Mechanical and thermal management design of a motor for an aircraft wheel actuator

Xu, Z.; Galea, M.; Tighe, C.; Hamiti, T.; Gerada, C.; Pickering, S.J.

doi:10.1109/ICEMS.2014.7014056

A Review of Carbon Emissions from Electrical Machine Materials (2024)
Journal Article
Zhang, X., Gerada, D., Xu, Z., Zhang, F., & Gerada, C. (2024). A Review of Carbon Emissions from Electrical Machine Materials. Electronics, 13(9), Article 1714. https://doi.org/10.3390/electronics13091714

As the world embarks on a global mission to tackle climate change, reducing carbon represents a key challenge given the escalating global warming. The U.K. is among many other nations that are determined to decarbonise all sectors and strive to achie... Read More about A Review of Carbon Emissions from Electrical Machine Materials.

A Taguchi-LHS-RSM Double-Staged Approach for Design Optimization of Self-Ventilated Cooling Systems Utilized in PMSMs (2023)
Presentation / Conference Contribution
Zhu, G., Xu, Z., Zhang, F., Gerada, C., & Gerada, D. (2023). A Taguchi-LHS-RSM Double-Staged Approach for Design Optimization of Self-Ventilated Cooling Systems Utilized in PMSMs. In 26th International Conference on Electrical Machines and Systems (ICEMS). https://doi.org/10.1109/icems59686.2023.10344616

Thermal management is critical for high-power-density permanent magnet synchronous machines (PMSMs). To realize the efficient and effective design optimization of self-ventilated air cooling systems for PMSMs, in this paper, a Taguchi-preconditioned... Read More about A Taguchi-LHS-RSM Double-Staged Approach for Design Optimization of Self-Ventilated Cooling Systems Utilized in PMSMs.

Design of Hairpin Winding and Random Winding Stators for High Speed Heavy-Duty Traction Motor (2023)
Presentation / Conference Contribution
Jiang, J., Zou, T., La Rocca, A., La Rocca, S., Liu, C., Xu, Z., …Gerada, D. (2023). Design of Hairpin Winding and Random Winding Stators for High Speed Heavy-Duty Traction Motor. In 2023 IEEE Vehicle Power and Propulsion Conference (VPPC). https://doi.org/10.1109/VPPC60535.2023.10403273

Hairpin winding with rectangularly shaped conductors are gradually replacing random winding wound with stranded wires in electric vehicle (EV) industry. As the newgeneration winding technology, hairpin winding features high electromagnetic and therma... Read More about Design of Hairpin Winding and Random Winding Stators for High Speed Heavy-Duty Traction Motor.

Analytical Calculation and Experimental Validation of Litz Wires Axial Thermal Conductivity (2023)
Journal Article
Li, Z., Xu, Z., Zhang, F., Gerada, D., Guo, R., Zhang, H., …Zhang, C. (2024). Analytical Calculation and Experimental Validation of Litz Wires Axial Thermal Conductivity. IEEE Transactions on Transportation Electrification, 10(1), 1167-1179. https://doi.org/10.1109/TTE.2023.3262766

Litz wires are widely used in electrical machines with reduced AC losses, compared to traditional random winding. The reduced AC losses can improve both electrical machines electromagnetic performance, such as efficiency and thermal performance. Ther... Read More about Analytical Calculation and Experimental Validation of Litz Wires Axial Thermal Conductivity.

Airgap Length Analysis of a 350kW PM-Assisted Syn-Rel Machine for Heavy Duty EV Traction (2022)
Journal Article
Zou, T., Gerada, D., La Rocca, S., La Rocca, A., Walker, A., Vakil, G., …Gerada, C. (2023). Airgap Length Analysis of a 350kW PM-Assisted Syn-Rel Machine for Heavy Duty EV Traction. IEEE Transactions on Industry Applications, 59(2), 1557-1570. https://doi.org/10.1109/TIA.2022.3225255

Synchronous reluctance (Syn-Rel) machines with embedded permanent magnets (PMs) are research hotspots in variable speed motor drives due to their robust rotor structure and wide constant power speed range (CPSR). In this paper, the potential of PM-as... Read More about Airgap Length Analysis of a 350kW PM-Assisted Syn-Rel Machine for Heavy Duty EV Traction.

