Advanced Manufacturability of Electrical Machine Architecture through 3D Printing Technology

Machines, Journal Year: 2023, Volume and Issue: 11(9), P. 900 - 900

Published: Sept. 10, 2023

The rapid evolution of electric machines requires innovative approaches to boost performance, efficiency, and sustainability. Additive Manufacturing (AM) has emerged as a transformative technique, reshaping the landscape machine components, ranging from magnetic materials windings extending thermal management. In area materials, AM’s capacity fabricate intricate structures optimizes flux dynamics, yielding advanced shape-profile cores self-coating laminations for superior performance. windings, prowess is evident through concepts, effectively mitigating AC conduction effects while reducing weight. Furthermore, AM revolutionizes management, exemplified by 3D-printed ceramic heat exchangers, cooling channels, novel housing designs, all contributing enhanced efficiency power density. integration not only transcends conventional manufacturing constraints but also promises usher in an era unprecedented innovation, addressing interplay magnetic, winding, dynamics.

Language: Английский

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Innovative 3D Printed Coil and Cooling Designs for Weight-Sensitive Energy-Saving Electrical Machine

IEEE Transactions on Transportation Electrification, Journal Year: 2023, Volume and Issue: 10(3), P. 5282 - 5293

Published: Oct. 6, 2023

The performance of electrical machines is often limited by manufacturability challenges. With the emergence additive manufacturing (AM) technology, new design solutions that were previously impossible using conventional production techniques are becoming applicable. This work addresses novel possibilities in machine windings. Using AM a series 3D-printed coils designed and prototyped for high-power density machines. power losses these measured compared with 3D coil designs combine higher easier manufacturability. Moreover, thermal management concept introduced AM-shaped profile direct cooling channels featuring ridged surfaces. tubes have small grooves or ridges on their surface create indents, which help increase area improve efficiency. dimensions proposed heat exchanger optimized to achieve good balance between current performance. investigation includes identifying suitable materials both can enhance electromagnetic while achieving lightweight structure. Finally, experimental results demonstrate effectiveness approach significant improvements weight reduction. Compared copper coils, has twice carrying capacity only 53% weight.

Language: Английский

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Magnetic properties of as-built and heat treated M789 and M300 maraging steels produced via laser powder bed fusion

Next Materials, Journal Year: 2024, Volume and Issue: 6, P. 100287 - 100287

Published: July 30, 2024

Language: Английский

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Iron Loss Calculation Methods for Numerical Analysis of 3D-Printed Rotating Machines: A Review

Energies, Journal Year: 2023, Volume and Issue: 16(18), P. 6547 - 6547

Published: Sept. 12, 2023

Three-dimensional printing is a promising technology that offers increased freedom to create topologically optimised electrical machine designs with much smaller layer thickness achievable the current, laminated steel-sheet-based technology. These composite materials have magnetic behaviour, which can be competitive current materials. Accurately calculating iron losses challenging due steels’ highly nonlinear hysteretic behaviour. Many numerical methodologies been developed and applied in FEM-based simulations from first introduced Steinmetz formulae. However, these old curve-fitting-based loss models are still actively used modern finite-element solvers their simplicity high computational demand for more-accurate mathematical methods, such as Preisach- or Jiles–Atherton-model-based calculations. In case of 3D-printed machines, where printed material strongly anisotropic behaviour it hard define standardised measurement, applicability limited. The following paper proposes an overview problems solutions calculation measurement discusses designing optimising machines.

Language: Английский

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Examining the Practicality of Mobile-Based Gamification Assessment in Electrical Machine Course: A Study in Industrial Electrical Engineering

Journal of Applied Engineering and Technological Science (JAETS), Journal Year: 2023, Volume and Issue: 5(1), P. 349 - 360

Published: Dec. 10, 2023

Mobile-based gamification learning is increasingly popular for enhancing student interest and motivation in the process, including its application evaluating outcomes. However, practicality of use, from perspective students as users, needs further evaluation. This study aims to assess mobile-based assessment (M-BGA) outcomes Electrical Machine Course (EMC). M-BGA was developed using Kahoot! application. A survey-based quantitative research design employed, Practicality Assessment Instrument (PAI) data collection tool. The evaluated based on assessments after implementation an EMC. involved 83 second-year Industrial Engineering Study Program, Faculty Engineering, Universitas Negeri Padang, Indonesia. results indicate a high level several aspects. Ease Use aspect scored 92.23% (highly practical), Reliability 89.82% Student Engagement 88.55% Learning Impact 90.19% useful). Overall, responses, proved be highly practical can serve alternative approach assessing with innovative approach.

