Pub Date : 2021-12-07DOI: 10.1109/EDPC53547.2021.9684214
N. Urban, M. Masuch, Jan Paduch, J. Franke
Additive manufacturing (AM) is a primary forming technology that makes it possible to produce previously impossible geometries and tailored properties by selectively adding material to a workpiece under computer control. For small to medium quantities, the processes grouped under this technology are already established in the industry. Metals are often processed by laser powder bed fusion (PBF- LB/M). With PBF- LB/M, different powder materials can be processed with identical system equipment. With the successive spread of this production technology, the processing of functional materials in the electro-mechanical-engineering industry is increasingly becoming the focus of interest for users. The processing of copper by PBF - LB/M is already state of the art. Soft magnetic materials are currently the subject of research work, and promising results have already been published. The realization of components that provide lowest possible energy losses is also of decisive importance in the context of electromagnetic energy converters. According to the state of the art, multi-material systems of metal and polymer or ceramic, as used for the conventional design of sheet metal packages or soft magnetic composites (SMC) cores, cannot be processed on PBF-LB/M systems. As an alternative, area-filling structures, which cannot be produced conventionally, are known to reduce losses. By including thin non-consolidated areas inside the workpiece, eddy current paths can be interrupted and losses reduced. Initial studies on this show promising potential. In this publication, different area-filling patterns are numerically evaluated based on the eddy current density in the sample crosssection. However, PBF -LB/M-specific manufacturing influences, such as welding through thin powder layers, prevent the direct transfer of the numerical investigations into practice. Therefore, a comparison is made in experimental studies, which qualitatively confirm the findings and provide promising approaches for loss reduction.
{"title":"An Approach to Eddy Current Reduction in Laser Powder Bed Fused High Silicon Steel Considering Manufacturing Influences","authors":"N. Urban, M. Masuch, Jan Paduch, J. Franke","doi":"10.1109/EDPC53547.2021.9684214","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684214","url":null,"abstract":"Additive manufacturing (AM) is a primary forming technology that makes it possible to produce previously impossible geometries and tailored properties by selectively adding material to a workpiece under computer control. For small to medium quantities, the processes grouped under this technology are already established in the industry. Metals are often processed by laser powder bed fusion (PBF- LB/M). With PBF- LB/M, different powder materials can be processed with identical system equipment. With the successive spread of this production technology, the processing of functional materials in the electro-mechanical-engineering industry is increasingly becoming the focus of interest for users. The processing of copper by PBF - LB/M is already state of the art. Soft magnetic materials are currently the subject of research work, and promising results have already been published. The realization of components that provide lowest possible energy losses is also of decisive importance in the context of electromagnetic energy converters. According to the state of the art, multi-material systems of metal and polymer or ceramic, as used for the conventional design of sheet metal packages or soft magnetic composites (SMC) cores, cannot be processed on PBF-LB/M systems. As an alternative, area-filling structures, which cannot be produced conventionally, are known to reduce losses. By including thin non-consolidated areas inside the workpiece, eddy current paths can be interrupted and losses reduced. Initial studies on this show promising potential. In this publication, different area-filling patterns are numerically evaluated based on the eddy current density in the sample crosssection. However, PBF -LB/M-specific manufacturing influences, such as welding through thin powder layers, prevent the direct transfer of the numerical investigations into practice. Therefore, a comparison is made in experimental studies, which qualitatively confirm the findings and provide promising approaches for loss reduction.","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":"127136274","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/EDPC53547.2021.9684200
Linda Schlesinger, Ján Koller, O. Oechsle, Paul Molenda
Global waste expects to grow up to 3.4 billion tons by 2050, and the world is only 8.6 % circular; thus, our way of life is not sustainable. Therefore, society should move from the take--make--dispose principle towards a circular economy by optimizing resource consumption and reducing waste. Remanufacturing is a business model that enables the transformation by developing a circular economy in industrial companies. The remanufacturing process chain consists of disassembling, cleaning, sorting and inspection, reconditioning and reassembling. It extends the life cycle of products and reduces the use of new materials, energy consumption, costs, carbon dioxide emissions, landfill costs and waste compared to manufacturing new products. Due to the upcoming changes and transitions in the mobility sector focusing on electric drive systems, the circularity of their components will become a crucial lever for sustainability. An appropriate remanufacturing strategy is essential and enables manufacturer of electric drive systems to develop and implement sustainable remanufacturing. This paper presents a five-step implementation strategy for remanufacturing of e-mobility components. The five-step strategy includes Product Analysis, Market Research, Remanufacturing Technology Analysis, Remanufacturing Process Design and Business Models. This enables the implementation of a sustainable and market oriented business model in the e-mobility aftermarket.
