This paper presents current research trends and prospects of utilizing additive manufacturing (AM) techniques to manufacture electrical machines. Modern-day machine applications require extraordinary ...performance parameters such as high power-density, integrated functionalities, improved thermal, mechanical & electromagnetic properties. AM offers a higher degree of design flexibility to achieve these performance parameters, which is impossible to realize through conventional manufacturing techniques. AM has a lot to offer in every aspect of machine fabrication, such that from size/weight reduction to the realization of complex geometric designs. However, some practical limitations of existing AM techniques restrict their utilization in large scale production industry. The introduction of three-dimensional asymmetry in machine design is an aspect that can be exploited most with the prevalent level of research in AM. In order to take one step further towards the enablement of large-scale production of AM-built electrical machines, this paper also discusses some machine types which can best utilize existing developments in the field of AM.
Metal additive manufacturing (AM) technology is maturing. Although currently slower and less reliable than traditional production methods, AM systems shine when producing parts with unconventional ...topologies or in small quantities. Like countless other research communities, the electrical machine (EM) research community has shifted considerable efforts towards integrating AM systems into the EM production cycle to implement more powerful and efficient topology optimized (TO) next-generation EMs. In this paper, the state-of-the-art printing of soft magnetic, hard magnetic, and electrically conductive materials was investigated to evaluate the maturity of each material type for integration into EM construction. The highest maturity was identified for AM pure copper, showing characteristics equivalent to commercial high purity copper. In contrast, AM permanent magnets were the least mature: suffering from low power density and limited magnetization capacities. Printed soft magnetic steels were characterized as halfway in-between: on one side showing equivalent DC magnetic properties to conventional non-oriented steels, but on the other – suffering from high eddy current losses in AC applications. Based on the study's findings, it would appear that the emergence of additively manufactured EMs is only a matter of time. We predict a dramatic increase in the printing of prototype TO components within the next few years, focusing most likely on TO machine windings, heat exchangers, and synchronous rotors.
The bio-inspired algorithms are novel, modern, and efficient tools for the design of electrical machines. However, from the mathematical point of view, these problems belong to the most general ...branch of non-linear optimization problems, where these tools cannot guarantee that a global minimum is found. The numerical cost and the accuracy of these algorithms depend on the initialization of their internal parameters, which may themselves be the subject of parameter tuning according to the application. In practice, these optimization problems are even more challenging, because engineers are looking for robust designs, which are not sensitive to the tolerances and the manufacturing uncertainties. These criteria further increase these computationally expensive problems due to the additional evaluations of the goal function. The goal of this paper is to give an overview of the widely used optimization techniques in electrical machinery and to summarize the challenges and open problems in the applications of the robust design optimization and the prospects in the case of the newly emerging technologies.
This paper presents an analytical modelling technique based on modified winding function and co‐energy analysis, for characterisation of synchronous reluctance machines, in conjunction with a hybrid ...algorithm for mapping of the machine's operating point on BH curve and the corresponding performance parameters in non‐linear magnetic condition. The model successfully provides the mean torque and the torque profiles of a synchronous reluctance motor as a function of input current and load‐angle in the magnetic linear and non‐linear conditions. The obtained results of this proposed model are compared with finite‐element‐analysis (FEA) based commercial design software Simcentre‐MAGNET. The comparison proves this model's capability to estimate the machine's performance parameters with considerable accuracy from an already established design analysis technique, FEA. The proposed modelling technique requires only a fraction of simulation runtime when compared to other design analysis techniques. Considering the accuracy of this modelling technique and the least requirement of computation resources and simulation time, this model can be used as an initial iterative‐design tool for mass personalised, additively manufactured electrical machines where rapidness of the iterative design analysis tool is of paramount importance.
The increasing demand for intelligent machines, coupled with the drive for the more efficient utilization of these machines in various industries, and the emergence of Industry 4 ...
A review of the fault diagnostic techniques based on machine is presented in this paper. As the world is moving towards industry 4.0 standards, the problems of limited computational power and ...available memory are decreasing day by day. A significant amount of data with a variety of faulty conditions of electrical machines working under different environments can be handled remotely using cloud computation. Moreover, the mathematical models of electrical machines can be utilized for the training of AI algorithms. This is true because the collection of big data is a challenging task for the industry and laboratory because of related limited resources. In this paper, some promising machine learning-based diagnostic techniques are presented in the perspective of their attributes.
Additively manufactured soft magnetic Fe-3.7%w.t.Si toroidal samples with solid and novel partitioned cross-sectional geometries are characterized through magnetic measurements. This study focuses on ...the effect of air gaps and annealing temperature on AC core losses at the 50 Hz frequency. In addition, DC electromagnetic material properties are presented, showing comparable results to conventional and other 3D-printed, high-grade, soft magnetic materials. The magnetization of 1.5 T was achieved at 1800 A/m, exhibiting a maximum relative permeability of 28,900 and hysteresis losses of 0.61 (1 T) and 1.7 (1.5 T) W/kg. A clear trend of total core loss reduction at 50 Hz was observed in relation to the segregation of the specimen cross-sectional topology. The lowest 50 Hz total core losses were measured for the toroidal specimen with four internal air gaps annealed at 1200 °C, exhibiting a total core loss of 1.2 (1 T) and 5.5 (1.5 T) W/kg. This is equal to an 860% total core loss reduction at 1 T and a 510% loss reduction at 1.5 T magnetization compared to solid bulk-printed material. Based on the findings, the advantages and disadvantages of printed air-gapped material internal structures are discussed in detail.
Designed to store and discharge electrical energy, rechargeable batteries consist of elementary storage cell assemblies. Aging is affected by various aggravating factors, mainly temperature. There ...are many electric or electrochemical models which describe their operation. Most standard models do not consider the aging phenomena of batteries and their consequences, while batteries deteriorate when used or stored. Precisely, most battery models do not simulate the influence of cell aging on other cells. The model presented in this paper incorporates aging and the effects of mutual interactions between cells. The model can be established based on four measurement points on the cell characteristic curve and allows the simulation of a single cell’s or multiple coupled cells’ behavior. The model can then be easily implemented in simulation software like Matlab.
This article explores the transformative potential of digital twin (DT) technology in the automotive sector, focusing on its applications in enhancing propulsion drive systems. DT technology, a ...virtual representation of physical objects, has gained momentum due to its real-time monitoring and analysis capabilities. Within the automotive industry, where propulsion systems dictate vehicle performance, DTs offer a game-changing approach. Propulsion drive systems encompass electric motors, transmissions, and related components, significantly impacting efficiency and power delivery. Traditional design and testing methods need help addressing these systems’ intricate interactions. This article aims to investigate how DTs can revolutionize propulsion systems. The study examines various applications of DTs, ranging from predictive maintenance to performance optimization and energy efficiency enhancement. The article underscores the technology’s potential by reviewing case studies and real-world implementations. It also outlines challenges tied to integration and validation. In unveiling the capabilities of DT technology for propulsion systems, this article contributes to a comprehensive understanding of its role in shaping a more data-driven and efficient automotive industry.
Nowadays, electrical machines and drive systems are playing an essential role in different applications. Eventually, various failures occur in long-term continuous operation. Due to the increased ...influence of such devices on industry, industrial branches, as well as ordinary human life, condition monitoring and timely fault diagnostics have gained a reasonable importance. In this review article, there are studied different diagnostic techniques that can be used for algorithms’ training and realization of predictive maintenance. Benefits and drawbacks of intelligent diagnostic techniques are highlighted. The most widespread faults of electrical machines are discussed as well as techniques for parameters’ monitoring are introduced.
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