Rectangular and Random Conductors: AC Losses Evaluations and Manufacturing Considerations

Eraldo Preci, Giorgio Valente, Anuvav Bardalai, Tommaso Transi, Tianjie Zou, David Gerada, Michele Degano, Giampaolo Buticchi, Christopher Gerada

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

7 Citations (Scopus)

Abstract

This paper presents a comparison between hairpin and random distributed winding in electrical machines for automotive applications. Indeed, the overall performance of an electrical drive system is seriously affected by its winding design. The considered electrical machine has a peak power of 115kW and a maximum operating speed of 12000 rpm. Both cost and manufacturing aspects are here discussed in detail. Two different machine topologies have been investigated and Finite Element Analysis (FEA) results are presented and discussed. Then, the comparison between hairpin and random winding configuration in terms of AC copper losses are presented for the selected geometry. The accurate AC losses estimation can be done by modelling each single conductor. In order to significantly reduce the simulation time, a domain model reduction has been adopted. Based on two different driving cycles, Urban Dynamometer Driving Schedule (UDDS) and Highway Fuel Economy Test (HWFET), the AC losses have been evaluated. It is shown that horizontal pin segmentation can contribute to considerable AC loss reduction.

Original languageEnglish
Title of host publicationProceedings - IECON 2020
Subtitle of host publication46th Annual Conference of the IEEE Industrial Electronics Society
PublisherIEEE Computer Society
Pages1076-1081
Number of pages6
ISBN (Electronic)9781728154145
DOIs
Publication statusPublished - 18 Oct 2020
Event46th Annual Conference of the IEEE Industrial Electronics Society, IECON 2020 - Virtual, Singapore, Singapore
Duration: 19 Oct 202021 Oct 2020

Publication series

NameIECON Proceedings (Industrial Electronics Conference)
Volume2020-October

Conference

Conference46th Annual Conference of the IEEE Industrial Electronics Society, IECON 2020
Country/TerritorySingapore
CityVirtual, Singapore
Period19/10/2021/10/20

Keywords

  • AC losses
  • HWFET
  • UDDS
  • automotive
  • electrical machines
  • hairpin
  • high frequency
  • manufacturing
  • mass production
  • random
  • segmented hairpin
  • winding

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Electrical and Electronic Engineering

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