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Rectangular and Random Conductors: AC Losses Evaluations and Manufacturing Considerations

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

Rectangular and Random Conductors: AC Losses Evaluations and Manufacturing Considerations Thumbnail


Authors

Eraldo Preci

Giorgio Valente

Anuvav Bardalai

Tommaso Transi

Giampaolo Buticchi



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.

Citation

Preci, E., Valente, G., Bardalai, A., Transi, T., Zou, T., Gerada, D., Degano, M., Buticchi, G., & Gerada, C. (2020, October). Rectangular and Random Conductors: AC Losses Evaluations and Manufacturing Considerations. Presented at IECON 2020 - 46th Annual Conference of the IEEE Industrial Electronics Society, Singapore, Singapore

Presentation Conference Type Edited Proceedings
Conference Name IECON 2020 - 46th Annual Conference of the IEEE Industrial Electronics Society
Start Date Oct 18, 2020
End Date Oct 21, 2020
Acceptance Date Jul 15, 2020
Online Publication Date Nov 18, 2020
Publication Date Oct 18, 2020
Deposit Date Feb 26, 2021
Publicly Available Date Feb 26, 2021
Publisher Institute of Electrical and Electronics Engineers
Pages 1076-1081
Series Title IEEE Industrial Electronics Society. Annual Conference. Proceedings
Series Number 46
Series ISSN 1553-572X
ISBN 9781728154152
DOI https://doi.org/10.1109/iecon43393.2020.9254278
Public URL https://nottingham-repository.worktribe.com/output/5352311
Publisher URL https://ieeexplore-ieee-org/document/9254278
Additional Information © 2020 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.

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