Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684211
A. Winter, G. Cooke, J. Birchall, L. Tinkler
We report a novel method for automating the place-ment of suface-mounted permanent magnets within electrical machine rotors. This process was part of the manufacture of a generator being developed for offshore wind turbines. Magnetic forces during placement were predicted to exceed 5 kN, which would exceed the payload of all but the largest industrial robots. A robot end-effector was designed and manufactured to overcome these magnetic forces. Its design incorporated structural elements that interfaced with the steel hub, thus isolating the robot from the forces. Instead of requiring a large robot to resist the magnetic forces, this end effector allows the process be carried out by any robot capable of lifting the end effector and magnet. In addition, the automated solution allowed the process time to be reduced from 55 minutes per magnet to 55 seconds, with scope to reduce this further in the future.
{"title":"Robotic placement of high-strength permanent magnets for a wind turbine generator","authors":"A. Winter, G. Cooke, J. Birchall, L. Tinkler","doi":"10.1109/EDPC53547.2021.9684211","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684211","url":null,"abstract":"We report a novel method for automating the place-ment of suface-mounted permanent magnets within electrical machine rotors. This process was part of the manufacture of a generator being developed for offshore wind turbines. Magnetic forces during placement were predicted to exceed 5 kN, which would exceed the payload of all but the largest industrial robots. A robot end-effector was designed and manufactured to overcome these magnetic forces. Its design incorporated structural elements that interfaced with the steel hub, thus isolating the robot from the forces. Instead of requiring a large robot to resist the magnetic forces, this end effector allows the process be carried out by any robot capable of lifting the end effector and magnet. In addition, the automated solution allowed the process time to be reduced from 55 minutes per magnet to 55 seconds, with scope to reduce this further in the future.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"49 2 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121238149","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684227
Wilken Wößner, M. Heim, Marco Walter, J. Fleischer
The growing demand for highly efficient and power dense electric traction motors increases the complexity and amount of technical challenges in the production of permanent magnet rotors. For instance, rotors designed for particularly high power densities must withstand rotational speeds of up to 18 000rpm and temperatures of up to 180°C, but need to be manufactured at minimum unit costs and cycle times. Especially initial unbalances and changes of unbalance during operation can be a challenge to rotor manufacturers. Thus, a profound knowledge of technical challenges and potential solutions for reduced unbalance is required for the economically viable and resource-saving production of highly efficient motors. Therefore, this paper presents an overview of technical challenges and potential solutions for unbalance reduction in the production of permanent magnet rotors for electric traction motors according to the current state of research and development. The summarized challenges and approaches are subsequently prioritized by experimental investigations as well as FE-simulations following a design of experiments. They are finally complemented by further concepts in order to present optimization potentials for reduction of unbalance along the production of permanent magnet rotors. In future, these can be implemented in industry and research in order to enable a sustainable electrification of individual mobility.
{"title":"Challenges and Potential Solutions for Reduced Unbalance of Permanent Magnet Rotors for Electric Traction Motors","authors":"Wilken Wößner, M. Heim, Marco Walter, J. Fleischer","doi":"10.1109/EDPC53547.2021.9684227","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684227","url":null,"abstract":"The growing demand for highly efficient and power dense electric traction motors increases the complexity and amount of technical challenges in the production of permanent magnet rotors. For instance, rotors designed for particularly high power densities must withstand rotational speeds of up to 18 000rpm and temperatures of up to 180°C, but need to be manufactured at minimum unit costs and cycle times. Especially initial unbalances and changes of unbalance during operation can be a challenge to rotor manufacturers. Thus, a profound knowledge of technical challenges and potential solutions for reduced unbalance is required for the economically viable and resource-saving production of highly efficient motors. Therefore, this paper presents an overview of technical challenges and potential solutions for unbalance reduction in the production of permanent magnet rotors for electric traction motors according to the current state of research and development. The summarized challenges and approaches are subsequently prioritized by experimental investigations as well as FE-simulations following a design of experiments. They are finally complemented by further concepts in order to present optimization potentials for reduction of unbalance along the production of permanent magnet rotors. In future, these can be implemented in industry and research in order to enable a sustainable electrification of individual mobility.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"23 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123555351","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684223
Franz Teske, Adrian Fehrle, J. Praß, J. Franke
Temporarily high electricity demand resulting from simultaneous charging of many electric vehicles (EVs) require massive expansion of the future grid infrastructure. Using EVs in a way that serves the power system in such by contributing to peak shaving, valley filling, and flattening the load curve of the grid would help to reduce the cost of grid expansion. Based on the current market design, grid-serving bidirectional charging of EVs is still uneconomical for the EVs owners in Germany since it is burdened with various levies, taxes, and fees. We propose an adapted pricing scheme for bidirectional charging that incentivizes a system-serving behavior. For this purpose, we develop a mixed-integer linear optimization model that considers different types of electricity use in the EVs. Based on a simulation, we show that bidirectional charging can generate significant profits under the condition that the system-serving electricity quantities are billed without levies, taxes, and fees or if the EVs are treated like other storage units operating on the electricity market. The analysis shows that bidirectional grid interactions are particularly worthwhile for parking situations at residential properties, especially with long parking times on weekends, high electricity consumption and when taking advantage of volatile intraday prices.
