article · Machines
Growing demand for electrical machines with higher power density creates electrical, mechanical, and thermal stresses that can lead to operational failure. Managing these stresses and the associated losses is critical to maintaining reliable performance. Winding losses constitute the primary loss mechanism in many electrical machines, though approaches to mitigating them and their associated stresses vary. Examining various winding topologies enables a clearer understanding of performance challenges and constraints across different machine types. A review of existing literature compares reported cases and highlights the application of additive manufacturing for winding production, noting that this manufacturing method has reached a high level of maturity. Critical design challenges persist, including high-frequency alternating current losses, thermal management, mechanical and acoustic issues, insulation ageing, automated manufacturing, and overall winding manufacturability.
Electrical machines need to deliver higher power while remaining reliable under harsh operating conditions. Because windings are the primary source of efficiency losses and potential points of failure, understanding design topologies and new manufacturing techniques helps engineers address overheating, wear, and mechanical noise in next-generation electric equipment.
This work informs electrical machine manufacturers and designers seeking to optimise winding production and machine reliability. The synthesis covers emerging additive manufacturing techniques that show high maturity, indicating potential near-term industrial use for prototype and specialised winding production, alongside ongoing applied research into automated production and thermal management challenges.
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The ever-increasing demand for higher-power dense electrical machines has resulted in different electrical, mechanical, and thermal stresses, which can eventually cause machine failure. For this reason, the management of stresses and losses must be thoughtfully investigated to have a highly reliable electrical machine. The literature agrees that winding losses are the dominant loss mechanism in many electrical machines. However, statements vary on how to mitigate these losses along with the aforementioned stresses. To avoid winding failure, a study of the various winding topologies would allow for a better consideration of the challenges and limitations in the performance of different electrical machines. To this aim, this paper introduces a comprehensive review for different winding topologies. Many reported cases in the literature are summarized and compared. Moreover, the utilization of additive manufacturing (AM) in the production of the machine windings is presented, showing a high level of maturity of this emerging technology. Finally, different challenges facing the design of machine windings are introduced including the AC high frequency losses, thermal management, mechanical and acoustic problems, insulation aging, automated production, and winding manufacturability.
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DOI: 10.3390/machines10070563
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