Ingenieurwissenschaften

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  • listelement.badge.dso-type Item ,
    Multi-Material Topology Optimization for IPM Machine with Efficient Rare-Earth PM Utilization
    (New York, NY : IEEE, 2025-10-14) Mahmoud, Mohamed Reda; Ibrahim, Mohamed N.; Sergeant, Peter
    This paper presents a multi-material topology optimization (TO) to efficiently utilize rare-earth permanent magnet (REPM) material and improve the machine performance. The proposed approach employs a density-based TO method to optimize the multi-material distribution inside the rotor domain. The TO algorithm optimally redistributes air, silicon-steel, and REPM. The objective function of the TO is to maximize the average torque of the IPM motor while constraining the material volume of both silicon-steel and REPM to below that utilized in the conventional design. The results demonstrate that multi-material TO is a highly effective strategy for developing a new generation of sustainable electric machines. The topology optimized configuration achieved an approximate 4% increase in torque density while reducing the amount of REPM used by 12.5%. Moreover, the amount of silicon steel required for the optimized rotor is 9% lower than the conventional design.
  • listelement.badge.dso-type Item ,
    Topology Optimization for Enhancing Electric Machine Performance: A Review
    (New York, NY : IEEE, 2024-09-01) Mahmoud, Mohamed Reda; Ibrahim, Mohamed N.; Sergeant, Peter
    Exploring the design space is essential in the pursuit of developing high-performance and power-dense electric machines. This article explores the transformative potential of topology optimization (TO) in enhancing the performance of electric machines. Conventional techniques for optimizing the design of electric machines use optimization algorithms to determine geometric variables within a predefined range. However, these methods are limited by manufacturing constraints and the designer's expertise in parameterization. On the other hand, topology optimization aims to enhance the performance of electric machines by manipulating the distribution of materials as a design factor. The enhancement is facilitated by additive manufacturing (AM), particularly via the manufacturing of intricate metal parts. In this paper, the main concepts of topology optimization in electric machines are reviewed. Firstly, the requirement for topology optimization is illustrated, and both the achievements and challenges of this technique over the traditional parametric optimization are described. Then, a description is given of different topology optimization methods that were reported in the literature. Finally, the development opportunities of this technology are shown in the electric machine design field.
  • listelement.badge.dso-type Item ,
    Topology Optimization for a Magnetic Actuator Using Different Gradient-Based Solvers
    (New York, NY : IEEE, 2025-01-13) Mahmoud, Mohamed Reda; Ibrahim, Mohamed N.; Sergeant, Peter
    This paper presents a comparative study on the performance of density-based topology optimization using different gradient-based solvers. Three common solvers are employed: the method of moving asymptotes (MMA), interior point optimizer (IPOPT), and sparse nonlinear optimizer (SNOPT). The gradient solvers are compared regarding the convergence behaviour, computational time, and solution quality, i.e. maximizing the attractive force, when topology optimization is used to design a magnetic actuator as a case study. The results provide valuable insights into the strengths and limitations of MMA, IPOPT, and SNOPT in solving topology optimization and offering guidance for selecting the appropriate solvers. The results proved that SNOPT is suitable for largescale problems as it has fast convergence and low computation time compared to MMA and IPOPT solvers. Further, IPOPT is not suitable for large-scale problems due to high computation time and large amounts of intermediate materials, i.e. regions where the density function differs from 0 and 1. Moreover, the quality of the optimal solution is only slightly affected by the used solver.
