This article presents a novel use of three-dimensional printed direct winding heat exchangers (3-D-DWHX) to improve the thermal management stator in high power density electric machines. The 3-D-DWHX is contact with windings, enabling continuous current densities. dielectric polymer for exchanger allows windings without an additional insulation material. By occupying otherwise unused space between double layer concentrated there no significant impact on electromagnetic design, and smaller...

Direct winding oil cooling offers more effective than conventional alternatives and can therefore increase the torque density of electric machines; however, this technique is limited by thermophysical properties oil. The use a direct heat exchanger (DWHX) allows glycol-water coolant mixture to be used which leads significant improvement in transfer reduction pumping losses compared cooling. This paper proposed ceramic 3D printed exchangers (3D-DWHX) significantly improve concentrated...

Direct cooling of the windings in a motor using oil offers more effective thermal management than conventional alternatives and can therefore increase torque density electric machines; however, this technique is limited by thermophysical properties oil. The use direct winding heat exchanger allows glycol-water coolant mixture to be used, which leads significant improvement transfer reduction pumping losses compared cooling. This article proposes ceramic 3-D printed exchangers (3D-DWHX),...

In this work, additively manufactured (AM) aluminum nitride (AlN) ceramic heat pipes were developed to improve spacecraft rejection capabilities beyond the current state-of-the-art metal systems. A low sintering temperature slurry is for digital light processing printing (DLP) and optimal debinding curves are examined. Printed AlN parts characterized via SEM optical profilometry. 3D-printed also tested compatibility with bromide, chloride, iodine, among other proposed working fluids at...

As the power density of electric machines increases, rotor thermal analysis becomes critical as losses caused by higher fundamental frequencies increase. The often has poor communication with stator cooling medium, and therefore alternative methods may be required in high to maintain safe operating temperature, especially mounted permanent magnet motors. In this paper, a review design considerations is discussed, along key tools used rotors for machines.

The High Efficiency Megawatt Motor (HEMM) is being designed to meet the needs of Electrified Aircraft Propulsion (EAP). A detailed design in progress with changes that are informed by component testing. These risk reduction activities conducted three key areas: cryogenic cooler design, superconducting rotor coil and manufacturing, stator thermal management. objective HEMM establish a motor technology which simultaneously attains high specific power (>16 kW/kg ratio electromagnetic weight)...

The objective of this article is to evaluate the self-cooling performance a novel integrated flux-switching permanent magnet (FSPM) machine with an airfoil-shaped rotor. rotor proposed functioning as both motor well axial fan. It rotates draw air from ambient into and accelerate flow through stage. high-speed provides forced convection rotor, stator, windings, magnets. Therefore, achieved. Accounting for manufacturing challenges airfoil blades, three-dimensional (3-D) printed blade caps are...

This paper investigates the design and testing of a high-speed dual-stator 6/4 flux-switching permanent magnet (FSPM) machine. A is used to solve issue second harmonic presented in flux linkage conventional FSPM Different designs are investigated compared against each other terms performance manufacturability. Comparison between proposed FPSM machine commonly seen 12/10 done at 10 kW, 15000 rpm condition. Due 60% reduction fundamental frequency, significant iron loss eddy current observed,...

The surface permanent magnet (SPM) and flux-switching (FSPM) machines are good candidates for high power density high-speed applications. SPM FSPM share several similarities such as negligible reluctance torque equivalent air gap length. This paper gives a comprehensive comparison on the design of an eight pole dual-stator 6/4 at two different speeds. choice characteristics retaining sleeves in machine material, thickness, loss speeds discussed. Depending sleeve, can have severe thermal...

The objective of this paper is to investigate the self-cooling performance a novel integrated flux-switching PM (FSPM) machine with airfoil-shaped rotor. rotor proposed functioning as both motor well an axial fan. It rotates draw air from ambient into and accelerate flow through stage. high-speed provides forced convection rotor, stator, windings, magnets. Therefore, achieved. Accounting for manufacturing challenges airfoil blades, 3-D printed blade caps are designed assembled over laminated...

