Cast coils for electrical machines and their application in automotive and industrial drive systems

The casting production of coils for electrical machines is an innovative approach that offers significant advantages over conventional production methods in terms of achievable performance, torque density, and the thermal behaviour of electrical machines. Slot filling factors up to 90 % can be reached, whereas the production cost can be reduced due to good automation capability. On the other hand the cast coils are solid conductors which might lead to additional losses especially at high operating frequencies. In this paper, the electromagnetic and thermal characteristics of cast coils are presented. Two examples for automotive and industrial applications are shown.