AC losses reduction in Hairpin Windings produced via Additive Manufacturing

R. Notari, M. Pastura, S. Nuzzo, D. Barater, G. Franceschini, C. Gerada

Research output: Chapter in Book/Conference proceedingConference contributionpeer-review

Abstract

One of the key challenges of hairpin windings is the reduction of their high losses at high-frequency operations. Hairpin layouts comprising conductors with variable cross sections have proven good loss performance in previous studies. However, they come at the cost of significant manufacturing complications.The aim of this work is to design hairpin layouts featuring reduced losses compared to classical configurations, exploiting the flexibility enabled by additive manufacturing. In this context, the choice of a proper material with relatively high conductivity and low ecological impact plays an important role. Hence, this article first presents an overview of materials that can be used for the winding additive manufacturing, aiming to select the most suitable one for the application at hand. Then, the loss performance is evaluated and compared against classical copper hairpins. The results demonstrate that opportunely selected alloys featuring asymmetric configurations can compete against classical hairpin windings.

Original languageEnglish
Title of host publication2022 International Conference on Electrical Machines, ICEM 2022
PublisherInstitute of Electrical and Electronics Engineers Inc.
Pages1144-1149
Number of pages6
ISBN (Electronic)9781665414326
DOIs
Publication statusPublished - 2022
Event2022 International Conference on Electrical Machines, ICEM 2022 - Valencia, Spain
Duration: 5 Sep 20228 Sep 2022

Publication series

Name2022 International Conference on Electrical Machines, ICEM 2022

Conference

Conference2022 International Conference on Electrical Machines, ICEM 2022
Country/TerritorySpain
CityValencia
Period5/09/228/09/22

Keywords

  • AC losses
  • Additive Manufacturing
  • Aluminium Hairpins
  • Asymmetric windings
  • Hairpin

ASJC Scopus subject areas

  • Electrical and Electronic Engineering
  • Mechanical Engineering

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