{"title":"Remanufacturing of E-mobility Components - Five-Step Implementation Strategy to increase Sustainability within Circular Economy","authors":"Linda Schlesinger, Ján Koller, O. Oechsle, Paul Molenda","doi":"10.1109/EDPC53547.2021.9684200","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684200","url":null,"abstract":"Global waste expects to grow up to 3.4 billion tons by 2050, and the world is only 8.6 % circular; thus, our way of life is not sustainable. Therefore, society should move from the take--make--dispose principle towards a circular economy by optimizing resource consumption and reducing waste. Remanufacturing is a business model that enables the transformation by developing a circular economy in industrial companies. The remanufacturing process chain consists of disassembling, cleaning, sorting and inspection, reconditioning and reassembling. It extends the life cycle of products and reduces the use of new materials, energy consumption, costs, carbon dioxide emissions, landfill costs and waste compared to manufacturing new products. Due to the upcoming changes and transitions in the mobility sector focusing on electric drive systems, the circularity of their components will become a crucial lever for sustainability. An appropriate remanufacturing strategy is essential and enables manufacturer of electric drive systems to develop and implement sustainable remanufacturing. This paper presents a five-step implementation strategy for remanufacturing of e-mobility components. The five-step strategy includes Product Analysis, Market Research, Remanufacturing Technology Analysis, Remanufacturing Process Design and Business Models. This enables the implementation of a sustainable and market oriented business model in the e-mobility aftermarket.","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":"125925481","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/EDPC53547.2021.9684198
Xinjun Liu, Christian Bentheimer, F. Hilpert, M. Hofmann, B. Eckardt, M. Maerz
Reliable and high power density electric machine and inverter solutions are essential for a variety of applications. Digital twin for future electric aircraft applications can contribute to analyze the system behavior and the effects between the fast-switching inverter and the electric machine. Within this paper, the concept of a “Digital Twin for a 10 MW Electrical Drive System for Future Electric Aircraft Application” is presented. A digital twin platform is based on an outer-rotor permanent magnet synchronous machine and serval interleaved multi-level SiC-inverters, which allows the usage of high switching frequencies and a high DC link voltage of 1500 V. The combination of those components have advantages in future electric aircraft applications. Several multi-level inverter topologies have been investigated and a first system design for a 10.5 MW inverter system is presented. Industry 4.0 Applications in Electric Drives Production
{"title":"Digital Twin for a 10 MW Electrical Drive System for Future Electric Aircraft Applications","authors":"Xinjun Liu, Christian Bentheimer, F. Hilpert, M. Hofmann, B. Eckardt, M. Maerz","doi":"10.1109/EDPC53547.2021.9684198","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684198","url":null,"abstract":"Reliable and high power density electric machine and inverter solutions are essential for a variety of applications. Digital twin for future electric aircraft applications can contribute to analyze the system behavior and the effects between the fast-switching inverter and the electric machine. Within this paper, the concept of a “Digital Twin for a 10 MW Electrical Drive System for Future Electric Aircraft Application” is presented. A digital twin platform is based on an outer-rotor permanent magnet synchronous machine and serval interleaved multi-level SiC-inverters, which allows the usage of high switching frequencies and a high DC link voltage of 1500 V. The combination of those components have advantages in future electric aircraft applications. Several multi-level inverter topologies have been investigated and a first system design for a 10.5 MW inverter system is presented. Industry 4.0 Applications in Electric Drives Production","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"70 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":"122217988","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/EDPC53547.2021.9684226
S. Reuter, T. Sorg, Johannes Liebertseder, M. Doppelbauer
In the project GehMo a motor concept with an internal cooling concept, based on a concentrated winding, was developed. The key elements of the development are presented in this paper. The focus points of the motor development were put on simple manufacturing and exploiting all advantages of the internal cooling concept. Simulative structural investigations proved that the stator could act as a load-bearing element and therefore no housing is necessary to ensure the functionality of the motor. This approach reduces the number of parts and reduces the weight. Through optimization by computational fluid dynamics simulation, the pressure loss of the internal cooling channels is brought to a level similar to that of a conventional external cooling sleeve, despite the smaller cross-section of the internal cooling channels. The production of the plastic overmolding of the stator was carried out on an injection molding machine. Its design and detailed technical solutions are presented in this paper. First prototypes of the motor were produced. The quality of the prototypes is analyzed, and the manufacturing process is evaluated.
