Using the Potentials of Additive Manufacturing on the Field of Electrical Machine Production with Focus on Synchronous Reluctance Machine Rotors

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Additive manufacturing processes produce components and assemblies layer by layer without using formative tools. This process allows using additional and new degrees of freedom in designing the geometry of the components as well as in designing the material properties.The focus of this research project is using these new degrees of freedom for improving the design and manufacturing of electrical machines, especially of rotors of synchronous reluctance synchronous machines. This machine type has gained new importance in recent years as energy efficient driver of pumps and fans. For this purpose, especially the use of an ferro-silicon alloy with 6,5 % silicon is focused for additive manufacturing.In previous research, fundamental knowledge on different material systems for AM, their characterization and their application in electrical machines were achieved in tight cooperation between the University of Paderborn's Direct Manufacturing Research Center (DMRC) and the Institute for Drive Systems and Power Electronics (IAL) of Leibniz University Hannover, which shall now be used for finding new ways for a preferable design of synchronous reluctance machines.