  • listelement.badge.dso-type Item ,
    Reducing AC Joule Losses in Hairpin Windings of Electric Machines: Strategies for Minimizing Losses Due to Radial and Tangential Flux
    (New York, NY : IEEE, 2025-10-22) Bekele, Yitbarek; Korolova, Olga; Biebighäuser, Andreas; Akbar, Siddique; Ebrahimi, Amir; Ponick, Bernd
    This paper presents a comprehensive analysis of conductor design strategies to reduce joule losses in hairpin windings of high-speed permanent magnet synchronous machines (PMSMs). With the increasing demand for high torque density, efficiency, and high-speed operation in electric vehicles and aircraft, minimizing these losses is crucial. Starting with a reference winding layout, various loss mechanisms due to radial and tangential flux components are investigated using finite element analysis (FEA) under both no-load and short-circuit conditions. Design variants including adjustments to conductor geometry, slot opening shapes, layer-specific conductor height tuning and segmented conductor designs with overhang twisting are explored. The findings are relevant for improving the performance and manufacturability of electric machines, with additive manufacturing offering new design opportunities for enhanced efficiency and lower losses.
  • listelement.badge.dso-type Item ,
    The Evolution and Future of Composite Construction in Light Aircraft
    (Hannover : Technische Informationsbibliothek, 2025) Wu, William
    Within this study the historical development, current applications and future topics of light aircraft construction shall be analyzed. It describes the evolution of used materials and construction methods starting from traditional materials such as wood and aluminum to advanced composite materials. Furthermore, the different types of composite materials and construction methods are categorized, their advantages and disadvantages are discussed. The implementation in current aircraft models by leading manufacturers such as Diamond Aircraft, Cirrus, and Elixir is presented. Further, the challenges that likely arise with the adoption of advanced composites in general aviation are discussed and finally emerging trends and technologies that may be adapted in future aircraft construction are described.
  • listelement.badge.dso-type Item ,
    Additively Manufactured Spoke-type Permanent Magnet Rotors: Solutions to Multidisciplinary Design Challenges and Comparison with Traditional Design
    (New York, NY : IEEE, 2025-10-09) Ajamloo, Akbar Mohammadi; Tiismus, Hans; Kallaste, Ants; Ibrahim, Mohamed N.; Sergeant, Peter
    Sustainability in electrical machines demands minimizing material waste, eliminating rare-earth permanent magnets (PMs), and improving efficiency and reliability. Additive manufacturing (AM) offers a promising pathway toward these goals by enabling near-zero material waste, streamlined production, and enhanced design freedom. This study leverages the compatibility of spoke-type rotor configurations with nonrare-earth PMs and the unique advantages of AM to achieve a highly sustainable design. The paper proposes innovative solutions to address the existing challenges of using AM for developing ferrite PM rotor topologies and provides a comprehensive comparison with traditional laminated topology. A novel technique is presented, reducing torque ripple from 42% to 16%, and voltage THD from 11% to 5%. The proposed solution not only maintains the average torque but also avoids added manufacturing complexity and cost, unlike skewing techniques. Moreover, a new grooving technique is implemented, reducing the eddy current loss in the bulk rotor by more than 40%. A spoke-type design with open bridges is selected over the closed-bridge design, and a comprehensive multidisciplinary analysis is conducted. Two spoke-type rotors are 3D printed, and one traditional laminated rotor is manufactured. The experimental comparisons show that the proposed 3D printed rotors outperform the laminated design in terms of torque ripple, voltage THD, and material usage, while offering comparable power rating and back-emf.
  • listelement.badge.dso-type Item ,
    Hydrogen in General Aviation for an efficient and sustainable future
    (Hannover : Technische Informationsbibliothek, 2025-10-01) Wu, William
    As global climate change accelerates, the aviation sector faces increased urgency to reduce carbon emissions in pursuit of the global goal of Net Zero 2050. Hydrogen has emerged as a promising fuel for future green aviation, offering high energy density per unit mass and virtually zero carbon dioxide emissions. The study examines two major pathways of hydrogen implementation in general aviation: combustion in piston engines and hydrogen fuel cells. Within combustion systems, both spark-ignited and compression-ignited (by using a kerosene jet) engines are analyzed, their pros and cons. The challenges they encounter are also addressed, including premature ignition, NOx emissions, and backfiring. Hydrogen fuel cells are evaluated efficiency across varying load conditions and operating temperatures, cooling systems, and long-life spans. At the same time, major drawbacks, including weight, storage limitations, and design complexity, are also accounted for. Hydrogen use in internal combustion chambers shows a practical short-term solution as it has a high technology readiness level and requires minimal modifications to existing engines. On the contrary, Hydrogen fuel cells hold the most promising future, but are hindered by current technological barriers. The study presents a detailed comparison chart between internal combustion engines (ICE) and Hydrogen fuel cells, including efficiencies, emissions and complexity. Finally, the study concludes the importance of hydrogen in green aviation, while highlighting the need for infrastructure development and innovations in hydrogen storage.