{"title":"Design and Evaluation of a Houseless High-Performance Machine with Thermoset Molded Internal Cooling","authors":"S. Reuter, T. Sorg, Johannes Liebertseder, M. Doppelbauer","doi":"10.1109/EDPC53547.2021.9684226","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684226","url":null,"abstract":"In the project GehMo a motor concept with an internal cooling concept, based on a concentrated winding, was developed. The key elements of the development are presented in this paper. The focus points of the motor development were put on simple manufacturing and exploiting all advantages of the internal cooling concept. Simulative structural investigations proved that the stator could act as a load-bearing element and therefore no housing is necessary to ensure the functionality of the motor. This approach reduces the number of parts and reduces the weight. Through optimization by computational fluid dynamics simulation, the pressure loss of the internal cooling channels is brought to a level similar to that of a conventional external cooling sleeve, despite the smaller cross-section of the internal cooling channels. The production of the plastic overmolding of the stator was carried out on an injection molding machine. Its design and detailed technical solutions are presented in this paper. First prototypes of the motor were produced. The quality of the prototypes is analyzed, and the manufacturing process is evaluated.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"25 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":"134280541","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/EDPC53547.2021.9684194
Tim Raffin, A. Mayr, Jonathan Fuchs, Marcel Baader, Andreas Morello, A. Kühl, J. Franke
Data-driven technologies such as machine learning promise great potentials for electric drives production. However, present information systems do not allow flexible and reliable accumulation of high-dimensional data such as images and time series, so feature-rich data are often discarded in practice. The advent of edge computing and microservice-based software architectures in recent years enables low latencies, high data integrity, and flexibility towards different communication protocols, thus offering new possibilities to accumulate data in a manufacturing environment. Hence, this paper proposes a microservice architecture deployed on the edge that serves as a communication layer between data sources and downstream data analytics capabilities. The architecture's flexibility is demonstrated and validated on different process steps along the process chain of hairpin stator production. In conclusion, the developed microservice architecture is suitable for reliable data acquisition at the edge and can enable subsequent machine learning analyses across the process chain.
{"title":"A Microservice-Based Architecture for Flexible Data Acquisition at the Edge in the Context of Hairpin Stator Production","authors":"Tim Raffin, A. Mayr, Jonathan Fuchs, Marcel Baader, Andreas Morello, A. Kühl, J. Franke","doi":"10.1109/EDPC53547.2021.9684194","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684194","url":null,"abstract":"Data-driven technologies such as machine learning promise great potentials for electric drives production. However, present information systems do not allow flexible and reliable accumulation of high-dimensional data such as images and time series, so feature-rich data are often discarded in practice. The advent of edge computing and microservice-based software architectures in recent years enables low latencies, high data integrity, and flexibility towards different communication protocols, thus offering new possibilities to accumulate data in a manufacturing environment. Hence, this paper proposes a microservice architecture deployed on the edge that serves as a communication layer between data sources and downstream data analytics capabilities. The architecture's flexibility is demonstrated and validated on different process steps along the process chain of hairpin stator production. In conclusion, the developed microservice architecture is suitable for reliable data acquisition at the edge and can enable subsequent machine learning analyses across the process chain.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"43 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":"127342576","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/EDPC53547.2021.9684195
H. Schillingmann, S. Gehler, M. Henke
This paper analyzes different electric machines considering sustainable and resource-efficient production using a life cycle assessment (LCA) in the European area (RER) and in the rest of the world area (RoW). Four machines are considered, the induction machine (IM), the externally excited synchronous machine (EESM), the permanent magnet synchronous machine (PMSM), and the synchronous reluctance machine (SynRM), each with an output power of 100 kW. This paper examines these three-phase machines on the basis of their material composition and classifies their needs for raw materials into critical and non-critical materials. The researchers used the Umberto LCA+ program to simulate a LCA for each machine based on the ReCiPe method and to calculate each machine's global warming potential (GWP). The ReCiPe method shows the damage caused during manufacturing to ecosystem quality, human health, and resource availability The GWP method maps the effect of individual manufacturing phases on emissions of CO2 and other greenhouse gases. The researchers' methodology yielded an overall environmental impact for each machine in its each of its individual manufacturing phases.
