Design and Analysis of Compressed Windings for a Permanent Magnet Integrated Starter Generator

This paper focuses on the improved thermal performance of electrical machines by increasing the conductor fill factor. A comparative design study of the integrated starter generator is used as a case study to investigate the mechanical, electrical, and thermal aspects of pressing coils. By performing quasi-static explicit dynamics simulations, deformation of insulation has been investigated. Magnet wires of 1.25 mm diameter are simulated and demonstrated to be compressible up to a 0.73 fill factor without observing insulation failure. Thermal conductivity enhancement of the stator windings at improved slot fill factor is investigated by performing steady-state finite element analysis thermal simulations and short-time thermal transient tests.