Power loss observations in algorithmically designed PMSM stator windings utilizing the freedoms afforded by additive manufacturing

Permanent magnet synchronous machines (PMSM) are an increasingly popular motor topology for many industries such as automotive, aerospace, manufacturing, energy and premium consumer goods. PMSM offer many advantages compared to other topologies such as induction machines due to their higher power density, greater operational efficiency and high torque, whilst remaining robust and fault tolerant. One specific area of interest is the stator windings. With increasing operational speed, the geometric configuration of the winding becomes ever increasingly important in order to mitigate increasing AC losses. The windings conductor lay in slot, position, shape and orientation become critical in combating loss mechanisms such as skin effect, proximity effect and armature reaction. Additive manufacturing offers a novel geometric design freedom that has previously been unattainable using traditional manufacturing methods and enables the ability to create highly novel winding design methodologies that could potentially revolutionise winding design and performance. This work investigates the losses observed from an algorithmically designed stator winding, additively manufactured in AlSi10Mg using the laser powder bed fusion process. A motorette sub-assembly was constructed and the DC and AC power losses were measured and compared against a theoretical 3D FEA based simulation model. The outcome observed a 9.4% difference in losses comparing theoretical and measured winding values utilising the RAC/RDC measured. Samples of the additively manufactured conductor parts have been tested for resistivity and conductivity.