Additive Manufacturing of High Performance Shaped-Profile Electrical Machine Windings

高性能异形电机绕组的增材制造

• 批准号: EP/T02125X/1
• 负责人: Nick Simpson
• 金额: $ 42.42万
• 依托单位: University of Bristol
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2020
• 资助国家: 英国
• 起止时间: 2020 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FT02125X%2F1
• 关键词: Additive; Manufacturing; Performance; Shaped; Profile

Performance improvement of electrical machines in terms of power-density and efficiency is central to the success of hybrid- and electric- vehicles and more- or all- electric aircraft, as indicated by the UK Advanced Propulsion Centre and the Aerospace Technology Institute. Efficiency and packaging volume of conventional electrical machines are limited by the method used to manufacture electrical windings, i.e. using pre-insulated conductors of uniform cross-section wound around the teeth of the stator. Here, we propose the use of metal additive manufacturing (3d printing), in which feedstock or powdered material is selectively bonded in a succession of 2D layers to incrementally form a compact 3D winding. The geometric freedom offered by additive manufacturing allows the simultaneous minimisation of end-winding volume and individual shaping of conductor profiles to optimise efficiency all while acting as a substrate for high performance inorganic electrical insulation materials. The technology could address the increasing drive to low batch size, flexibility and customisation in design for high integrity and high value electrical machines for the aerospace, energy and high value automotive sectors while enabling CO2 reductions demanded by legislation and market sentiment.Specifically, I will lead this multidisciplinary project exploring the potential benefits of Additive Manufacturing of High Performance Shaped Profile Electrical Machine windings leveraging expertise from industrial and academic partners Renishaw, 3TAM, Motor Design Ltd and Teesside University. The partners represent leading electrical machine design (Motor Design Ltd, University of Bristol), electrical insulation materials (Teesside University), UK additive manufacturing supply chain (Renishaw) and end-use additive manufacturing part production (3TAM). This range of partners cover the necessary skills and capability to go from theoretical winding design to manufactured, insulated prototype windings. As such, the project will result in a significant growth in the UK's knowledge and skills base in this area and develop a technology demonstrator to illustrate the quantitative benefit of such windings to industry and academia. This will allow new cross-sector relationships and collaborations to be cultivated with a view to perpetuate the research beyond the project period, ultimately leading to industrial adoption and further poising the UK as a centre for excellence in high value electrical machine technologies.

正如英国先进推进中心和航空航天技术研究所所指出的那样，电机在功率密度和效率方面的性能改进是混合动力和电动汽车以及多电动或全电动飞机成功的核心。传统电机的效率和封装体积受到用于制造电绕组的方法的限制，即，使用缠绕在定子的齿周围的均匀横截面的预绝缘导体。在这里，我们提出使用金属增材制造（3D打印），其中原料或粉末材料选择性地结合在一系列2D层中，以逐步形成紧凑的3D绕组。增材制造提供的几何自由度允许同时最小化端部绕组体积和导体轮廓的单独成形，以优化效率，同时作为高性能无机电绝缘材料的基材。该技术可以满足航空航天、能源和高价值汽车行业对高完整性和高价值电机设计的低批量、灵活性和定制化的日益增长的需求，同时实现立法和市场情绪所要求的二氧化碳减排。我将领导这个多学科项目，探索高性能异形截面电机绕组增材制造的潜在好处。利用工业和学术合作伙伴雷尼绍、3TAM、Motor Design Ltd和Teesside University的专业知识。合作伙伴代表领先的电机设计（布里斯托大学电机设计有限公司），电气绝缘材料（提赛德大学），英国增材制造供应链（雷尼绍）和最终用途增材制造零件生产（3TAM）。这些合作伙伴涵盖了从理论绕组设计到制造绝缘原型绕组所需的技能和能力。因此，该项目将导致英国在这一领域的知识和技能基础的显着增长，并开发一个技术演示器，以说明这种绕组对工业和学术界的量化好处。这将使新的跨部门关系和合作得以培养，以期使研究在项目期后得以延续，最终导致工业采用，并进一步使英国成为高价值电机技术的卓越中心。

项目成果

Additive Manufacturing of a Conformal Hybrid-Strand Concentrated Winding Topology for Minimal AC Loss in Electrical Machines

共形混合股集中绕组拓扑的增材制造，可实现电机中最小交流损耗

• DOI: 10.1109/ecce47101.2021.9595059
• 发表时间: 2021
• 作者: Simpson N

Functionally Graded Electrical Windings Enabled by Additive Manufacturing

通过增材制造实现功能分级电气绕组

• DOI: 10.1109/icem51905.2022.9910912
• 发表时间: 2022
• 作者: Simpson N

Fabrication of Insulation Coatings on Additively Manufactured CuCrZr Electrical Windings

增材制造 CuCrZr 电气绕组绝缘涂层的制造

• DOI: 10.1109/tdei.2023.3324285
• 发表时间: 2024
• 期刊: IEEE Transactions on Dielectrics and Electrical Insulation
• 影响因子: 3.1
• 作者: Munagala S

Electrical Conductivity of Additively Manufactured Copper and Silver for Electrical Winding Applications.

• DOI: 10.3390/ma15217563
• 发表时间: 2022-10-28
• 期刊: Materials (Basel, Switzerland)
• 作者: Robinson J;Munagala SP;Arjunan A;Simpson N;Jones R;Baroutaji A;Govindaraman LT;Lyall I
• 通讯作者: Lyall I

Statistical Simulation of Conductor Lay and AC Losses in Multi-Strand Stator Windings

多股定子绕组中导体捻距和交流损耗的统计模拟

• DOI: 10.1109/iemdc47953.2021.9449582
• 发表时间: 2021
• 作者: Hoole J