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High performance electrical machine operation is limited by the losses generated in the machine and how well the heat developed by these losses is extracted. For conductive heat transfer from the main winding body, the insulation materials provide the main heat transfer pathway. As a machine ages through its lifetime, these materials will change their properties, and therefore these heat transfer...
Design optimisation of electromagnetic devices is strongly affected by thermal behaviour. In order to check whether thermal limitations are exceeded, one has to accurately evaluate the loss generated for each working condition using an electromagnetic model, and feed it to a thermal model. Using the two models in a sequential manner, however, can lead to an error in the loss estimation. Moreover,...
In this paper a computationally efficient high-fidelity multi-physics design tool applicable to E-core power inductors is developed. The tool is composed of 2-D electromagnetic and 3-D thermal finite analyses coupled to models for inductor core and winding loss. The models are fully parametrically defined and appear as a black-box problem which can be used to perform parameter studies or design optimisation...
A methodology is proposed whereby performing a series of tests on a stator/winding subassembly can estimate the thermal envelope of a modular-wound single-layer machine topology. Concentrated windings offer many advantages, such as reduced manufacturing costs, improved thermal performance and readily lend themselves to fault-tolerant designs. Single-layer modular windings have inherent magnetic, thermal...
This paper presents an iterative coupled electromagnetic and thermal design methodology applied to a short-duty high-force-density permanent magnet tubular linear actuator. A difficulty with such coupled methodologies is balancing the accuracy of the modelling methods with the computation time. This problem is often addressed by employing a relatively detailed electromagnetic model and a coarse low...
This paper presents an investigation into proximity losses in end-windings informed from the 3D finite element analysis of an ac power inductor. The proximity effect in winding conductors is a result of circulating ac currents caused by magnetic fields generated by nearby conductors. The calculated results confirm that the effects within the end-winding whist significant are lower compared to those...
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