Dovetail Design for Direct Cooled Rotor: Design and Manufacturing

This work investigates dovetail joints as a means to mount pre-wound coils in an electrically excited rotor for a synchronous machine for EV application. The aim is to manufacture a prototype of a direct cooled machine with hollow rectangular rotor windings which requires a rotor design where the windings can be applied on the poles separately. Two experimental tensile tests are made to validate the mechanical simulation data, which are combined with electromagnetic simulations to optimize a dovetail design for assembly, mechanical strength and electromagnetic performance. The prototype is manufactured and assembled and preliminary tests are performed.