{"title":"Adapted pricing scheme for the integration of vehicle-to-grid into the energy system","authors":"Franz Teske, Adrian Fehrle, J. Praß, J. Franke","doi":"10.1109/EDPC53547.2021.9684223","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684223","url":null,"abstract":"Temporarily high electricity demand resulting from simultaneous charging of many electric vehicles (EVs) require massive expansion of the future grid infrastructure. Using EVs in a way that serves the power system in such by contributing to peak shaving, valley filling, and flattening the load curve of the grid would help to reduce the cost of grid expansion. Based on the current market design, grid-serving bidirectional charging of EVs is still uneconomical for the EVs owners in Germany since it is burdened with various levies, taxes, and fees. We propose an adapted pricing scheme for bidirectional charging that incentivizes a system-serving behavior. For this purpose, we develop a mixed-integer linear optimization model that considers different types of electricity use in the EVs. Based on a simulation, we show that bidirectional charging can generate significant profits under the condition that the system-serving electricity quantities are billed without levies, taxes, and fees or if the EVs are treated like other storage units operating on the electricity market. The analysis shows that bidirectional grid interactions are particularly worthwhile for parking situations at residential properties, especially with long parking times on weekends, high electricity consumption and when taking advantage of volatile intraday prices.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129857039","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684204
Franz Teske, Felix Funk, Adrian Fehrle, J. Franke
In the next few years, many electric vehicles (EV s) will need to be integrated into low-voltage (LV) grids, which, according to current paradigms, will result in high grid expansion requirements and enormous costs. Therefore, it is planned to reduce the grid expansion in the distribution grid and to implement smart solutions to manage the locally limited transmission capacity. It must be ensured that no overloads of transformers and power lines as well as undervoltage problems occur. In this paper, the implementation of a smart market that efficiently distributes the limited infrastructure is proposed. This is accomplished by calculating the available grid capacity based on the grid topology and other local supply and demand. The remaining capacity is distributed through a market mechanism. Based on a typical grid setup, it can be shown that the presented concept utilizes the existing power grid more efficiently than time-based control and time-limited prohibitions of charging processes. Through the market mechanism, the individual charging requirements can be considered and thus an improved temporal distribution of the charging quantities can be achieved.
{"title":"Integration of electric vehicles into low-voltage grids with limited capacity using a smart market","authors":"Franz Teske, Felix Funk, Adrian Fehrle, J. Franke","doi":"10.1109/EDPC53547.2021.9684204","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684204","url":null,"abstract":"In the next few years, many electric vehicles (EV s) will need to be integrated into low-voltage (LV) grids, which, according to current paradigms, will result in high grid expansion requirements and enormous costs. Therefore, it is planned to reduce the grid expansion in the distribution grid and to implement smart solutions to manage the locally limited transmission capacity. It must be ensured that no overloads of transformers and power lines as well as undervoltage problems occur. In this paper, the implementation of a smart market that efficiently distributes the limited infrastructure is proposed. This is accomplished by calculating the available grid capacity based on the grid topology and other local supply and demand. The remaining capacity is distributed through a market mechanism. Based on a typical grid setup, it can be shown that the presented concept utilizes the existing power grid more efficiently than time-based control and time-limited prohibitions of charging processes. Through the market mechanism, the individual charging requirements can be considered and thus an improved temporal distribution of the charging quantities can be achieved.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"200 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"132332836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684209
B. Horn, H. Vogt, O. Tyshakin, R. Leidhold
In this paper a concept for the determination of the current and frequency dependent inductance maps of (salient-pole) permanent magnet synchronous machines (PMSM) is presented. This is realised using a simple voltage inverter. Only the measured currents and the reference voltage are used in an extended and automated standard procedure for the standstill frequency response (SSFR). Detailed inductance maps can be estimated within seconds without having to consider the non-linearities of the inverter or the need of additional voltage sensors. No extensive inverter setup is required because the non-linearities of the inverter are not laboriously compensated, but rather bypassed and interpolated purposefully through the holistic map. With a sufficient map resolution, a reliable identification of the inductances is accomplished. For the generation of the characteristic map only a few equations are required and implemented directly on the controller of the inverter. The experimentally determined maps are finally verified with highquality laboratory measurement data at different frequencies.
