Stator-Ironless Electrical Machines for Future Transportation Applications

电气化是脱碳运输的主要推动力。为了在2050年之前实现英国的“净零”目标，英国已经制定了雄心勃勃的路线图，以推动电气化动力系统的性能界限，其中的核心是电机。功率密度（kW/kg）被广泛认为是电机的第一关键性能指标（KPI），但受到重铁磁材料使用的限制，这不仅是不可持续的，而且基于碳密集型制造工艺。定子无铁芯电机有可能在未来彻底改变运输应用。它们可以设计为自支撑绕组，具有重量轻，效率高，可靠性高以及高扭矩质量的特点，使其成为无人机，电动汽车和飞机的理想选择。然而，最先进的无铁芯电机仍然受到相对较低的扭矩/功率密度，由于低电流负载，这是受到热管理和绕组的机械完整性的限制。本博士项目的目的是通过结合先进的制造技术，强化冷却策略以及建议的创新机器拓扑结构。通过定制三维磁通路径设计，该研究思路可以为机电工程知识的扩展做出重大贡献。研究成果也可能为将无铁芯电机的应用领域从低扭矩致动器扩展到重型牵引提供奖励。博士工作将从无铁芯电机的文献综述开始，最先进的绕组解决方案（发夹，方摆，增材制造等）。以及先进的冷却装置。博士候选人将获得多学科领域的专业知识，并开发一个干净的分析工具，用于基于拟议的无铁芯机器拓扑结构的电磁，热和机械设计和优化。一个原理验证原型将被制造和实验测试，以验证研究思路。

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.