Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

Nick Simpson; Phil H Mellor

doi:10.1109/IEMDC.2017.8002337

Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

Nick Simpson, Phil H Mellor

Research output: Chapter in Book/Report/Conference proceeding › Conference Contribution (Conference Proceeding)

36 Citations (Scopus)

1151 Downloads (Pure)

Abstract

Wound components typically represent approximately 50 % of the total mass of a power converter, consequently minimising the mass and volume of transformers and filter inductors is an important challenge in the design of compact power dense converters in transport and other demanding applications. The research described in this paper contributes to a body of work investigating design tools and new manufacturing processes aimed at reducing the mass and volume of wound components. In this instance, the design and manufacture of minimal AC loss shaped profile windings using metal additive manufacturing is explored. A prototype inductor is manufactured and experimentally tested to demonstrate the advantages of shaped windings for AC loss reduction.

Original language	English
Title of host publication	2017 IEEE International Electric Machines and Drives Conference (IEMDC 2017)
Publisher	Institute of Electrical and Electronics Engineers (IEEE)
Number of pages	7
ISBN (Electronic)	9781509042814
ISBN (Print)	9781509042821
DOIs	https://doi.org/10.1109/IEMDC.2017.8002337
Publication status	Published - 8 Aug 2017
Event	2017 International Electric Machines and Drives Conference (IEMDC 2017) - Miami, United States Duration: 21 May 2017 → 24 May 2017

Conference

Conference	2017 International Electric Machines and Drives Conference (IEMDC 2017)
Country/Territory	United States
City	Miami
Period	21/05/17 → 24/05/17

Keywords

AC loss
wound passive component
additive manufacturing
copper

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10.1109/IEMDC.2017.8002337

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Accepted author manuscript, 1.2 MB

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@inproceedings{76a2c74dc2df46cea5965b8e37ea7f6a,

title = "Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors",

abstract = "Wound components typically represent approximately 50 % of the total mass of a power converter, consequently minimising the mass and volume of transformers and filter inductors is an important challenge in the design of compact power dense converters in transport and other demanding applications. The research described in this paper contributes to a body of work investigating design tools and new manufacturing processes aimed at reducing the mass and volume of wound components. In this instance, the design and manufacture of minimal AC loss shaped profile windings using metal additive manufacturing is explored. A prototype inductor is manufactured and experimentally tested to demonstrate the advantages of shaped windings for AC loss reduction.",

keywords = "AC loss, wound passive component, additive manufacturing, copper",

author = "Nick Simpson and Mellor, {Phil H}",

year = "2017",

month = aug,

day = "8",

doi = "10.1109/IEMDC.2017.8002337",

language = "English",

isbn = "9781509042821",

booktitle = "2017 IEEE International Electric Machines and Drives Conference (IEMDC 2017)",

publisher = "Institute of Electrical and Electronics Engineers (IEEE)",

address = "United States",

note = "2017 International Electric Machines and Drives Conference (IEMDC 2017) ; Conference date: 21-05-2017 Through 24-05-2017",

}

Simpson, N & Mellor, PH 2017, Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors. in 2017 IEEE International Electric Machines and Drives Conference (IEMDC 2017). Institute of Electrical and Electronics Engineers (IEEE), 2017 International Electric Machines and Drives Conference (IEMDC 2017), Miami, United States, 21/05/17. https://doi.org/10.1109/IEMDC.2017.8002337

Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors. / Simpson, Nick ; Mellor, Phil H.
2017 IEEE International Electric Machines and Drives Conference (IEMDC 2017). Institute of Electrical and Electronics Engineers (IEEE), 2017.

Research output: Chapter in Book/Report/Conference proceeding › Conference Contribution (Conference Proceeding)

TY - GEN

T1 - Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

AU - Simpson, Nick

AU - Mellor, Phil H

PY - 2017/8/8

Y1 - 2017/8/8

N2 - Wound components typically represent approximately 50 % of the total mass of a power converter, consequently minimising the mass and volume of transformers and filter inductors is an important challenge in the design of compact power dense converters in transport and other demanding applications. The research described in this paper contributes to a body of work investigating design tools and new manufacturing processes aimed at reducing the mass and volume of wound components. In this instance, the design and manufacture of minimal AC loss shaped profile windings using metal additive manufacturing is explored. A prototype inductor is manufactured and experimentally tested to demonstrate the advantages of shaped windings for AC loss reduction.

AB - Wound components typically represent approximately 50 % of the total mass of a power converter, consequently minimising the mass and volume of transformers and filter inductors is an important challenge in the design of compact power dense converters in transport and other demanding applications. The research described in this paper contributes to a body of work investigating design tools and new manufacturing processes aimed at reducing the mass and volume of wound components. In this instance, the design and manufacture of minimal AC loss shaped profile windings using metal additive manufacturing is explored. A prototype inductor is manufactured and experimentally tested to demonstrate the advantages of shaped windings for AC loss reduction.

KW - AC loss

KW - wound passive component

KW - additive manufacturing

KW - copper

U2 - 10.1109/IEMDC.2017.8002337

DO - 10.1109/IEMDC.2017.8002337

M3 - Conference Contribution (Conference Proceeding)

SN - 9781509042821

BT - 2017 IEEE International Electric Machines and Drives Conference (IEMDC 2017)

PB - Institute of Electrical and Electronics Engineers (IEEE)

T2 - 2017 International Electric Machines and Drives Conference (IEMDC 2017)

Y2 - 21 May 2017 through 24 May 2017

ER -

Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

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