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

Çakal, Gökhan
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.


Flat winding made of aluminum or copper sheet for axial flux machines
Çakal, Gökhan; Keysan, Ozan (2021-04-01)
A novel flat winding topology has been proposed as an alternative to conventional windings with stranded round wires and other bar wound windings. The proposed winding is manufactured from thin conductor sheets by industrial tools such as stamping press, laser cutter, or water jet. As these tools are widely used in the production of electric machines, the flat winding topology can provide ease of manufacturing without significant modification to the production line. Besides, superior current ratings, shorte...
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Analysis and Fault Tolerant Control of a Five-Phase Axial Flux Permanent Magnet Synchronous Machine
Bayazıt, Göksenin Hande; Keysan, Ozan; Department of Electrical and Electronics Engineering (2021-9-06)
This study investigates the fault-tolerance capability of an air-cored, axial flux, five-phase permanent magnet synchronous machine. The air-cored stator is designed by adopting a novel winding topology that is called flat winding. The coils of flat winding are made by bending and grouping one within another of the flat wires made of a laser-cut thin aluminum sheet. This topology provides superior current ratings, better cooling performance, and a robust structure for the stator. As the coils are covered w...
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.