Performance Study and Parameters Optimization of Additively Manufactured Windings Applied to Permanent Magnet Synchronous Motors

This paper proposes an additively manufactured (AM) winding structure for permanent magnet synchronous motors (PMSMs) that can significantly improve the slot fill factor. A comprehensive analysis is conducted on the electromagnetic and thermal characteristics of the AM winding, and a comparison is made with the conventional winding. The results of the comparison indicate that the AM winding can significantly increase the output torque while reducing the temperature rise of the AM winding. The parameters affecting the output performance of the PMSM using the AM winding are subjected to sensitivity analysis and optimization design using orthogonal test. The specific power and efficiency of the optimized motor are increased. And then the variation of winding turns on thermal performance is analyzed. Lastly, the AM winding samples are fabricated and the physical properties of the AM winding samples are tested. And the temperature rise characteristics are compared with those of the conventional winding.