This paper focuses on the influence windage loss brought by different rotor structures of flux-switching permanent magnet machines. Ribs and shrouds are added to salient pole reduce loss. The baseline machine has a dual-stator/rotor structure, which introduces complications in evaluating with empirical methods. Computational fluid dynamics tool finite element analysis used evaluate characteristics electromagnetic performance types rotors, respectively. results show that is most effective...

The objective of this paper is to investigate the influence rotor pole thickness on combinations stator slots and poles in a novel integrated flux-switching motor-compressor. motor-compressor also an axial-flow compressor. Therefore, requirements are based both motor compressor performances. optimal slot determined considering electromagnetic thermodynamic winding connections machines different investigated. performances compared by analytical methods finite element analysis (FEA).

View Video Presentation: https://doi.org/10.2514/6.2023-3878.vid As electrified aircraft propulsion (EAP) matures and power electronics, electric machines, batteries achieve higher density, the thermal management of these devices becomes ever more critical. In this paper, a heat pipe made from dielectric ceramic material is proposed, which enables its use in high frequency filter inductor for an EAP electronics application. The manufacturing process sintered powder wick was developed...

Single-layer winding structure is able to increase the factor of dual-stator 6/4 flux-switching permanent magnet (FSPM) machine compared conventional double-layer winding. The use toroidal in single-layer significantly reduces manufacturing complexity and risk turn-to-turn short. This paper investigates design performance winding, FSPM equipped with Because higher factor, topology can achieve same power smaller size or lower electric loading topology. In addition, shown have better field...

This study investigates the thermal impact of using different winding topologies and encapsulation materials on dual‐stator 6/4 flux‐switching permanent magnet (FSPM) machine with water jacket cooling. The performance four design cases are compared lumped‐parameter network models. modelling heat transfer in stator slot, air gap channel presented. It is shown that FSPM machines circumferential toroidal have limiting components material has a two topologies. Prototype motors built tested to validate

Flux-switching permanent magnet (FSPM) machine is a type of stator with high torque density. In this paper, an overlapping winding (OW) design employed on dual-stator 6/4 FSPM machine. The has larger coil span and therefore, brings almost double flux-linkage back EMF, which leads to higher density comparing non-overlapping design. Advantages are discussed in the paper. Analytical derivation slot vector used study connection. Direct performance comparison finite element analysis made between...

View Video Presentation: https://doi.org/10.2514/6.2023-4505.vid This paper presents a concept design for the 5 MW generators on NASA's SUSAN hybrid electric flight concept. The performance targets this machine are 25 kW/kg and 99% efficiency. is partially superconducting that builds past work its High Efficiency Megawatt Motor (HEMM). A tool used to create preliminary capable of achieving target specifications generator. Higher fidelity analysis applied design. After high predicted achieve...

View Video Presentation: https://doi.org/10.2514/6.2021-3335.vid As the power density of electric machines and electronics continues to increase meet demands more aircraft, thermal management these devices becomes increasingly important. Ideally, solution device should have high conductivity be electrically insulating so that it can directly integrated with in question. Technical ceramics are a class materials two requirements. Direct liquid cooling by submerging components dielectric fluid...

This paper presents a novel use of 3D printed heat exchangers for advanced thermal management electric machines. Thermal and computational fluid dynamics models are used to quantify the effectiveness printed, Direct Winding Heat eXchangers (3D-DWHX). printing enables complex flow geometries be produced which facilitates integration exchanger reduces component count. The dielectric polymer allows direct contact with high voltage components minimize resistance between windings coolant. By...

View Video Presentation: https://doi.org/10.2514/6.2021-3275.vid High specific power density, megawatt-scale electric machines (motors and generators) are needed to enable aircraft propulsion systems for single-aisle aircraft. Thermally insulating electrical insulation materials in the stator windings limits ability thermally manage heat produced these machines. Polymer-ceramic composites along with novel processing techniques offer viable options improve thermal conductivity of system. This...

View Video Presentation: https://doi.org/10.2514/6.2023-4507.vid Megawatt (MW) electric aircraft propulsion (EAP) is seen as a significant contributor toward achieving the goals set forth by Sustainable Flight National Partnership. A large part of enabling MW EAP developing specific-power-dense machines. As machines are scaled up from kW to power levels, thermal stresses on increase in both magnitude and performance-affecting characteristics. This particularly true for stators these Analysis...