Radial Force Analysis and Optimization of Interior Permanent Magnet Traction Motor for Reduction of Electromagnetic Vibration (2022)
Presentation / Conference Contribution
Li, H., Cui, M., Zou, T., Zhang, X., Zhang, H., Xu, Z., …Gerada, C. (2022). Radial Force Analysis and Optimization of Interior Permanent Magnet Traction Motor for Reduction of Electromagnetic Vibration. In 2022 International Conference on Electrical Machines (ICEM) (1906-1912). https://doi.org/10.1109/ICEM51905.2022.9910879

Interior permanent magnet (IPM) machines are subject to rich harmonics of air-gap magnetic field, which correspond to electromagnetic forces and resulting noise, vibration, and harshness (NVH) issues. In this paper, the NVH issue is evaluated based o... Read More about Radial Force Analysis and Optimization of Interior Permanent Magnet Traction Motor for Reduction of Electromagnetic Vibration.

Performance Entitlement by Using Novel High Strength Electrical Steels and Copper Alloys for High-Speed Laminated Rotor Induction Machines (2022)
Journal Article
Zhang, F., Gerada, D., Xu, Z., He, Y., Zhang, H., Hua, W., & Gerada, C. (2022). Performance Entitlement by Using Novel High Strength Electrical Steels and Copper Alloys for High-Speed Laminated Rotor Induction Machines. Electronics, 11(2), 210. https://doi.org/10.3390/electronics11020210

The laminated rotor Induction Machine (IM), with its simple construction and manufacturing, robustness, ease of control and comparatively lower cost remains by far the most utilized electromechanical energy converter. At very high speeds, traditional... Read More about Performance Entitlement by Using Novel High Strength Electrical Steels and Copper Alloys for High-Speed Laminated Rotor Induction Machines.

Carbon Emission Analysis of Electrical Machines (2021)
Presentation / Conference Contribution
Zhang, X., Xu, Z., Gerada, C., & Gerada, D. (2021). Carbon Emission Analysis of Electrical Machines. In 2021 24th International Conference on Electrical Machines and Systems (ICEMS) (1678-1683). https://doi.org/10.23919/ICEMS52562.2021.9634279

The industry places increased importance on carbon reduction. Many are focused on lowering the fuel consumption of electrical machines, however, carbon emissions from the acquisition of raw materials and the energy consumption of manufacturing proces... Read More about Carbon Emission Analysis of Electrical Machines.

Improved Thermal Modeling and Experimental Validation of Oil-Flooded High-Performance Machines with Slot-Channel Cooling (2021)
Journal Article
Zhang, F., Gerada, D., Xu, Z., Zhang, X., Zhang, H., Gerada, C., …Degano, M. (2022). Improved Thermal Modeling and Experimental Validation of Oil-Flooded High-Performance Machines with Slot-Channel Cooling. IEEE Transactions on Transportation Electrification, 8(1), 312-324. https://doi.org/10.1109/TTE.2021.3106819

Thermal management is often considered a bottleneck in the pursuit of the next-generation electrical machines for electrified transportation with a step change in power density. Slot-channel cooling is considered to be an effective cooling technique,... Read More about Improved Thermal Modeling and Experimental Validation of Oil-Flooded High-Performance Machines with Slot-Channel Cooling.