{"title":"Dead-Time Independent Generation of Inductance Maps of Permanent Magnet Synchronous Machines (PMSM) using a Voltage Source Inverter (VSI)","authors":"B. Horn, H. Vogt, O. Tyshakin, R. Leidhold","doi":"10.1109/EDPC53547.2021.9684209","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684209","url":null,"abstract":"In this paper a concept for the determination of the current and frequency dependent inductance maps of (salient-pole) permanent magnet synchronous machines (PMSM) is presented. This is realised using a simple voltage inverter. Only the measured currents and the reference voltage are used in an extended and automated standard procedure for the standstill frequency response (SSFR). Detailed inductance maps can be estimated within seconds without having to consider the non-linearities of the inverter or the need of additional voltage sensors. No extensive inverter setup is required because the non-linearities of the inverter are not laboriously compensated, but rather bypassed and interpolated purposefully through the holistic map. With a sufficient map resolution, a reliable identification of the inductances is accomplished. For the generation of the characteristic map only a few equations are required and implemented directly on the controller of the inverter. The experimentally determined maps are finally verified with highquality laboratory measurement data at different frequencies.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116592912","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684202
J. Seefried, A. Mahr, M. Weigelt, A. Kühl, J. Franke
The electrical and mechanical contacting of insulated copper wires is one of the most challenging process steps in electromechanical engineering. Especially in the production of electric motors, flat wires are increasingly used as a result of the hairpin technology. The main goal here is to increase the copper fill factor and to implement a fully automated production of the motors. However, the use of flat wires can also lead to an increase of the filling factor in the case of winded single teeth. In order to achieve the required number of turns for the electromagnetic design, flat wires with a high width-to-thickness ratio are used. However, these pose challenges for the necessary contacting process with regard to the connection cross section. In the context of this publication, various contacting methods for thin flat wires and their process-related challenges are therefore compared.
{"title":"Challenges of Contacting Processes for Thin Copper Flat Wires in the Context of Electromechanical Engineering","authors":"J. Seefried, A. Mahr, M. Weigelt, A. Kühl, J. Franke","doi":"10.1109/EDPC53547.2021.9684202","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684202","url":null,"abstract":"The electrical and mechanical contacting of insulated copper wires is one of the most challenging process steps in electromechanical engineering. Especially in the production of electric motors, flat wires are increasingly used as a result of the hairpin technology. The main goal here is to increase the copper fill factor and to implement a fully automated production of the motors. However, the use of flat wires can also lead to an increase of the filling factor in the case of winded single teeth. In order to achieve the required number of turns for the electromagnetic design, flat wires with a high width-to-thickness ratio are used. However, these pose challenges for the necessary contacting process with regard to the connection cross section. In the context of this publication, various contacting methods for thin flat wires and their process-related challenges are therefore compared.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"2010 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125628906","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684221
Alexander Dorninger, Simon Weitzhofer, Markus Schörgenhumer, A. Sorgdrager, Eike Janssen
Electrical machine design candidates are typically assessed against several requirements during the development process, including the rotor's mechanical soundness. At present, this is primarily a manual process done by an experienced engineer after the initial electromagnetic design stage. Consequently, there is significant potential to increase the efficiency of the development process and the degree of optimality of the resulting solutions by integrating the mechanical assessment into an automated design optimization workflow. As part of the optimization, the automated process must estimate the mechanical soundness of the current design within a reasonable time and accuracy. To this end, a tailor-made software package combined with a post-processing framework was developed. The software package uses the rotor definition to create and compute a 2D finite element model for the mechanical strain and stress fields. In the post-processing step, a decision is made whether the current geometry should be rejected or further considered in the optimization. Several strategies for such an automated assessment and design decision algorithm are shown and compared in this work.
