3D Printing as a Technology Enabler for Electrical Machines: Manufacturing and Testing of a Salient Pole Rotor for SRM

Gargalis, Leonidas; Madonna, Vincenzo; Giangrande, Paolo; Hardy, Mark; Ashcroft, Ian; Galea, Michael; Hague, Richard

Abstract

Among the various technology enablers for modern electrical machines, additive manufacturing plays a key role. The advantage of having a precise control of the shape of ferromagnetic structures, whilst achieving good electromagnetic performance, fits well with the design requirements of rotating electrical machines. To a certain extent, some of the physical properties of the material can be “tuned”, allowing for quick trade-off studies (i.e., prototyping), as opposed to conventional manufacturing techniques. Despite being considered an enabling technology, 3D printing of soft magnetic materials for electric motors is still at an embryonic stage. This work, thus, aims in providing an initial proof of concept. For the purpose, a switched reluctance machine is chosen as a case study. Its rotor core is additively manufactured through selective laser melting. Its performances are compared to those of an identical commercial motor featuring a laminated rotor core, via in-depth experimental tests. Initial results show that the 3D printed machine can actually develop the rated power, but with an efficiency reduction.

Citation

Gargalis, L., Madonna, V., Giangrande, P., Hardy, M., Ashcroft, I., Galea, M., & Hague, R. (2020). 3D Printing as a Technology Enabler for Electrical Machines: Manufacturing and Testing of a Salient Pole Rotor for SRM. In 2020 International Conference on Electrical Machines (ICEM) (12-18). https://doi.org/10.1109/icem49940.2020.9270737

• Presentation Conference Type: Edited Proceedings
• Conference Name: 2020 International Conference on Electrical Machines (ICEM)
• Start Date: Aug 23, 2020
• End Date: Aug 26, 2020
• Acceptance Date: May 26, 2020
• Online Publication Date: Dec 1, 2020
• Publication Date: Dec 1, 2020
• Deposit Date: Feb 26, 2021
• Publicly Available Date: Feb 26, 2021
• Publisher: Institute of Electrical and Electronics Engineers
• Pages: 12-18
• Series Title: International Conference on Electrical Machines, ICEM
• Series ISSN: 2381-4802
• Book Title: 2020 International Conference on Electrical Machines (ICEM)
• ISBN: 9781728199450
• DOI: https://doi.org/10.1109/icem49940.2020.9270737
• Keywords: Rotors , Reluctance motors , Benchmark testing , Three-dimensional displays , Iron , Torque , Manufacturing
• Public URL: https://nottingham-repository.worktribe.com/output/5352774
• Publisher URL: https://ieeexplore-ieee-org.ezproxy.nottingham.ac.uk/document/9270737
• 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.