2022 12th International Electric Drives Production Conference (EDPC)最新文献

{"title":"Anodised Aluminium Foil Winding Axial Flux Machine for (Quasi-)Direct-Drive Robotic Applications: Preliminary Design and Manufacturing","authors":"Jordi Van Damme, H. Vansompel, G. Crevecoeur, K. Faes, Rafael Nunes, R. Tack","doi":"10.1109/EDPC56367.2022.10019769","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019769","url":null,"abstract":"Motivated by the need for higher torque density actuators in novel (quasi-)direct-drive robotics applications, a Yokeless and Segmented Armature Axial Flux Permanent Magnet Synchronous machine with anodised aluminium foil conductors instead of enamelled copper wire is considered in this work. Based on a requirements analysis of (quasi-)direct-drive actuators, a prototype axial flux machine is designed. Several design aspects are discussed keeping the application requirements in mind. It could be concluded that the combination of the machine topology and conductor material results in a high fill factor and excellent thermal properties, making it particularly promising for high torque density, low speed applications. A prototype was manufactured to demonstrate the feasibility of the design. The interconnection of aluminium foil to copper wire appeared to be challenging, two interconnection methods were tested and compared qualitatively.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115133550","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Further Developments in the Production of an Innovative Motor Concept with Radially Laminated Stator Sheets and Flux Barriers","authors":"Alena Babl, M. Bach, D. Gerling, M. Dix","doi":"10.1109/EDPC56367.2022.10019757","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019757","url":null,"abstract":"In the course of saving resources and energy caused by factors such as environmental protection and the climate crisis, various motor topologies are being developed and investigated continuously. One of these developments is being promoted by researchers at the EAA and IWU and concerns the implementation of an innovative motor concept with radially laminated stator steel sheets and flux barriers. Various new developments in design and manufacturing technology have to be implemented as well as analyzed for this new development. This paper provides an insight into the electromagnetic relationships within the newly arranged grain-oriented laminations as well as findings from the production of the first prototypes. Furthermore measurement results on the electromagnetic behavior of the stator are given as well as subsequent findings and derived decisions are presented.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"356 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115164857","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Manufacturing Process and Design Requirements of Litz Wire with Focus on Efficiency Improvement of Traction Motors","authors":"Henrik Christoph Born, Fabian Oehler, Volkmar Platte, A. Kampker, H. Heimes, Benjamin Dorn, F. Brans, David Drexler, F. Blanc, Sebastian Reising","doi":"10.1109/EDPC56367.2022.10019744","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019744","url":null,"abstract":"Enameled wire is a basic material for coil winding technologies. The manufacturing process varies and parameters depend on the final product. One competitive product for traction motors is profiled litz wire, which comprises of twisted enameled wire strands. Product design and manufacturing of litz wire is complex with many options. Profiled rectangular litz wire can substitute the solid rectangular enameled wire within the continuous hairpin technology. Due to thinner individual wires alternating current (AC) losses in electric traction motors can be reduced to improve efficiency and power density. Compared to solid wire, it has a lower a filling factor, which results in higher direct current (DC) resistance, however the overall weight is also reduced. Depending on the drive cycle, AC losses can overcome DC losses in low operating points. In contrast to that the AC losses can be significantly reduced at high frequencies compared to solid wire. A litz wire design can be simulated using litz wire models for analytical computing. Analysis of real traction motor parameters display benefits of litz wire windings compared to solid wire hairpin windings. This paper gives insights on the litz wire technology and its manufacturing process. Furthermore, it describes state of the art design parameters for the use of litz wire in electric motors. Finally, a simulation-based motor study presents the potential of performance increase by litz wire windings compared to solid wire windings.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"76 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116954176","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Development of Alternative Magnetic Fixation Technologies for Axial Flux Machines","authors":"Mike Fuchslocher, Thomas E. Albrecht, M. Bargende, A. Kulzer, Michael Auerbach, Ben Daly, G. Hyson, Jack Hodgson, S. Odling","doi":"10.1109/EDPC56367.2022.10019740","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019740","url":null,"abstract":"With the Mercedes-Benz strategy update from “Electric first” to “Electric only”, the transformation into the emission-free future is accelerated and the focus is placed on battery electric vehicles. Beyond to the widespread radial flux machines, axial flux machines offer new possibilities for drive topologies due to their comparatively compact package. Due to the small axial package, they are for example an enabler for compact dual drives. Because of this, they are subject of this scientific work. The focus here is on rotor production technology development for embedded magnets.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"5 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"123399541","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Inverter Control and its Effect on Copper Losses in Electrical Machines Equipped with Hairpin Winding","authors":"Robin Krüger, Samar Singh, Patricia Penabad Durán, K. Hameyer","doi":"10.1109/EDPC56367.2022.10019753","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019753","url":null,"abstract":"The electric drivetrain is considered as a closed loop system consisting of the controller, the inverter and the electrical machine in this contribution. Copper losses including AC and PWM effects are studied by using two different approaches for high accuracy or fast computation, based on the finite element method (FEM) and lookup tables (LUT) respectively. The influence of switching frequency and modulation method on both inverter and copper losses is analyzed. These losses are minimized by optimizing the inverter parameters in the speed-torque map. The inverter parameter's impact on the drive cycle energy loss is discussed. A permanent magnet excited synchronous machine equipped with hairpin winding is chosen as an exemplary machine.