{"title":"Life cycle assessment of electrical machine production considering resource requirements and sustainability","authors":"H. Schillingmann, S. Gehler, M. Henke","doi":"10.1109/EDPC53547.2021.9684195","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684195","url":null,"abstract":"This paper analyzes different electric machines considering sustainable and resource-efficient production using a life cycle assessment (LCA) in the European area (RER) and in the rest of the world area (RoW). Four machines are considered, the induction machine (IM), the externally excited synchronous machine (EESM), the permanent magnet synchronous machine (PMSM), and the synchronous reluctance machine (SynRM), each with an output power of 100 kW. This paper examines these three-phase machines on the basis of their material composition and classifies their needs for raw materials into critical and non-critical materials. The researchers used the Umberto LCA+ program to simulate a LCA for each machine based on the ReCiPe method and to calculate each machine's global warming potential (GWP). The ReCiPe method shows the damage caused during manufacturing to ecosystem quality, human health, and resource availability The GWP method maps the effect of individual manufacturing phases on emissions of CO2 and other greenhouse gases. The researchers' methodology yielded an overall environmental impact for each machine in its each of its individual manufacturing phases.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"51 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":"127670486","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/EDPC53547.2021.9684215
Alena Babl, M. Bach, K. Schubert, D. Gerling, V. Kräusel, M. Gedan‐Smolka
In the wake of the Paris Climate Agreement and the world wide obligation to reduce CO2 emissions, products and their manufacturing processes must be optimized in order to reduce resource consumption. This particularly concerns the topic of electric drives and machines. Regarding machines, one possibility to achieve this goal is the use of so-called flux barriers. This working concept offers further possibilities for structural optimization, such as radial lamination of the sheets, which then allows the use of grain-oriented electrical steel. Both mentioned principles increase the efficiency of the machine to a high degree and reduce manufacturing costs, as the iron losses are lessened and the material utilization is raised. This paper presents recent investigations of the use of grain-oriented electrical steel sheets for novel, radially laminated stators for electric motors with concentrated windings and flux barriers. The focus is on the analysis of the electromagnetic properties of the electrical sheets before and after forming, their coating and the operating characteristics of the planned demonstrator machine. Recent findings in the area of the technical implementation of the demonstrator machine and its electromagnetic design with the aid of FEM simulation are presented. Furthermore, challenges are evaluated with regard to eddy currents that arise due the innovative design. Finally, recommendations for further proceeding are derived and the next steps are explained.
{"title":"Current Insights into the Investigations on a New Motor Principle with Radially Laminated Stator Sheets, Concentrated Windings and Flux Barriers","authors":"Alena Babl, M. Bach, K. Schubert, D. Gerling, V. Kräusel, M. Gedan‐Smolka","doi":"10.1109/EDPC53547.2021.9684215","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684215","url":null,"abstract":"In the wake of the Paris Climate Agreement and the world wide obligation to reduce CO2 emissions, products and their manufacturing processes must be optimized in order to reduce resource consumption. This particularly concerns the topic of electric drives and machines. Regarding machines, one possibility to achieve this goal is the use of so-called flux barriers. This working concept offers further possibilities for structural optimization, such as radial lamination of the sheets, which then allows the use of grain-oriented electrical steel. Both mentioned principles increase the efficiency of the machine to a high degree and reduce manufacturing costs, as the iron losses are lessened and the material utilization is raised. This paper presents recent investigations of the use of grain-oriented electrical steel sheets for novel, radially laminated stators for electric motors with concentrated windings and flux barriers. The focus is on the analysis of the electromagnetic properties of the electrical sheets before and after forming, their coating and the operating characteristics of the planned demonstrator machine. Recent findings in the area of the technical implementation of the demonstrator machine and its electromagnetic design with the aid of FEM simulation are presented. Furthermore, challenges are evaluated with regard to eddy currents that arise due the innovative design. Finally, recommendations for further proceeding are derived and the next steps are explained.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"13 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":"129886234","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/EDPC53547.2021.9684210
Marcel Baader, A. Mayr, Tim Raffin, J. Selzam, A. Kühl, J. Franke
Optical coherence tomography (OCT) is increasingly being used to monitor and control laser-based welding processes. With the ability to provide pre-, in-, and post-process data, OCT represents a holistic sensor solution for advanced process monitoring and seam tracking. A prospective field of application is the laser welding of rectangular copper wires for so-called hairpin stators as used in electric traction motors. For each stator, a large number of high-quality contact points must be welded in a short cycle time. The quality of a weld not only depends on the laser welding process itself but also on possible manufacturing deviations from upstream process steps. Although OCT seems promising for pre-, in-, and post-process monitoring, no scientific studies exist to date concerning hairpin welding. Starting from a profound presentation of the necessary basics, this paper outlines the potentials of OCT in laser welding of hairpin windings based on first experiments. Regarding pre-process monitoring, it is shown which deviations can be detected by OCT even before the process. Analogously, the post-process monitoring feature can be used to evaluate the resulting weld shape. Further experiments explore whether in-process OCT data can be used to determine the keyhole depth during welding, providing an estimate of the welding depth. The welding of hairpins requires complex beamlines and high focus speeds, which pose high challenges to existing OCT systems. Therefore, the proof is first provided for a simplified welding task before it is performed for the hairpin use case. From the findings gained, the need for action for future research activities is derived, primarily focusing on enabling the OCT -based in-process monitoring for the hairpin welding.