Electrical Machine Slot Thermal Condition Effects on Back Iron Extension Thermal Benefits (2021)
Journal Article
Zhang, F., Gerada, D., Xu, Z., Tighe, C., Zhang, H., Yan, L., & Gerada, C. (2021). Electrical Machine Slot Thermal Condition Effects on Back Iron Extension Thermal Benefits. IEEE Transactions on Transportation Electrification, 7(4), 2927-2938. https://doi.org/10.1109/tte.2021.3085822

The slot thermal condition is critical for thermal management of high-performance electrical machines, due to the high heat losses and poor heat transfer ability within the slot. With a part of the back iron projected radially downward into the slot,... Read More about Electrical Machine Slot Thermal Condition Effects on Back Iron Extension Thermal Benefits.

Slot Number Thermal Effects on Electrical Machines (2020)
Journal Article
ZHANG, F., Gerada, D., Xu, Z., Zhang, X., Tighe, C., Zhang, H., …Gerada, C. (2021). Slot Number Thermal Effects on Electrical Machines. IEEE Transactions on Energy Conversion, 36(1), 23-35. https://doi.org/10.1109/tec.2020.3008219

Experimental study of thermal fracturing of Hot Dry Rock irradiated by moving laser beam: Temperature, efficiency and porosity (2020)
Journal Article
Wang, Y., Jiang, J., Darkwa, J., Xu, Z., Zheng, X., & Zhou, G. (2020). Experimental study of thermal fracturing of Hot Dry Rock irradiated by moving laser beam: Temperature, efficiency and porosity. Renewable Energy, 160, 803-816. https://doi.org/10.1016/j.renene.2020.06.138

A new laser irradiation fracturing method is employed to crack the Hot Dry Rock (HDR) and variations of rock temperature, specific energy (SE) and modified specific energy (MSE), thermal damages and open porosity of granite samples caused by moving l... Read More about Experimental study of thermal fracturing of Hot Dry Rock irradiated by moving laser beam: Temperature, efficiency and porosity.

Analytical Model of Modular Spoke-Type Permanent Magnet Machines for In-Wheel Traction Applications (2020)
Journal Article
Zhang, H., Hua, W., Gerada, D., Xu, Z., & Gerada, C. (2020). Analytical Model of Modular Spoke-Type Permanent Magnet Machines for In-Wheel Traction Applications. IEEE Transactions on Energy Conversion, 35(3), 1289-1300. https://doi.org/10.1109/tec.2020.2979886

This paper proposes an analytical model of modular spoke-type permanent magnet (MSTPM) machines based on air-gap field modulation (AFM) theory. Firstly, a fundamental AFM model of open-circuit MSTPM machines is introduced. The open-circuit air-gap fi... Read More about Analytical Model of Modular Spoke-Type Permanent Magnet Machines for In-Wheel Traction Applications.

Sensitivity Analysis of Machine Components Thermal Properties Effects on Winding Temperature (2019)
Presentation / Conference Contribution
Zhang, F., Gerada, D., Xu, Z., Zhang, H., & Gerada, C. (2019). Sensitivity Analysis of Machine Components Thermal Properties Effects on Winding Temperature. In 2019 22nd International Conference on Electrical Machines and Systems (ICEMS). https://doi.org/10.1109/ICEMS.2019.8922095

This paper investigates the sensitivity analysis of winding temperature to key parameters in electrical machine thermal design. With a validated 3D thermal model based on an existing 75kW traction machine for an electric vehicle, the methodology of t... Read More about Sensitivity Analysis of Machine Components Thermal Properties Effects on Winding Temperature.

Equivalent Slot Thermal Conductivity and Back-iron Extension Effects on Machine Cooling (2019)
Presentation / Conference Contribution
Zhang, F., Gerada, D., Xu, Z., Zhang, H., & Gerada, C. (2019). Equivalent Slot Thermal Conductivity and Back-iron Extension Effects on Machine Cooling. In Proceedings of 2019 22nd International Conference on Electrical Machines and Systems (ICEMS). https://doi.org/10.1109/ICEMS.2019.8921725

Back-iron Extension (BIE) is an effective thermal management technique which reduces the winding temperatures by projecting part of the back iron into the center of slot, thereby shortening the heat transfer path between the coil and back iron. Based... Read More about Equivalent Slot Thermal Conductivity and Back-iron Extension Effects on Machine Cooling.

