Design of 3D Printed High Performance Windings for Switched Reluctance Machines

This paper presents the design of high performance tooth coils for high speed switched reluctance machines (SRM) for automotive applications. The focus is on the calculation of the conductor losses taking into account eddy current effects induced by pulse shaped phase currents. A novel approach to produce completely ceramic insulated copper coils will be presented using an additive manufacturing technique which was developed at the Chemnitz University of Technology (TUC). The comparison between conventional resin insulated coils and ceramic insulated windings will be carried out considering the SRM characteristics at a specific point of operation taking into account the thermal behavior of the winding structures. The results show a significant increase in current loading capability of the proposed winding structure and higher acceptable operation temperatures of the machine.