{"title":"Automated Mechanical Rotor Design Assessment Based on 2D FEA Results","authors":"Alexander Dorninger, Simon Weitzhofer, Markus Schörgenhumer, A. Sorgdrager, Eike Janssen","doi":"10.1109/EDPC53547.2021.9684221","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684221","url":null,"abstract":"Electrical machine design candidates are typically assessed against several requirements during the development process, including the rotor's mechanical soundness. At present, this is primarily a manual process done by an experienced engineer after the initial electromagnetic design stage. Consequently, there is significant potential to increase the efficiency of the development process and the degree of optimality of the resulting solutions by integrating the mechanical assessment into an automated design optimization workflow. As part of the optimization, the automated process must estimate the mechanical soundness of the current design within a reasonable time and accuracy. To this end, a tailor-made software package combined with a post-processing framework was developed. The software package uses the rotor definition to create and compute a 2D finite element model for the mechanical strain and stress fields. In the post-processing step, a decision is made whether the current geometry should be rejected or further considered in the optimization. Several strategies for such an automated assessment and design decision algorithm are shown and compared in this work.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"6 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125215265","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684212
J. Bonart, Philipp Hümmer, W. Drossel
Production lines for electric drives consist of successive assembly steps. The highly integrated topology of the unit can lead to complex faults caused by poor components or incorrect assembly. To minimize the added value of a bad motor, a noise-vibration-harshness (NVH) measurement is performed on an in-line test bench (IL). Following the IL, other components (gearbox, inverter, …) are assembled, resulting in a finished electric drive unit. The final state is again tested by a NVH measurement on an end-of-line (EOL) test bench. A novel approach is presented that combines the results of both test benches into an overall picture, thus creating a contextual environment for the EOL. Depending on the interaction of the two test benches, different implications are derived. An identified defect on the EOL can be further classified by deviations already present in the IL test. Deviations that are not present on the IL also indicate processes between the two test stands and thus increase the ability to correctly classify defects on the EOL. If deviations are present on the IL, an indicator of significant testability is derived. This can be further used to accurately detect defects that were previously only detected on the EOL.
{"title":"Enhancing End-of-Line Defect Classifications and Evaluating Early Testability for Inline Test Stands Using NVH Measurements","authors":"J. Bonart, Philipp Hümmer, W. Drossel","doi":"10.1109/EDPC53547.2021.9684212","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684212","url":null,"abstract":"Production lines for electric drives consist of successive assembly steps. The highly integrated topology of the unit can lead to complex faults caused by poor components or incorrect assembly. To minimize the added value of a bad motor, a noise-vibration-harshness (NVH) measurement is performed on an in-line test bench (IL). Following the IL, other components (gearbox, inverter, …) are assembled, resulting in a finished electric drive unit. The final state is again tested by a NVH measurement on an end-of-line (EOL) test bench. A novel approach is presented that combines the results of both test benches into an overall picture, thus creating a contextual environment for the EOL. Depending on the interaction of the two test benches, different implications are derived. An identified defect on the EOL can be further classified by deviations already present in the IL test. Deviations that are not present on the IL also indicate processes between the two test stands and thus increase the ability to correctly classify defects on the EOL. If deviations are present on the IL, an indicator of significant testability is derived. This can be further used to accurately detect defects that were previously only detected on the EOL.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"57 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115656387","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684206
A. Abdallh, L. Vandenbossche, Lisa Lastra
The influence of high mechanical yield strength, low loss electrical steel (ES) grades on the design degree of freedom of interior permanent magnet (IPM) traction motors for electric vehicles is presented. Several ES grades with different electromagnetic and mechanical properties are compared in this investigation. Firstly, the optimal bridge thickness of the V -shaped IPM rotor is obtained by evaluating the von Mises stress at the maximum operating speed using a structural finite element (FE) analysis. Then, the optimal axial length is estimated by means of electromagnetic FE analysis using the mechanically optimized rotor design in order to achieve an equal output mechanical power of the traction motor for all evaluated ES grades. The results show that the ES grades with high mechanical yield strength and low loss adds a degree of freedom in the IPM design. It results in a higher torque density as well as lower magnetic losses in the stator and rotor cores. Hence, it leads to a more compact and lighter motor design that has a significant effect on the motor power losses and consequently on the vehicle drivetrain efficiency.