{"title":"Potentials of Optical Coherence Tomography for Process Monitoring in Laser Welding of Hairpin Windings","authors":"Marcel Baader, A. Mayr, Tim Raffin, J. Selzam, A. Kühl, J. Franke","doi":"10.1109/EDPC53547.2021.9684210","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684210","url":null,"abstract":"Optical coherence tomography (OCT) is increasingly being used to monitor and control laser-based welding processes. With the ability to provide pre-, in-, and post-process data, OCT represents a holistic sensor solution for advanced process monitoring and seam tracking. A prospective field of application is the laser welding of rectangular copper wires for so-called hairpin stators as used in electric traction motors. For each stator, a large number of high-quality contact points must be welded in a short cycle time. The quality of a weld not only depends on the laser welding process itself but also on possible manufacturing deviations from upstream process steps. Although OCT seems promising for pre-, in-, and post-process monitoring, no scientific studies exist to date concerning hairpin welding. Starting from a profound presentation of the necessary basics, this paper outlines the potentials of OCT in laser welding of hairpin windings based on first experiments. Regarding pre-process monitoring, it is shown which deviations can be detected by OCT even before the process. Analogously, the post-process monitoring feature can be used to evaluate the resulting weld shape. Further experiments explore whether in-process OCT data can be used to determine the keyhole depth during welding, providing an estimate of the welding depth. The welding of hairpins requires complex beamlines and high focus speeds, which pose high challenges to existing OCT systems. Therefore, the proof is first provided for a simplified welding task before it is performed for the hairpin use case. From the findings gained, the need for action for future research activities is derived, primarily focusing on enabling the OCT -based in-process monitoring for the hairpin welding.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"27 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":"122604620","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/EDPC53547.2021.9684197
N. Erd, A. Binder
The mechanical design and manufacturing process of a high-torque, outer rotor PMSM with tooth-coil winding and solid rotor yoke is presented. Throughout the design process the principle of modularisation is applied for efficient construction of this rather large machine in the context of university equipment and workshops.
{"title":"Design and Manufacturing of a High Torque PMSM with Tooth-Coil Winding and Solid Rotor Yoke","authors":"N. Erd, A. Binder","doi":"10.1109/EDPC53547.2021.9684197","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684197","url":null,"abstract":"The mechanical design and manufacturing process of a high-torque, outer rotor PMSM with tooth-coil winding and solid rotor yoke is presented. Throughout the design process the principle of modularisation is applied for efficient construction of this rather large machine in the context of university equipment and workshops.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"16 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":"116251729","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/EDPC53547.2021.9684208
P. S. Ghahfarokhi, Andrejs Podgornovs, A. M. Marques Cardoso, A. Kallaste, A. Belahcen, T. Vaimann
This paper investigates the hairpin winding configuration as a solution to increase the power density of electric vehicle motors by enhancing the slot filling factor. Moreover, the paper presents various manufacturing techniques of this winding and describes it in detail. Further, it provides a novel additive manufacturing method as an alternative option for conventional production methods to mitigate AC losses using flat rectangular conductors in hairpin winding rods. Following the proper connection of conductors in parallel paths is considered, and the essential rules for this purpose are described. Finally, the analytical and numerical approaches for calculating AC copper losses and the AC loss factor are presented in detail.
{"title":"Hairpin Windings Manufacturing, Design, and AC Losses Analysis Approaches for Electric Vehicle Motors","authors":"P. S. Ghahfarokhi, Andrejs Podgornovs, A. M. Marques Cardoso, A. Kallaste, A. Belahcen, T. Vaimann","doi":"10.1109/EDPC53547.2021.9684208","DOIUrl":"https://doi.org/10.1109/EDPC53547.2021.9684208","url":null,"abstract":"This paper investigates the hairpin winding configuration as a solution to increase the power density of electric vehicle motors by enhancing the slot filling factor. Moreover, the paper presents various manufacturing techniques of this winding and describes it in detail. Further, it provides a novel additive manufacturing method as an alternative option for conventional production methods to mitigate AC losses using flat rectangular conductors in hairpin winding rods. Following the proper connection of conductors in parallel paths is considered, and the essential rules for this purpose are described. Finally, the analytical and numerical approaches for calculating AC copper losses and the AC loss factor are presented in detail.","PeriodicalId":350594,"journal":{"name":"2021 11th International Electric Drives Production Conference (EDPC)","volume":"8 8","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-12-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114007016","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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