  • listelement.badge.dso-type Item ,
    Dauborn Extraktkonzentration : Sedimentationsarme Kaffee-/ Tee- Extraktkonzentrierung : Erhöhung der Verarbeitungs- und Rohstoffeffizienz durch neue Verfahrenskette
    (Hannover : Technische Informationsbibliothek, 2025) Stern, Andreas; Reinhardt , Eugen; Reinhardt, Eugen; Stern, Andreas
    Das Dauborn Verfahren ermöglicht durch den Einsatz einer dynamischen Mikro-/Ultrafiltration direkt nach der Extraktion der Röstkaffeebohnen, eine weitgehend sedimentationsfreie Konzentrierung des Kaffee-Rohextraktes. Die Filtrierung wird kontinuierlich betrieben. Durch den Verzicht auf die Abscheidung großmolekularer Bestandteile durch einen Separator, kann diese aufwendige Technologie durch das Verfahren verdrängt werden. Neben der Senkung der Betriebskosten (Energie, Wartung und Instandhaltung) können durch das neue Verfahren die Verarbeitungsverluste wesentlich reduziert werden. Ungelöste Extraktbestandteile, die bei der Separierung als Separatorrückstände ausgetragen und entsorgt werden müssen, können durch die Verfahrenskombination im Flüssigkaffee gehalten und stabilisiert werden. Zusammen mit anderen Effekten, kann dadurch die Rohstoffausbeute und Verarbeitungseffizient des Flüssigkaffees wesentlich erhöht werden. Die vorgeschaltete dynamische Mikro-/Ultrafiltration verbessert die Standzeiten der nachfolgenden Konzentrierungsanlagen (Eindampfung oder Umkehrosmose) durch die Reduzierung von Ablagerungen. Des Weiteren werden Spül- und Reinigungsintervalle reduziert. Durch diese Effekte werden die Betriebskosten deutlich gesenkt. Beim Einsatz einer Umkehrosmose zur Extraktkonzentrierung lassen sich nach der Vorbehandlung durch eine Mikro-/Ultrafiltration, deutlich höhere Endkonzentrationen erreichen. Ein prozessintegrierter Homogenisierungsschritt stellt sicher, dass Sedimentationen im Endprodukt vermieden werden. Dies ermöglicht eine weitgehend rückstandsfreie Verarbeitung.
  • listelement.badge.dso-type Item ,
    Enhanced findability and reusability of engineering data by contextual metadata
    (Cambridge : Cambridge University Press, 2023) Altun, Osman; Oladazimi, Pooya; Wawer, Max Leo; Raumel, Selina; Wurz, Marc; Barienti, Khemais; Nürnberger, Florian; Lachmayer, Roland; Mozgova, Iryna; Koepler, Oliver; Auer, Sören
    Complex research problems are increasingly addressed by interdisciplinary, collaborate research projects generating large amounts of heterogeneous amounts of data. The overarching processing, analysis and availability of data are critical success factors for these research efforts. Data repositories enable long term availability of such data for the scientific community. The findability and therefore reusability strongly builds on comprehensive annotations of datasets stored in repositories. Often generic metadata schema are used to annotate data. In this publication we describe the implementation of discipline specific metadata into a data repository to provide more contextual information about data. To avoid extra workload for researchers to provide such metadata a workflow with standardised data templates for automated metadata extraction during the ingest process has been developed. The enriched metadata are in the following used in the development of two repository plugins for data comparison and data visualisation. The added values of discipline-specific annotations and derived search features to support matching and reusable data is then demonstrated by use cases of two Collaborative Research Centres (CRC 1368 and CRC 1153).
