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Before going into detailed design of an electrical machine some assumptions or estimations are often sufficient. One aspect is the winding layout and the copper filling factor. For a rapid approach this article presents an algorithm for the filling factor calculation for random wound windings. Based on the geometry of the slot the maximum number of wires per slot is calculated for different magnet...
This paper addresses the key technical issues related to the design of a mass producible optimized BLDC drive for high pressure and dynamic automotive pump applications. The focus is on the electromechanical design of such a device for electro hydraulic suspension systems and other high pressure automotive pumps for the new 48V automotive standard for auxiliary drives. The motor comprises a fully...
In rotary converter generation system (RCGS), power conditioning system (PCS) rotate with rotor and power modules, which are critical components in PCS, are subjected to cyclic acceleration loading. The aim of this study was to predict the fatigue strength of power modules under acceleration loading. We analyzed this fatigue strength using finite element analysis and predetermined fatigue lifetime...
This paper presents a comparison of the thermal properties between infiltrated and non-infiltrated copper windings. The focus is on thermal conductivity in the radial direction on the winding. The samples have a fill factor above 65 % due to the manufacturing method of the samples. Samples are produced and measured with the transient plane source technique and then compared to FEM simulations and...
The goal of this paper is to describe the materials and building technique to design a high-temperature induction machine which temperature winding is about 500°C. First, the candidate materials are identified and because of the constraints imposed by these materials, a special geometry is proposed. The authors show that inorganic insulation has to be preferred for the conductors and the slot insulation...
This paper discusses the design procedure of a super high speed permanent magnet synchronous machine. A 3kW radial PMSM designed for operation up to 150,000 r/min is proposed in the paper. Thanks to the super high speed, the designed motor can achieve high energy density at 2.5 kW/kg(housing weight included) and efficiency is over 97%. The super high speed brings challenges both on electrical design...
High speed electric machines have been widely used in many applications nowadays and are gaining more attention. However, many special design challenges exist for HSEMs. This paper aims to discuss major challenges and design considerations for HSEMs. Four different loss components of high speed design are discussed and the methods to reduce each loss component are elaborated. Bearing options for HSEMs...
The paper studies potentials and limits of permanent magnet machines with toroidal windings in high speed applications. Three designs in different applications are used as test cases. The analyses based on analytical and FE models illustrate both merits and weaknesses of toroidally-wound machines that have not been addressed in literature. Strong external leakage of the armature field leads to relatively...
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