine position. Methods: The coupling system was manufactured using a rapid prototyping device using acrylonitrile butadiene styrene (ABS) plastic. Coupling to a gel phantom was achieved using a water bag filled with degassed water. The FUS transducer was immersed in the water bag. Results: The coupling system was successfully tested for MRI compatibility using fast-gradient pulse sequences in a gel phantom. The robotic system with its new coupling system was evaluated for its functionality for creating discrete and multiple (overlapping) lesions in the gel phantom. Conclusions: An MRI-conditional FUS coupling system integrated with an existing robotic system was developed that has the potential to create thermal lesions in targets using a top-to-bottom approach. This system has the potential to treat fibroid tumors with the patient lying in supine position

MRI-guided focused ultrasound robotic system for the treatment of bone cancer

Background: A novel MRI-conditional robot was developed that navigates a focused ultrasound (FUS) transducer. With this robotic system the transducer can access bones. The intended application is pain palliation from bone cancer using thermal ablation using FUS. Methods: The robotic system has four computer-controlled axes (three linear and one angular). The robotic system was manufactured using a digital manufacturing 3D printer, using acrylonitrile butadiene styrene (ABS) plastic. MRI-conditional optical encoders were used to accurately control the robotic system. Results: The robotic system was successfully tested for MRI safety and compatibility, using fast-gradient pulse sequences and a liquid phantom. The robotic system has been tested for its functionality for creating discrete and multiple (overlapping) lesions in a gel phantom. Conclusions: An MRI-conditional FUS robotic system was developed that has the potential to create thermal lesions with the intention of treating bone cancer for the purpose of pain palliation

MRI-guided coupling for a focused ultrasound system using a top-to-bottom propagation

Background: A novel magnetic resonance imaging (MRI)-conditional coupling system was developed that accommodates a focused ultrasound (FUS) transducer. With this coupling system, the transducer can access targets from top to bottom. The intended clinical application is treatment of fibroids using FUS with the patient placed in supine position. Methods: The coupling system was manufactured using a rapid prototyping device using acrylonitrile butadiene styrene (ABS) plastic. Coupling to a gel phantom was achieved using a water bag filled with degassed water. The FUS transducer was immersed in the water bag. Results: The coupling system was successfully tested for MRI compatibility using fast-gradient pulse sequences in a gel phantom. The robotic system with its new coupling system was evaluated for its functionality for creating discrete and multiple (overlapping) lesions in the gel phantom. Conclusions: An MRI-conditional FUS coupling system integrated with an existing robotic system was developed that has the potential to create thermal lesions in targets using a top-to-bottom approach. This system has the potential to treat fibroid tumors with the patient lying in supine position

MRI-compatible bone phantom for evaluating ultrasonic thermal exposures

Objective The goal of the proposed study was the development of a magnetic resonance imaging (MRI) compatible bone phantom suitable for evaluating focused ultrasound protocols. Materials and methods High resolution CT images were used to segment femur bone. The segmented model was manufactured with (Acrylonitrile Butadiene Styrene) ABS plastic using a 3-D printer. The surrounding skeletal muscle tissue was mimicked using an agar-silica-evaporated milk gel (2% w/v-2% w/v-40% v/v). MR thermometry was used to evaluate the exposures of the bone phantom to focused ultrasound. Results The estimated agar-silica-evaporated milk gel's T1 and T2 relaxation times in a 1.5 T magnetic field were 776 ms and 66 ms respectively. MR thermometry maps indicated increased temperature adjacent to the bone, which was also shown in situations of real bone/tissue interfaces. Conclusion Due to growing interest of using MRI guided Focused Ultrasound Surgery (MRgFUS) in palliating bone cancer patients at terminal stages of the disease, the proposed bone phantom can be utilized as a very useful tool for evaluating ultrasonic protocols, thus minimizing the need for animal models. The estimated temperature measured and its distribution near the bone phantom/agar interface which was similar to temperatures recorded in real bone ablation with FUS, confirmed the phantom's functionality

MRI-compatible breast/rib phantom for evaluating ultrasonic thermal exposures

Introduction: The target of this study was the development of a magnetic resonance imaging (MRI) compatible breast phantom for focused ultrasound which includes plastic (ABS) ribs. The objective of the current study was the evaluation of a focused ultrasound procedure using the proposed phantom that eliminates rib heating. Material and Methods: The proposed phantom was evaluated using two different focused ultrasound exposures. The surrounding breast tissue was mimicked using an agar–silica–evaporation milk gel (2% w/v – 2% w/v – 40% v/v). Results: The attenuation of the ABS was similar to that of ribs. MR thermometry of focused ultrasound exposures were acquired using the breast/rib phantom. In one exposure focused ultrasound was applied with far-field targeting of the ribs. In the other exposure, the transducer was positioned laterally, thus avoiding exposure of the rib to focused ultrasound. Conclusions: Due to growing interest in using MRI guided focused ultrasound (MRgFUS) for patients with breast cancer, the proposed breast/rib phantom can be utilized as a very useful tool for evaluating ultrasonic protocols