  • listelement.badge.dso-type Item ,
    Enhanced Design and Electromagnetic Analysis of Synchronous Reluctance Machines Using Multi-Material Additive Manufacturing
    (New York, NY : IEEE, 2025) Akbar, Siddique; Bekele, Yitbarek Tedla; Ebrahimi, Amir; Ponick, Bernd
    This article comprehensively investigates the design and simulation of synchronous reluctance machines (SynRMs) using multi-material additive manufacturing (MMAM) methods. The main goal is to improve the electromagnetic performance of the machine by strategically utilizing various materials in the rotor's edge bridges to reduce quadrature inductance Lq. A comparative analysis is led on various combinations of magnetic and non-magnetic materials, examining conventionally built machines with single materials alongside additively manufactured machines with both single and multiple materials. A demonstrator machine is built to analyze and determine essential performance parameters, emphasizing the optimization of the rotor. The research establishes an optimized rotor model to enhance electromagnetic performance and examines the operational impacts on electromagnetic torque and torque oscillations. Analytical and simulation findings illustrate the capability of multi-material additive manufacturing to improve the performance of conventional electric machines.
  • listelement.badge.dso-type Item ,
    Outstanding Platinum Recovery by Electrochemical Cathodic Leaching and Redeposition in One-Pot 2 M HCL Solution
    (Bristol : IOP Publishing, 2025-07-16) Sakthivel, Mariappan; Gandharva, Reshma; Schreiber, Christopher; Drillet, Jean-Francois
    Selective Pt recovery from spent Pt/C gas diffusion electrodes (GDE) is essential for sustainable proton exchange membrane fuel cell and electrolysis industry. This study presents a promising, environmentally friendly approach using pulsed electrochemical cathodic leaching (ECCL) and subsequent electrochemical cathodic deposition (ECCD) in one pot diluted HCl solution. The parameters of ECCL pulse signal were optimized by varying electrolyte concentration, cell voltage, duty cycle, pulse number, and pulse sequence. For aging of GDE, a standard accelerated degradation tests protocol was applied. The amount of dissolved Pt in the electrolyte was evaluated by UV–vis absorption peak intensity at 260 nm that is assigned to Pt (IV) chloro complex ions. A Pt dissolution rate of 99.8% from fresh and aged GDE was achieved in 2 M HCl by applying cell voltage of “only” −3 V (cathode potential: −0.55 V vs RHE) and combining long and short pulse voltage sequences. Remaining Pt in the electrode were determined from electrochemical surface area and thermogravimetric analysis profiles confirming UV–vis results. Finally, proof of concept of one-pot Pt recovery from ECCL electrolyte by means of ECCD step was demonstrated.
  • listelement.badge.dso-type Item ,
    Investigation of Different Pole Configurations in New Asymmetric Permanent Magnet Synchronous Reluctance Machines
    (New York, NY : IEEE, 2025-01-13) Ajamloo, Akbar Mohammadi; Ghaheri, Aghil; Ibrahim, Mohamed N.; Sergeant, Peter
    This paper investigates the impact of pole number and configuration on key performance characteristics of a new family of asymmetric permanent magnet synchronous reluctance machines (PMSynRMs). New variants of asymmetric PMSynRMs are presented here which integrate distinct interior PM (IPM) poles and reluctance poles into a single lamination. The torque enhancement principle relies on segregating the net torque into components generated by each pole type. Torque enhancement is achieved by optimally shifting the IPM poles relative to the reluctance poles, aligning the torque peaks generated by each pole type. A comprehensive comparative analysis is conducted between the proposed asymmetric and conventional topologies, with identical PM volume, copper loss, frequency, and frame size. The analysis evaluates torque production capability, unbalanced magnetic forces, torque ripple, losses, and power factor. The results reveal that the asymmetric PMSynRMs offer improved torque, power factor, and reduced torque ripple compared to conventional designs for pole numbers 4, 6, 8, and 10. However, some asymmetric designs exhibit the drawback of unbalanced magnetic forces, which should be taken into consideration. Finally, an asymmetric PMSynRM is prototyped and tested to verify the simulation results.