Thermo-Mechanical Modelling of Bearing Chambers of a High-Speed Starter/Generator (2019)
Presentation / Conference Contribution
Rocca, A. L., Connor, P. H., Xu, Z., Eastwick, C. N., Pickering, S. J., & Gerada, C. (2019). Thermo-Mechanical Modelling of Bearing Chambers of a High-Speed Starter/Generator. In 2019 IEEE International Electric Machines & Drives Conference (IEMDC) (322-328). https://doi.org/10.1109/iemdc.2019.8785357

This paper describes the thermal-mechanical characterisation methodology for the bearing chambers of a high-speed (32,000 rpm) electrical starter/generator [1]; presenting a low cost analysis approach and design guideline for future machines. The met... Read More about Thermo-Mechanical Modelling of Bearing Chambers of a High-Speed Starter/Generator.

Effective Thermal Conductivity Calculation and Measurement of Litz Wire based on the Porous Metal Materials Structure (2019)
Journal Article
Liu, X., Gerada, D., Xu, Z., Corfield, M., Gerada, C., & Yu, H. (2020). Effective Thermal Conductivity Calculation and Measurement of Litz Wire based on the Porous Metal Materials Structure. IEEE Transactions on Industrial Electronics, 67(4), 2667-2677. https://doi.org/10.1109/tie.2019.2910031

Litz wires are employed in high-frequency electrical machines due to their advantages of reducing the ac losses, including minimizing the skin effect and the proximity effect. In order to improve the reliability of such machines, and enable accurate... Read More about Effective Thermal Conductivity Calculation and Measurement of Litz Wire based on the Porous Metal Materials Structure.

Back-Iron Extension Thermal Benefits for Electrical Machines With Concentrated Windings (2019)
Journal Article
Zhang, F., Gerada, D., Xu, Z., Zhang, X., Tighe, C., Zhang, H., & Gerada, C. (2020). Back-Iron Extension Thermal Benefits for Electrical Machines With Concentrated Windings. IEEE Transactions on Industrial Electronics, 67(3), 1728-1738. https://doi.org/10.1109/tie.2019.2903758

A semi-flooded cooling for a high speed machine: Concept, design and practice of an oil sleeve (2017)
Presentation / Conference Contribution
Xu, Z., La Rocca, A., Arumugam, P., Pickering, S. J., Gerada, C., Bozhko, S., …Zhang, H. (2017). A semi-flooded cooling for a high speed machine: Concept, design and practice of an oil sleeve. In Proceedings IECON 2017 - 43rd Annual Conference of the IEEE Industrial Electronics Society (8557-8562). https://doi.org/10.1109/IECON.2017.8217503

This paper proposes a semi-flooded cooling concept for a high speed machine design. The electrical machine considered is for an aircraft starter-generator system where power density and efficiency are crucial. In order to achieve the high power densi... Read More about A semi-flooded cooling for a high speed machine: Concept, design and practice of an oil sleeve.

Mechanical and thermal management design of a motor for an aircraft wheel actuator (2014)
Presentation / Conference Contribution
Xu, Z., Galea, M., Tighe, C., Hamiti, T., Gerada, C., & Pickering, S. (2015). Mechanical and thermal management design of a motor for an aircraft wheel actuator. In 2014 17th International Conference on Electrical Machines and Systems (ICEMS). https://doi.org/10.1109/ICEMS.2014.7014056

A permanent magnet motor is designed as an actuator for taxiing large aircraft in an airport. The motor is attached to the main aircraft wheel to provide a direct drive. A special topology for this machine is developed selected and designed. Due to a... Read More about Mechanical and thermal management design of a motor for an aircraft wheel actuator.

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