Axial flux permanent magnet machine with novel flat winding made of conductor sheet

2020-10-13
Çakal, Gökhan
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This thesis proposes a novel winding topology, called flat winding, as an alternative to the conventional windings with stranded round wires for electric machines. It is made of a thin conductor sheet by industrial automation tools such as stamping press, laser, or water jet. Since these tools are widely used in the production of electric machines, the flat winding topology enjoys the advantage of the ease of manufacturing without significant modification on the production line. Superior current ratings, shortened end windings, and high fill factors are other advantages of flat winding. In order to evaluate its performance, it is implemented on the axial flux permanent magnet machine. Analytical modeling of the machine, including field modeling, voltage, torque derivations, and losses modeling, eliminated the finite element dependency. The promised advantages of flat winding are investigated on 1.4 kW, 26 Nm, and 48 V prototype machine, and the accuracy of the analytical models are validated through experimental verification. The feasibility of copper and aluminum flat windings is investigated on the prototype and compared in cost, manufacturing, and efficiency. The performance of flat winding topology in MW-scale machines are evaluated on 1 MW, 480 kNm, and 680 V direct-drive generator for wind turbine application. It is seen that flat winding has elevated the machine performance by achieving 46 Nm/kg torque density. In conclusion, the analysis in the thesis shows that novel flat winding topology is a promising alternative to the conventional windings for electric machines.
Electric machine winding, Axial flux permanent magnet machine, Analytical modeling, Wind turbine generator
https://hdl.handle.net/11511/69142
Graduate School of Natural and Applied Sciences, Thesis

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Citation Formats
G. Çakal, “Axial flux permanent magnet machine with novel flat winding made of conductor sheet,” M.S. - Master of Science, Middle East Technical University, 2020.
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