  • listelement.badge.dso-type Item ,
    Properties of Additively Manufactured Soft and Hard Magnetic Cores for Electrical Machines: Methods and Materials − A Review
    (New York, NY : IEEE, 2025-05-20) Ajamloo, Akbar Mohammadi; Ibrahim, Mohamed N.; Sergeant, Peter
    Additive Manufacturing (AM) is an emerging topic in the field of electrical machines (EMs), offering the potential to overcome challenges imposed by conventional manufacturing methods. This paper provides an overview of various AM methods and materials used to manufacture soft and hard magnetic cores for EMs, with a particular focus on their multiphysics properties. Since each AM method involves unique processes—such as particle bonding, melting, or sintering—the resulting microstructural properties of the printed cores differ, leading to varied multi-physics characteristics that require indepth study. The paper outlines both the benefits and challenges associated with AM techniques and materials. Importantly, it explores the detailed properties of Fe-Si and Fe-Co soft magnetic cores as well as hard magnetic cores including NdFeB, ferrite, and alnico printed through different AM methods, comparing them to traditional laminations and commercial hard magnets.
  • listelement.badge.dso-type Item ,
    Principle of Torque-Axis Alignment in New Asymmetric PM Synchronous Reluctance Machines: Toward Less-Rare-Earth PM Machines
    (Piscataway, NJ : IEEE, 2024-12-05) Ajamloo, Akbar Mohammadi; Ghaheri, Aghil; Ibrahim, Mohamed N.; Sergeant, Peter
    This article reveals the principle of a new torque-axis alignment technique as the basis for a new class of asymmetric permanent magnet synchronous reluctance machines (PMSynRMs). These machines are characterized by having distinct permanent magnet (PM) and SynRM poles. The objective is to precisely align peak torque from each pole type by adjusting the relative shift angle, minimizing the rare-Earth PM usage. A new analytical model is proposed, segregating torque generated by each pole type in a rotating dq reference frame. The impact of PM pole configuration—surface PM (SPM) and interior PM (IPM)—is examined, and the effects of cross-coupling and saturation are investigated. Two different torque separation models are used to describe key torque characteristics of the machines. The analysis indicates that the asymmetric IPMSynRM and SPMSynRM offer the same torque rating at a significantly lower PM volume usage compared with the conventional PM-assisted synchronous reluctance machine (PMaSynRM). In addition, it is observed that asymmetric IPMSynRM exhibits superior torque performance compared with asymmetric SPMSynRM, attributed to additional reluctance torque generated by IPM poles. Finally, a prototype is manufactured and tested to evaluate the presented principle in the asymmetric topologies.
