Stator-Ironless Electrical Machines for Future Transportation Applications

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Electrification is a main enabler for decarbonised transportation. To achieve the "Net Zero" target by 2050 in the UK, ambitious roadmaps have been drawn up to push the performance boundaries of electrified powertrains, at the heart of which there are the electrical machines. Power density (kW/kg), widely regarded as No. 1 key performance indicator (KPI) of electrical machines, is limited by the usage of heavy ferromagnetic materials, which is not only unsustainable but also based on carbon-intensive manufacturing processes.Stator-ironless electrical machines have the potential to revolutionize transportation applications in the future. They can be designed with self-supporting windings to feature light-weight, high efficiency, high reliability as well as high torque quality, making them ideal for use in drones, electric vehicles and aircraft. However, the state-of-the-art ironless machines are still subject to relatively low torque/power density due to low electrical current loading, which is limited by thermal management and mechanical integrity of the windings.This PhD project will be aimed at significantly enhancing the power-to-weight ratio of stator-ironless electrical machines by combining advanced manufacturing technology, intensive cooling strategy together with proposed innovative machine topology. With customized 3D magnetic flux path design, the research idea could lead to significant contribution to knowledge extension of electromechanical engineering. The research output may also provide reward in expanding the application area of ironless machines from low torque actuator to heavy duty traction.The PhD work will start with literature review of ironless electrical machines, state-of-the-art winding solutions (hairpin, edgewise, additive manufacturing, etc,.) as well as advanced cooling arrangements. The PhD candidate will gain expertise in multi-disciplinary fields and develop a clean-sheet analytical tool for combined electromagnetic, thermal and mechanical design & optimisation based on proposed ironless machine topology. A proof-of-principle prototype will be manufactured and experimentally tested to validate the research ideas.