The Mitigation of Eddy-Current Losses in Ferromagnetic Samples Produced by Laser Powder Bed Fusion
We study the use of topology optimization in the design of low-loss ferromagnetic core structures for additively manufactured electrical machines. The test case was a simple toroid core with a primary and a secondary winding. A 2D axisymmetric finite element method model was implemented for the toro...
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description | We study the use of topology optimization in the design of low-loss ferromagnetic core structures for additively manufactured electrical machines. The test case was a simple toroid core with a primary and a secondary winding. A 2D axisymmetric finite element method model was implemented for the toroid, and the core topology was optimized for minimum losses and maximum secondary flux linkage. The optimized core was then modified for additive manufacturing, and test samples were built via laser powder bed fusion. The B-H characteristics and losses of the core were measured in several operation points. The losses were compared against an additively manufactured solid core, a laminated core, and an additively manufactured core with evenly placed air gaps (i.e., grooves). The results show that the losses in the topology-optimized core are on the same level as the losses in the laminated core and considerably smaller than those in the solid core, which is a considerable improvement to previous published works. |
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The test case was a simple toroid core with a primary and a secondary winding. A 2D axisymmetric finite element method model was implemented for the toroid, and the core topology was optimized for minimum losses and maximum secondary flux linkage. The optimized core was then modified for additive manufacturing, and test samples were built via laser powder bed fusion. The B-H characteristics and losses of the core were measured in several operation points. The losses were compared against an additively manufactured solid core, a laminated core, and an additively manufactured core with evenly placed air gaps (i.e., grooves). The results show that the losses in the topology-optimized core are on the same level as the losses in the laminated core and considerably smaller than those in the solid core, which is a considerable improvement to previous published works.</description><identifier>ISSN: 2169-3536</identifier><identifier>EISSN: 2169-3536</identifier><identifier>DOI: 10.1109/ACCESS.2022.3218669</identifier><identifier>CODEN: IAECCG</identifier><language>eng</language><publisher>Piscataway: IEEE</publisher><subject>Additive manufacturing ; Air gaps ; Coils ; Current loss ; Design optimization ; Eddy currents ; Ferromagnetism ; Finite element method ; Grooves ; Magnetic cores ; Optimization ; Powder beds ; Rapid prototyping ; Soft magnetic materials ; Solids ; Three dimensional printing ; Topology optimization ; Windings</subject><ispartof>IEEE access, 2022, Vol.10, p.1-1</ispartof><rights>Copyright The Institute of Electrical and Electronics Engineers, Inc. (IEEE) 2022</rights><lds50>peer_reviewed</lds50><oa>free_for_read</oa><woscitedreferencessubscribed>false</woscitedreferencessubscribed><citedby>FETCH-LOGICAL-c338t-f700ad5ca6942a181eee57a201741f3f69e6b0bfe015a1ca4f47d6727566cff03</citedby><cites>FETCH-LOGICAL-c338t-f700ad5ca6942a181eee57a201741f3f69e6b0bfe015a1ca4f47d6727566cff03</cites><orcidid>0000-0002-9698-1549 ; 0000-0003-0631-6711 ; 0000-0002-6671-6162 ; 0000-0001-6113-4377</orcidid></display><links><openurl>$$Topenurl_article</openurl><openurlfulltext>$$Topenurlfull_article</openurlfulltext><thumbnail>$$Tsyndetics_thumb_exl</thumbnail><linktohtml>$$Uhttps://ieeexplore.ieee.org/document/9933759$$EHTML$$P50$$Gieee$$Hfree_for_read</linktohtml><link.rule.ids>314,780,784,864,2102,4024,27633,27923,27924,27925,54933</link.rule.ids></links><search><creatorcontrib>Manninen, Aino</creatorcontrib><creatorcontrib>Pippuri-Makelainen, Jenni</creatorcontrib><creatorcontrib>Riipinen, Tuomas</creatorcontrib><creatorcontrib>Lindroos, Tomi</creatorcontrib><creatorcontrib>Metsa-Kortelainen, Sini</creatorcontrib><creatorcontrib>Antikainen, Atte</creatorcontrib><title>The