  • listelement.badge.dso-type Item ,
    Optimisation of Additively Manufactured Hairpin Windings for High Power Density Traction Motors
    (Piscataway, NJ : IEEE, 2025-07-04) Tesfamikael, Hadish Habte; Notari, Riccardo; Murataliyev, Mukhammed; Wang, Meiqi; Gerada, Chris; Degano, Michele
    Despite the widespread use of hairpin winding (HW) in electric vehicle (EV) traction motors, several AC loss phenomena hinder its broader application at higher operating frequencies. This paper investigates methods for reducing AC copper losses, focusing on both design approaches and advanced manufacturing techniques, particularly additive manufacturing (AM). A comprehensive analysis of various HW layouts is conducted, evaluating AC copper losses through finite element (FE) and analytical approaches, while considering the effects of circulating currents and short pitching. Detailed analysis of a HW motor is performed to address the influence of magnetic saturation and rotor-magnetomotive force (MMF) on AC copper losses. Moreover, sizing of HW dimensions at a specific operating speed is carried out analytically and validated using FE analysis, with the aim of minimizing high-frequency losses. The potential of AM to enhance manufacturing flexibility and facilitate conductor size optimization is briefly explored. A case study with in-depth optimization is performed to determine the optimal HW dimensions at representative operating points along the torque-speed curve. As a result, the most suitable HW design for EV applications is proposed and benchmarked against results from rigorous optimization processes.
  • listelement.badge.dso-type Item ,
    A New Hybrid Permanent Magnet-Assisted Synchronous Reluctance Motor with Efficient Utilization of Rare-Earth Permanent Magnets
    (New York, NY : IEEE, 2024-10-28) Ajamloo, Akbar Mohammadi; Ghaheri, Aghil; Ibrahim, Mohamed N.; Sergeant, Peter
    This paper proposes a novel hybrid permanent magnet assisted synchronous reluctance machine (PMaSynRM) aiming to overcome limitations of the conventional PMaSynRM. In the conventional topology, the design of flux barriers and PMs are interdependent, causing the dimensions of PMs to be influenced by barrier geometry rather than solely adhering to magnetic requirements. Additionally, in conventional topology, the peaks of reluctance and PM torque components occur at different current angles (CAs). These are identified as major factors contributing to the inefficient utilization of PMs. The proposed topology adopts a unique approach by incorporating two distinct pole types in one lamination: SynRM poles and IPM poles. This configuration decouples the magnetic design of PMs and flux barriers, promoting efficient utilization of PMs. Additionally, a strategic relative displacement between the IPM and SynRM poles ensures that the peak torque generated by both pole types occurs at the same CA. The proposed design is compared to the conventional PMaSynRM, both optimized to achieve the required torque rating with minimal PM usage using response surface methodology. The results are compared in terms of PM usage, efficiency, etc. Finally, the proposed machine is manufactured, and a test set-up is provided to evaluate the simulation results.
  • listelement.badge.dso-type Item ,
    Design Considerations of a New IPM Rotor With Efficient Utilization of PMs Enabled by Additive Manufacturing
    (New York, NY : IEEE, 2024-04-29) Ajamloo, Akbar Mohammadi; Ibrahim, Mohamed N.; Sergeant, Peter
    This paper presents a new design concept for interior permanent magnet (IPM) rotor using the capabilities of additive manufacturing (AM). In conventional laminated IPM topology, the presence of rotor ribs is essential for maintaining the mechanical integrity of the rotor. However, these pole ribs are a primary contributor to flux leakage, leading to inefficient utilization of costly rare-earth PMs. Addressing this challenge, a rib-less IPM rotor is proposed that takes advantage of the AM potential which eliminates the need for traditional ribs while maintaining the structural integrity of the rotor. Nevertheless, the additively manufactured cores, in contrast to conventionally laminated rotor cores, demand specific design considerations, especially in terms of eddy current loss and structural performance. In this regard, a strategy involving the incorporation of shallow grooves on the rotor surface is employed to mitigate eddy current loss. The mechanical performance of the proposed topology is carefully examined, and the impact of pole geometry on rotor displacement induced by centrifugal forces is investigated. To evaluate the performance of the proposed topology, an optimization procedure based on response surface methodology is conducted for both the proposed rotor and a conventional IPM rotor. The results indicate that the proposed IPM topology can offer significantly more efficient utilization of PMs and enhanced torque rating by approximately 8% compared to the laminated IPM topology.