{"title":"Higher Strength Low Loss Electrical Steels for Improved Design and Performance of Interior Permanent Magnet Traction Motors","authors":"A. Abdallh, L. Vandenbossche, Lisa Lastra","doi":"10.1109/EDPC53547.2021.9684206","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684206","url":null,"abstract":"The influence of high mechanical yield strength, low loss electrical steel (ES) grades on the design degree of freedom of interior permanent magnet (IPM) traction motors for electric vehicles is presented. Several ES grades with different electromagnetic and mechanical properties are compared in this investigation. Firstly, the optimal bridge thickness of the V -shaped IPM rotor is obtained by evaluating the von Mises stress at the maximum operating speed using a structural finite element (FE) analysis. Then, the optimal axial length is estimated by means of electromagnetic FE analysis using the mechanically optimized rotor design in order to achieve an equal output mechanical power of the traction motor for all evaluated ES grades. The results show that the ES grades with high mechanical yield strength and low loss adds a degree of freedom in the IPM design. It results in a higher torque density as well as lower magnetic losses in the stator and rotor cores. Hence, it leads to a more compact and lighter motor design that has a significant effect on the motor power losses and consequently on the vehicle drivetrain efficiency.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"2011 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123928014","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684217
M. Halwas, F. Hoffmann, Philipp Bader, Tom Heyde, M. Doppelbauer, J. Fleischer
The demand for new winding technologies for electric traction drives leads to various winding types. Especially round and rectangular wire windings need to be differentiated: Round wires are advantageous in terms of frequency-dependent losses but possess lower fill factors than the rectangular wire windings. An important issue concerns the thermal conductivity of the winding in the stator slots, particularly when different wire geometries and layer structures are faced. A high thermal conductivity is essential in order to dissipate the generated heat in the windings through the laminated core into the cooling medium. The amount of heat transport out of the windings in the slots determines the continuous and peak power operation in an electrical machine. The practical proof of thermal conductivity at different wire layer structures and its coherences has not yet been investigated in terms of a realistic slot structure. Against this background, a test bench including a slot model and a suitable experimental setup is developed in this paper. Hence, slots with different wire types and layer structures are examined at the test bench and compared to each other. The main influencing factors investigated are the wire geometry, layer structure, compression of the windings and the use of insulation paper. Furthermore, the outcome of the measurements is compared to known analytical lumped circuit slot models. The results of the investigations are intended to give reference points about the realistic differences in the thermal conductivity of different slot structures and can be used to design electrical machines and their production systems. The strength of the influencing factors on thermal conductivity is demonstrated and assessed.
{"title":"Influence of Wire Layer Structures on the Thermal Behavior in Electrical Machine Slots","authors":"M. Halwas, F. Hoffmann, Philipp Bader, Tom Heyde, M. Doppelbauer, J. Fleischer","doi":"10.1109/EDPC53547.2021.9684217","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684217","url":null,"abstract":"The demand for new winding technologies for electric traction drives leads to various winding types. Especially round and rectangular wire windings need to be differentiated: Round wires are advantageous in terms of frequency-dependent losses but possess lower fill factors than the rectangular wire windings. An important issue concerns the thermal conductivity of the winding in the stator slots, particularly when different wire geometries and layer structures are faced. A high thermal conductivity is essential in order to dissipate the generated heat in the windings through the laminated core into the cooling medium. The amount of heat transport out of the windings in the slots determines the continuous and peak power operation in an electrical machine. The practical proof of thermal conductivity at different wire layer structures and its coherences has not yet been investigated in terms of a realistic slot structure. Against this background, a test bench including a slot model and a suitable experimental setup is developed in this paper. Hence, slots with different wire types and layer structures are examined at the test bench and compared to each other. The main influencing factors investigated are the wire geometry, layer structure, compression of the windings and the use of insulation paper. Furthermore, the outcome of the measurements is compared to known analytical lumped circuit slot models. The results of the investigations are intended to give reference points about the realistic differences in the thermal conductivity of different slot structures and can be used to design electrical machines and their production systems. The strength of the influencing factors on thermal conductivity is demonstrated and assessed.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"2 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122230278","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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