Detection and Mitigation of Hotspots in Electrical Machine Windings Using 3D Printing Technology

Electrical machines are integral to various industries, and their reliable operation is crucial for smooth processes. This paper investigates the common reasons for electrical machines failures and proposes effective mitigation strategies. The advent of additive manufacturing (AM) technology has unlocked previously inapplicable design possibilities, making them feasible and practical in ways that were not possible with conventional techniques. This research explores innovative design solutions in the fabrication of machine windings and their thermal management components. With AM technology, the study involves the design and prototyping of 3D-printed coils specifically built for high-power density electrical machines. The primary causes of hotspot in the machine windings are identified, and their locations are detected by scanning the coil at stranded level. Mitigation measures, such as advanced cooling, and improved materials are presented to minimize winding failures. Finite element modeling is employed to compare the performance of these innovative 3D coils with conventional windings in the high-frequency domain. The findings reveal that the 3D coil designs offer a combination of improved performance, simplified manufacturability, and significant weight reduction.