  • listelement.badge.dso-type Item ,
    A Review on Properties of 3D Printed Magnetic Cores for Electrical Machines: Additive Manufacturing Methods and Materials
    (Piscataway, NJ : IEEE, 2024-10-09) Ajamloo, Akbar Mohammadi; Ibrahim, Mohamed N.; Sergeant, Peter
    Additive Manufacturing (AM) is a new topic in the field of electrical machines (EMs), offering the potential to overcome the limitations in the design of EMs. Through AM, complex 3D geometries and the utilization of Fe-Si cores with 6.5% silicon can be achieved, leading to enhanced EM performance without concerns about manufacturing cost and complexity. This paper provides an overview of various AM methods and materials used in manufacturing soft magnetic cores for EMs, with a particular emphasis on the multi-physics properties of these cores. Due to the distinct fusion processes in each AM method, the microstructural properties of the printed cores vary, leading to diverse multi-physics properties that require detailed investigation. The paper outlines both the benefits and challenges associated with AM techniques and materials. Importantly, it explores the detailed characteristics of Fe-Si and Fe-Co cores manufactured through different AM methods, comparing them with commercial laminations such as 35A300, JNEX Super Core, and Hiperco 50A.
  • listelement.badge.dso-type Item ,
    Topology Optimization for Enhancing Electric Machine Performance: A Review
    (Piscataway, NJ : IEEE, 2024-10-09) Reda Mahmoud, Mohamed; Ibrahim, Mohamed N.; Sergeant, Peter
    Exploring the design space is essential in the pursuit of developing high-performance and power-dense electric machines. This article explores the transformative potential of topology optimization (TO) in enhancing the performance of electric machines. Conventional techniques for optimizing the design of electric machines use optimization algorithms to determine geometric variables within a predefined range. However, these methods are limited by manufacturing constraints and the designer's expertise in parameterization. On the other hand, topology optimization aims to enhance the performance of electric machines by manipulating the distribution of materials as a design factor. The enhancement is facilitated by additive manufacturing (AM), particularly via the manufacturing of intricate metal parts. In this paper, the main concepts of topology optimization in electric machines are reviewed. Firstly, the requirement for topology optimization is illustrated, and both the achievements and challenges of this technique over the traditional parametric optimization are described. Then, a description is given of different topology optimization methods that were reported in the literature. Finally, the development opportunities of this technology are shown in the electric machine design field.
  • listelement.badge.dso-type Item ,
    Triply Periodic Minimal Surfaces Structure for Efficient Heat Dissipation in Motor Housings: A Convective Potential Analysis
    (Piscataway, NJ : IEEE, 2024-10-09) Hassan, Shaheer Ul; Shah, Mazahir Hussain; Gruber, Pavel; Chomat, Miroslav
    With the advent of 3D printing, advanced geometries started replacing the conventional designs in electric machines. Various modified rotor, stator and coil designs are 3D printed to enhance the machine properties and minimize the losses but there are still some heat losses generated which can cause temperature rise inside the motor and disturb the stability of machine, unless this heat is removed from the machine properly. Motors use conventional housing with fins or cooling systems to remove this heat but it provides poor heat transfer and affects the performance of the motor. This paper focuses on developing Triply Periodic Minimal Surfaces (TPMS) housing structures with varying heights, volume fractions and cell sizes to optimize heat management in the motor. TPMS provides heat dissipation in multiple directions as compared to conventional fin. They provide a large surface area to volume ratio, hence better heat dissipation & heat distribution within the structure, improving performance and saving material. Mathematical modeling and numerical simulations of these structures using Finite Volume Method are done, and results of each structure are investigated and compared. Comparison with another research work is also done to justify the results. Finally, an optimal structure is chosen to replace the original housing structure. Comparative analysis is done to study the improvement in properties. Results are compared with conventional housing. Complete heat analysis of the original and proposed design is presented. Heat distribution and propagation is carried out. Improved results and the future scope of the project is presented.