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- ItemA 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, PeterAdditive 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.© 2024 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.
- ItemTopology Optimization for Enhancing Electric Machine Performance: A Review(Piscataway, NJ : IEEE, 2024-10-09) Reda Mahmoud, Mohamed; Ibrahim, Mohamed N.; Sergeant, PeterExploring 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.© 2024 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.
- ItemDesign 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, PeterThis 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.
- ItemA 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, PeterThis 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.© 2024 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.
- ItemTriply 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, MiroslavWith 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.© 2024 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.