Additively manufactured electric machine conductors with integrated end turn heat exchangers

James Pecotich; David Klink; Greg Heins; Behrooz Bahrani

doi:10.1109/ICEM51905.2022.9910686

Additively manufactured electric machine conductors with integrated end turn heat exchangers

James Pecotich, David Klink, Greg Heins, Behrooz Bahrani

Electrical and Computer Systems Engineering

Research output: Chapter in Book/Report/Conference proceeding › Conference Paper › Research › peer-review

12 Citations (Scopus)

Abstract

Conductors within a loaded electric machine commonly induce the highest loss. Numerous cooling solutions exist for high-power density electric machine conductors with external water jackets being the most common. The inherent disadvantage of water jacket cooling is the thermal resistance between the conductor and the cooling medium, which reduces the maximum cooling capacity, regardless of the jacket design. This restriction commonly leads designers to implement solutions such as end-turn cooling. The advances in additive manufacturing have unlocked new potential for conductor end-turn cooling. This paper investigates an additively-manufactured conductor with an integrated end-turn heat exchanger. The conductor is based around a Formula Student in-hub motor. This concept utilizes air-cooling and demonstrates a steady-state current density of 11 A/mm2 for a AlSi10Mg end-turn heat-exchanger conductor, without the added mass and complexity of liquid cooling solutions. If copper is used instead of AlSi10Mg, this value increases to approximately 22 A/mm2.

Original language	English
Title of host publication	2022 International Conference on Electrical Machines (ICEM 2022)
Editors	Antonio Luque, Vicente Biot Monterde
Place of Publication	Piscataway NJ USA
Publisher	IEEE, Institute of Electrical and Electronics Engineers
Pages	1498-1504
Number of pages	7
ISBN (Electronic)	9781665414326
ISBN (Print)	9781665414333
DOIs	https://doi.org/10.1109/ICEM51905.2022.9910686
Publication status	Published - 2022
Event	International Conference on Electrical Machines 2022 - Valencia, Spain Duration: 5 Sept 2022 → 8 Sept 2022 https://ieeexplore.ieee.org/xpl/conhome/9910604/proceeding (Proceedings) https://icem.cc/icem-2022-conference/ (Website)

Publication series

Name	2022 International Conference on Electrical Machines, ICEM 2022
Publisher	IEEE, Institute of Electrical and Electronics Engineers
ISSN (Print)	2381-4802

Conference

Conference	International Conference on Electrical Machines 2022
Abbreviated title	ICEM 2022
Country/Territory	Spain
City	Valencia
Period	5/09/22 → 8/09/22
Internet address	https://ieeexplore.ieee.org/xpl/conhome/9910604/proceeding (Proceedings) https://icem.cc/icem-2022-conference/ (Website)

Keywords

Additive Manufacturing
Conductors
Electric Machines
Energy Dissipation
Motors
Stators
Thermal Management

Access to Document

10.1109/ICEM51905.2022.9910686

Cite this

Pecotich, J., Klink, D., Heins, G., & Bahrani, B. (2022). Additively manufactured electric machine conductors with integrated end turn heat exchangers. In A. Luque, & V. Biot Monterde (Eds.), 2022 International Conference on Electrical Machines (ICEM 2022) (pp. 1498-1504). (2022 International Conference on Electrical Machines, ICEM 2022). IEEE, Institute of Electrical and Electronics Engineers. https://doi.org/10.1109/ICEM51905.2022.9910686

Pecotich, James ; Klink, David ; Heins, Greg et al. / Additively manufactured electric machine conductors with integrated end turn heat exchangers. 2022 International Conference on Electrical Machines (ICEM 2022). editor / Antonio Luque ; Vicente Biot Monterde. Piscataway NJ USA : IEEE, Institute of Electrical and Electronics Engineers, 2022. pp. 1498-1504 (2022 International Conference on Electrical Machines, ICEM 2022).

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title = "Additively manufactured electric machine conductors with integrated end turn heat exchangers",

abstract = "Conductors within a loaded electric machine commonly induce the highest loss. Numerous cooling solutions exist for high-power density electric machine conductors with external water jackets being the most common. The inherent disadvantage of water jacket cooling is the thermal resistance between the conductor and the cooling medium, which reduces the maximum cooling capacity, regardless of the jacket design. This restriction commonly leads designers to implement solutions such as end-turn cooling. The advances in additive manufacturing have unlocked new potential for conductor end-turn cooling. This paper investigates an additively-manufactured conductor with an integrated end-turn heat exchanger. The conductor is based around a Formula Student in-hub motor. This concept utilizes air-cooling and demonstrates a steady-state current density of 11 A/mm2 for a AlSi10Mg end-turn heat-exchanger conductor, without the added mass and complexity of liquid cooling solutions. If copper is used instead of AlSi10Mg, this value increases to approximately 22 A/mm2.",

keywords = "Additive Manufacturing, Conductors, Electric Machines, Energy Dissipation, Motors, Stators, Thermal Management",

