Thermal Influence of Physical Parameters of Additively Manufactured Windings in Permanent Magnet Synchronous Motors

For permanent magnet synchronous motor (PMSM), additively manufactured (AM) windings with variable cross-sectional shapes offer significant advantages in enhancing the slot fill factor and thermal properties, thereby contributing to an increase in power density. This paper presents a thermal model for AM windings of PMSM that accounts for the anisotropy of the equivalent insulation thermal conductivity at various locations within the slot. This model improves the accuracy of the predicted winding temperature rise. The physical parameters of AM windings can be controlled by modifying the printing parameters and post-processing conditions. The impact of electrical conductivity, thermal conductivity, and winding insulation parameters on the losses and temperature rise of PMSMs at various frequencies is then investigated. Finally, the temperature rise characteristics of the prototype PMSMs with the AM windings and the conventional windings are tested and compared, thereby confirming the validity of the thermal model for AM windings as well as their superior thermal properties.