Language: Английский

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Design of Electric Machines Based on Additively Manufactured Lattice Structures

AIAA SCITECH 2022 Forum, Journal Year: 2024, Volume and Issue: unknown

Published: Jan. 4, 2024

Recent developments in additive manufacturing (AM) bring about unprecedented potentials designing and developing electromagnetic components; this paper presents a novel concept for magnetic cores of electric machines based on triply periodic minimal surface (TPMS) lattices the development high specific power efficiency machines. Fabrication TPMS is enabled by uniquely well-suited manufacturing. Compared to additively manufactured bulk cores, lattice can improve performance (a) mitigating eddy current losses thus total through presence large volume distributed internal voids, (b) allowing be operated at higher speeds and/or torques relaxing thermal limits enhanced cooling. In present study, 3D finite element analysis used quantify compare characteristics three representative types with those structure. A functionally graded design, comprising alternating thin layers soft materials electrical insulating materials, subsequently proposed minimize level comparable that conventional laminated over wide range operating frequencies. Finally, conceptual design core synchronous reluctance motor (SynRM), i.e., rotor stator, presented illustrate idea.

Language: Английский

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Frequency- and Temperature-Dependent Uncertainties in Hysteresis Measurements of a 3D-Printed FeSi wt6.5% Material

Sensors, Journal Year: 2024, Volume and Issue: 24(9), P. 2738 - 2738

Published: April 25, 2024

Additive manufacturing of soft magnetic materials is a promising technology for creating topologically optimized electrical machines. High-performance machines can be made from high-silicon-content FeSi alloys. Fe-6.5wt%Si material has exceptional properties; however, this steel with the classical cold rolling methodology not possible due to brittleness material. Laser powder bed fusion (L-PBF) offers solution problem. Finding optimal printing parameters challenging task. Nevertheless, it crucial resolve created so they used in commercial applications. The temperature dependence hysteresis properties presented paper. were examined 20 °C 120 °C. measurements by precision current generator–based measurement tool, which uses fast Fourier transformation–based filtering techniques increase accuracy measurements. details applied scalar sensor and uncertainties discussed first paper; then, three characteristic points static curve ten L-PBF-manufactured identical toroidal cores investigated compared at different temperatures. These show that, despite volumetric ratio porosities being below 0.5%, mean crack length samples significant samples. small defects cause 5% decrement some values curve.

Language: Английский

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Enhancing measurement efficiency for 3D printed magnet through radial basis function interpolation

Journal of Magnetism and Magnetic Materials, Journal Year: 2024, Volume and Issue: 602, P. 172192 - 172192

Published: May 29, 2024

Language: Английский

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Design and additive manufacturing of a lightweight aerospace electric actuator

Open Research Europe, Journal Year: 2024, Volume and Issue: 4, P. 121 - 121

Published: June 21, 2024

Background The ambitious electrification targets set for the aeronautical sector are leading to a thorough research into improving performance of different electromechanical components. In this regard, Additive Manufacturing is gaining strength due positive physical properties processed parts and freedom in manufacturable geometries. Methods Thus, article presents design an electric actuator aerospace active sidestick which used with aim minimising weight power consumption device. electromagnetic detailed, considering 8 permanent magnet machine topologies, mechanical applying Topology Optimisation reduce overall component carried out. Results Three prototypes involving rotor, stator casing manufactured via Laser Powder Bed Fusion stainless steel Permendur (Fe49Co49V2) corresponding actuators experimentally tested, showing great agreement between tests simulations excellent repeatability behaviour prototypes. Conclusions results highlight potential manufacture functional electrical components.

Language: Английский

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Final Technical Report: Manufacturing and Additive Design of Electric Machines by 3D Printing (MADE3D)

Published: Dec. 11, 2024

As the U.S clean energy transition hinges on growth of offshore wind, this is expected to be a major driver for innovations in manufacturing, material and design advancements enable robust cost-competitive wind turbines. The race build larger taller turbines rated 10 megawatts (MW) beyond, has intensified pressure OEMs terms logistics handling transporting large components, securing critical raw as well scaling up necessary domestic production infrastructure meet demand. There increased interest building lightweight, more efficient, high-power dense drivetrains that will ease burden installation, minimize demand, increasing sourceability. Despite good efficiency reliability, existing drivetrain technologies such direct-drive permanent magnet generators are heavy (> 300 tons), expensive, often rely quantities rare-earth magnets (PMs), steel copper. Existing manufacturing techniques lightweighting time intensive, result complex topologies difficult manufacture wastage. Substantial needed improve their scalability. MADE3D project led by National Renewable Energy Laboratory partnership with Oak Ridge (ORNL) NASA Glenn Research Center aimed at advancing next generation lightweight turbine potential reduce demand materials than 25% designs multimaterial additive (AM). part project, new capabilities were developed every component generator, including magnetic core packs reduced rare earth content. Electrical conductors insulation, structural/mechanical components designed built collaboration small original equipment manufacturer (OEM), Bergey Windpower Company. NREL development electric machine toolsets (topology optimization shape techniques) magnets, electrical core, used radial flux synchronous generators. methods space exploration 15-MW generator 15-kW commercial generator. ORNL investigated feasibility Fe3.0Si Fe6.0Si candidate laminate rotor selective laser melting. New insert molding technique was extrusion-based printing processes polymer bonded composite made from SmFeN Dy-free NdFeB steel. researchers advanced direct-ink write approach both insulation achieve 70% fill factor beneficial achieving high power densities. tools through anticipated provide opportunities next-generation generators, alleviate pressures supply chain, create eliminate multiple processes, wastage exploring novel optimized enabled via 3D printing.

Language: Английский

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