author = "James Pecotich and David Klink and Greg Heins and Behrooz Bahrani",

note = "Funding Information: This project received grant funding from the Australian Government under Grant AEGP000004. This project was completed in partnership with the Monash Centre for Additive Manufacturing. Publisher Copyright: {\textcopyright} 2022 IEEE.; International Conference on Electrical Machines 2022, ICEM 2022 ; Conference date: 05-09-2022 Through 08-09-2022",

year = "2022",

doi = "10.1109/ICEM51905.2022.9910686",

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Pecotich, J, Klink, D, Heins, G & Bahrani, B 2022, Additively manufactured electric machine conductors with integrated end turn heat exchangers. in A Luque & V Biot Monterde (eds), 2022 International Conference on Electrical Machines (ICEM 2022). 2022 International Conference on Electrical Machines, ICEM 2022, IEEE, Institute of Electrical and Electronics Engineers, Piscataway NJ USA, pp. 1498-1504, International Conference on Electrical Machines 2022, Valencia, Spain, 5/09/22. https://doi.org/10.1109/ICEM51905.2022.9910686

Additively manufactured electric machine conductors with integrated end turn heat exchangers. / Pecotich, James; Klink, David; Heins, Greg et al.
2022 International Conference on Electrical Machines (ICEM 2022). ed. / Antonio Luque; Vicente Biot Monterde. Piscataway NJ USA: IEEE, Institute of Electrical and Electronics Engineers, 2022. p. 1498-1504 (2022 International Conference on Electrical Machines, ICEM 2022).

Research output: Chapter in Book/Report/Conference proceeding › Conference Paper › Research › peer-review

TY - GEN

T1 - Additively manufactured electric machine conductors with integrated end turn heat exchangers

AU - Pecotich, James

AU - Klink, David

AU - Heins, Greg

AU - Bahrani, Behrooz

N1 - Funding Information: This project received grant funding from the Australian Government under Grant AEGP000004. This project was completed in partnership with the Monash Centre for Additive Manufacturing. Publisher Copyright: © 2022 IEEE.

PY - 2022

Y1 - 2022

N2 - Conductors within a loaded electric machine commonly induce the highest loss. Numerous cooling solutions exist for high-power density electric machine conductors with external water jackets being the most common. The inherent disadvantage of water jacket cooling is the thermal resistance between the conductor and the cooling medium, which reduces the maximum cooling capacity, regardless of the jacket design. This restriction commonly leads designers to implement solutions such as end-turn cooling. The advances in additive manufacturing have unlocked new potential for conductor end-turn cooling. This paper investigates an additively-manufactured conductor with an integrated end-turn heat exchanger. The conductor is based around a Formula Student in-hub motor. This concept utilizes air-cooling and demonstrates a steady-state current density of 11 A/mm2 for a AlSi10Mg end-turn heat-exchanger conductor, without the added mass and complexity of liquid cooling solutions. If copper is used instead of AlSi10Mg, this value increases to approximately 22 A/mm2.

AB - Conductors within a loaded electric machine commonly induce the highest loss. Numerous cooling solutions exist for high-power density electric machine conductors with external water jackets being the most common. The inherent disadvantage of water jacket cooling is the thermal resistance between the conductor and the cooling medium, which reduces the maximum cooling capacity, regardless of the jacket design. This restriction commonly leads designers to implement solutions such as end-turn cooling. The advances in additive manufacturing have unlocked new potential for conductor end-turn cooling. This paper investigates an additively-manufactured conductor with an integrated end-turn heat exchanger. The conductor is based around a Formula Student in-hub motor. This concept utilizes air-cooling and demonstrates a steady-state current density of 11 A/mm2 for a AlSi10Mg end-turn heat-exchanger conductor, without the added mass and complexity of liquid cooling solutions. If copper is used instead of AlSi10Mg, this value increases to approximately 22 A/mm2.

KW - Additive Manufacturing

KW - Conductors

KW - Electric Machines

KW - Energy Dissipation

KW - Motors

KW - Stators

KW - Thermal Management

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M3 - Conference Paper

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T3 - 2022 International Conference on Electrical Machines, ICEM 2022

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EP - 1504

BT - 2022 International Conference on Electrical Machines (ICEM 2022)

A2 - Luque, Antonio

A2 - Biot Monterde, Vicente

PB - IEEE, Institute of Electrical and Electronics Engineers

CY - Piscataway NJ USA

T2 - International Conference on Electrical Machines 2022

Y2 - 5 September 2022 through 8 September 2022

ER -

Pecotich J, Klink D, Heins G, Bahrani B. Additively manufactured electric machine conductors with integrated end turn heat exchangers. In Luque A, Biot Monterde V, editors, 2022 International Conference on Electrical Machines (ICEM 2022). Piscataway NJ USA: IEEE, Institute of Electrical and Electronics Engineers. 2022. p. 1498-1504. (2022 International Conference on Electrical Machines, ICEM 2022). doi: 10.1109/ICEM51905.2022.9910686

Additively manufactured electric machine conductors with integrated end turn heat exchangers

Abstract

Publication series

Conference

Keywords

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