Mitigation of Eddy-Current Losses in Ferromagnetic Samples Produced by Laser Powder Bed Fusion</title><title>IEEE access</title><addtitle>Access</addtitle><description>We study the use of topology optimization in the design of low-loss ferromagnetic core structures for additively manufactured electrical machines. The test case was a simple toroid core with a primary and a secondary winding. A 2D axisymmetric finite element method model was implemented for the toroid, and the core topology was optimized for minimum losses and maximum secondary flux linkage. The optimized core was then modified for additive manufacturing, and test samples were built via laser powder bed fusion. The B-H characteristics and losses of the core were measured in several operation points. The losses were compared against an additively manufactured solid core, a laminated core, and an additively manufactured core with evenly placed air gaps (i.e., grooves). The results show that the losses in the topology-optimized core are on the same level as the losses in the laminated core and considerably smaller than those in the solid core, which is a considerable improvement to previous published works.</description><subject>Additive manufacturing</subject><subject>Air gaps</subject><subject>Coils</subject><subject>Current loss</subject><subject>Design optimization</subject><subject>Eddy currents</subject><subject>Ferromagnetism</subject><subject>Finite element method</subject><subject>Grooves</subject><subject>Magnetic cores</subject><subject>Optimization</subject><subject>Powder beds</subject><subject>Rapid prototyping</subject><subject>Soft magnetic materials</subject><subject>Solids</subject><subject>Three dimensional printing</subject><subject>Topology optimization</subject><subject>Windings</subject><issn>2169-3536</issn><issn>2169-3536</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2022</creationdate><recordtype>article</recordtype><sourceid>ESBDL</sourceid><sourceid>RIE</sourceid><sourceid>DOA</sourceid><recordid>eNpNUV1r4zAQNEcLV9r8gr4I-uxUH7ZkPfZMcg3kaCHps1hbq9QhsXKSzZF_X6Uu5fSyYlYzs6vJsntG54xR_fhU14vNZs4p53PBWSWl_pHdcCZ1Lkohr_67_8xmMe5pOlWCSnWTNdt3JH-6odvB0PmeeEcW1p7zegwB-4GsfYwYSdeTJYbgj7DrcehasoHj6ZAar8HbsUVLmjNZQ8RAXv0_m8qvhC3HmDTvsmsHh4izr3qbvS0X2_o5X7_8XtVP67wVohpypygFW7YgdcGBVQwRSwWcMlUwJ5zUKBvaOKSsBNZC4QplpeKqlLJ1jorbbDXpWg97cwrdEcLZeOjMJ-DDzkBIsx_QlIWViagYNFhohCp56sZJKhqnWCOT1sOkdQr-74hxMHs_hj6Nb7gShdCci4ujmF61IX1TQPftyqi5ZGOmbMwlG_OVTWLdT6wubfjN0FoIVWrxAYFBicU</recordid><startdate>2022</startdate><enddate>2022</enddate><creator>Manninen, Aino</creator><creator>Pippuri-Makelainen, Jenni</creator><creator>Riipinen, Tuomas</creator><creator>Lindroos, Tomi</creator><creator>Metsa-Kortelainen, Sini</creator><creator>Antikainen, Atte</creator><general>IEEE</general><general>The Institute of Electrical and Electronics Engineers, Inc. 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The test case was a simple toroid core with a primary and a secondary winding. A 2D axisymmetric finite element method model was implemented for the toroid, and the core topology was optimized for minimum losses and maximum secondary flux linkage. The optimized core was then modified for additive manufacturing, and test samples were built via laser powder bed fusion. The B-H characteristics and losses of the core were measured in several operation points. The losses were compared against an additively manufactured solid core, a laminated core, and an additively manufactured core with evenly placed air gaps (i.e., grooves). 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subjects | Additive manufacturing Air gaps Coils Current loss Design optimization Eddy currents Ferromagnetism Finite element method Grooves Magnetic cores Optimization Powder beds Rapid prototyping Soft magnetic materials Solids Three dimensional printing Topology optimization Windings |
title | The Mitigation of Eddy-Current Losses in Ferromagnetic Samples Produced by Laser Powder Bed Fusion |
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