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"24 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134090795","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Analysis of the Behaviour of the Winding Head of a Hairpin Stator","authors":"A. Kampker, Benjamin Dorn, F. Brans, C. Stäck, Matthäus Windhausen, Kaustubh Vishnu Patil","doi":"10.1109/EDPC56367.2022.10019766","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019766","url":null,"abstract":"Electric mobility offers significant potential in the reduction of harmful emissions and is increasingly establishing itself on the market. Despite the long-established existence of electric motors, their use in automotive applications poses major challenges for manufacturers. The so-called hairpin technology, a winding technique with rectangular solid conductors, is increasingly replacing established round wire winding techniques in automotive stator production. The process step of welding can be identified as a quality gate of the entire process chain. The commonly used laser welding in combination with the material properties of the copper hairpins results in a sensitive process step that requires precise welding preparation. To improve the quality of existing clamping procedures or facilitate the development and design of new innovative clamping techniques, a detailed analysis of the forces occurring in a winding head is created. The forces required for aligning the contacting surfaces during welding preparation are calculated based on the geometric deviations of the hairpin ends. This could enable the accurate dimensioning of clamping operations or even an adaptive process in the welding preparation. Hereby, the process reliability in stator production could be sustainably improved. Within the scope of this work, the problem is first examined and geometric deviations after twisting are defined. Then the forces in the winding head are calculated by simulation and analytically and validated by practical tests. The conducted examinations are presented and analysed individually. The results obtained are compared with each other and possible limitations are investigated. Subsequently, the performance of existing clamping methods is analysed and compared with the previously calculated, occurring forces in the winding head. In summary, this work is intended to provide an overview of the forces occurring in a winding head. By means of the procedures determined in the context of this work, an approximated calculation of the forces to be expected in the welding preparation and welding fixture are made possible.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"18 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129384712","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Suitability of a 2 kw 515 nm Continous Wave Laser for Deep Penetration Welding of Copper","authors":"Manuela Ockel, A. Hensel, J. Franke","doi":"10.1109/EDPC56367.2022.10019737","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019737","url":null,"abstract":"With advancing electromobility the demands regarding electrically conductive copper connections are increasing. In order to withstand the critical conditions in an electric traction motor the connections have to be stable and of high quality. Welding is a possible method to produce material bonded joints that, while fulfilling the requirements regarding electrical conductivity and mechanical stability, also allow for an increased integration density and reduced construction space by substituting screw connections. Especially laser welding offers a flexible, fully automatable approach while only needing single-sided optical access to the welding spot. While being an established industrial process, the joining of copper via laser-welding is still classified as difficult. The high thermal conductivity and low absorptivity of copper for infrared wavelength is challenging for a stable welding processes and sensitive to different material properties like material thickness, oxidation and roughness. Green wavelengths have significantly higher absorption rates at room temperature and are less sensitive to absorption-dependent material properties. The advantages are clearly visible in heat conduction welding applications. If these advantages are also applicable to a deep penetration welding process is investigated in this paper. The results are compared with weld seams produced by state-of-the-art industrial infrared lasers.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"35 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133572428","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Book Cover Page","authors":"","doi":"10.1109/edpc56367.2022.10019770","DOIUrl":"https://doi.org/10.1109/edpc56367.2022.10019770","url":null,"abstract":"","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"33 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115237370","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"MRAS-based sensorless control of AFPMSM using minimum current point tracking to reduce multiple parameter variation effects","authors":"M. Brüns, Christian Rudolph","doi":"10.1109/EDPC56367.2022.10019768","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019768","url":null,"abstract":"In this paper a novel approach is presented to tune the application of sensorless control strategy based on the model reference adaptive system method (MRAS-based). Thus the influence of multiple parameter variations on the control is balanced. The method was used for speed and position estimation of a field-oriented controlled (FOC) wheel hub drive with an axial flux permanent magnet synchronous motor (AFPMSM). Parameter deviations could be described mathematically as disturbances of the MRAS scheme. Their influences are reduced by an enhancement of the fundamental wave model. The investigated tuning method compensates the mean value of the flux orientation angle error of the sensorless control caused by parameter variations using these occurring disturbances. In order to investigate the proposed method, a model-based system engineering (MBSE) approach was chosen to compare simulation and experimental results. The simulation study of the control strategy was performed using MATLAB®/Simulink®. Further on, the MRAS-based method was implemented on a target system directly from the simulation model using code generation software. A performance evaluation of the tuning application boundaries is focused on accuracy, sensitivity and stability of the control. The dynamic response can be calculated.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"45 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125173707","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Experimental Investigation of an Extrusion Profile for Slot Liner Insulation of an Electric Traction Machine with Winding Direct Cooling","authors":"Florian Braunbeck, T. Schmack, H. Reuss","doi":"10.1109/EDPC56367.2022.10019738","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019738","url":null,"abstract":"This study addresses the use of an alternative approach to ensure adequate slot insulation in electric traction drives. While the use of insulation composite materials, also called insulation papers, is state of the art and predominantly applied, a slot insulation with a closed, extrusion profile offers advantages especially for winding direct cooled electric machines. The results presented in this study provide an overview of the special features regarding electrical strength and the advantages of the slot insulation, referred to below as the insulation sleeve. The insulation sleeve is made of a PSU thermoplastic which is highly chemical resistant and can be used at temperatures of up to 180 °C. Its excellent resistance to cooling media enables it to be used in direct-cooled electric machines. In particular, the design of the profile allows higher cooling capacities to be achieved with the same installation space. Another advantage is the elimination of the overlap required for slot insulation papers, which can increase the copper fill factor or the cooling capacity. In the experimental investigations, the suitability of the insulation sleeve for use in an electric machine can be demonstrated. Significant increases in the breakdown voltage of more than 25% are achieved in the structure investigated, while at the same time the wall thickness is reduced. Comparable tests of the partial discharge inception voltage show no significant deviation between the two materials. The influence of defects within the insulation sleeve is also the subject of investigation. In addition, economies of scale mean that the insulation costs per slot can be sustainably reduced by using the insulation sleeve.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"11 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125324117","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}