Direct thermal management of windings enabled by additive manufacturing

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dc.contributor.authorSimpson, Nick
dc.contributor.authorYiannakou, Georgios
dc.contributor.authorFelton, Harry
dc.contributor.authorRobinson, John
dc.contributor.authorArjunan, Arun
dc.contributor.authorMellor, Philip
dc.date.accessioned2022-10-03T10:39:57Z
dc.date.available2022-10-03T10:39:57Z
dc.date.issued2022-09-27
dc.date.updated2022-09-29T16:11:49Z
dc.descriptionThis is an accepted manuscript of an article published by IEEE in IEEE Transactions on Industry Applications on 27/09/2022, available online: https://doi.org/10.1109/TIA.2022.3209171 The accepted version of the publication may differ from the final published version.en
dc.description.abstractThe electrification and hybridization of ground- and air-transport, in pursuit of Carbon Net Zero targets, is driving demand for high power-density electrical machines. The power-density and reliability of electrical machines is ultimately limited by their ability to dissipate internally generated losses within the temperature constraints of the electrical insulation system. As the electrical windings are typically the dominant source of loss, their enhanced design is in the critical path to improvements in power-density. Application of metal additive manufacturing has the potential to disrupt conventional winding design by removing restrictions on conductor profiles, topologies and embedded thermal management. In this paper, a modular end-winding heat exchanger concept is presented, which enables effective direct cooling without occupying valuable stator slot cross-section. In addition, this arrangement eliminates the need for a good stator-winding thermal interface, thereby allowing mechanical or other less permanent winding retention methods to be used, facilitating non-destructive disassembly and repair. A prototype winding is fabricated and experimentally tested to demonstrate the feasibility of the concept, yielding promising results.en
dc.description.sponsorshipThis work has been funded by EPSRC Grant Number EP/f02125X/1 and EP/S018034/1 as part of a Future Electrical Machines Manufacturing (FEMM) Hub feasibility study.en
dc.description.versionPublished version
dc.formatapplication/pdfen
dc.identifier.citationN. Simpson, G. Yiannakou, H. Felton, J. Robinson, A. Arjunan and P. H. Mellor (2022) Direct Thermal Management of Windings enabled by Additive Manufacturing," in IEEE Transactions on Industry Applications, 59(2), pp. 1319-1327 doi: 10.1109/TIA.2022.3209171.en
dc.identifier.doi10.1109/tia.2022.3209171en
dc.identifier.eissn1939-9367
dc.identifier.journalIEEE Transactions on Industry Applicationsen
dc.identifier.urihttp://hdl.handle.net/2436/624949
dc.language.isoenen
dc.publisherInstitute of Electrical and Electronics Engineersen
dc.relation.urlhttps://ieeexplore.ieee.org/document/9904302en
dc.source.beginpage1
dc.source.beginpage1319
dc.source.endpage9
dc.source.endpage1327
dc.source.issue2
dc.source.volume59
dc.subjectadditive manufacturingen
dc.subjectelectrical machinesen
dc.subjectthermal managementen
dc.subjecthigh power densityen
dc.subjectwinding designen
dc.titleDirect thermal management of windings enabled by additive manufacturingen
dc.typeJournal articleen
refterms.dateFCD2022-09-30T08:12:01Z
refterms.dateFOA2022-10-03T10:39:58Z
refterms.versionFCDAM
rioxxterms.funderEPSRCen
rioxxterms.identifier.projectEP/f02125X/1en
rioxxterms.licenseref.startdate2022-10-03en
rioxxterms.licenseref.urihttps://creativecommons.org/licenses/by/4.0/
rioxxterms.versionAMen
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