Design and Performance Analysis of Additively Manufactured Windings with High Slot Fill Factor for Permanent Magnet Synchronous Motors

With the rapid development of additive manufacturing (AM), applying this technology to the fabrication of structural components for motors has received widespread attention. The low slot fill factor and low thermal conductivity of traditionally-manufactured windings prevent further improvements of motor performance. Therefore, this paper proposes two concentrated winding structures with variable cross-sectional area based on AM that can significantly improve the slot fill factor. The realisation of high slot fill factor greatly improves the output performance of the motor. However, the design of the variable cross-sectional area also increases the sensitivity of the winding losses to frequency variations. On this basis, the temperature rise modelling method and temperature rise distribution of AM windings are discussed, taking into account the special structure of AM windings. The above characteristics have also been compared with traditional windings.