Reducing Embedded Emissions from Electrical Machines

The urgent need to reduce CO₂ emissions has prompted industry to prioritise performance and efficiency improvements. Although significant progress has been made in thermal and electromagnetic optimisation, the carbon footprint of material selection and manufacturing processes remains an under-explored area. This study proposes a novel way from materials CO2 aspect to reduce embedded carbon emissions for a wound-field synchronous machine (WFSM). A structured material selection framework is applied to both active and passive components, with particular attention paid to end brackets, housing, and the fan, components that are often overlooked in carbon reduction studies. Composite materials are evaluated alongside traditional metals for passive structural parts. Finite element analysis (FEA) is used to evaluate the mechanical performance of the proposed designs in terms of stress and safety factors. The redesigned machine achieves a 35.4% reduction in embedded CO₂ emissions and a 35.0% decrease in total mass. This demonstrates that substantial environmental gains can be achieved without compromising structural integrity. These findings underscore the significance of selecting sustainable materials in designing low-carbon electrical machines.