Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical Machine
Additive manufacturing (AM) enables the creation of parts with exceptional geometric versatility, creating new possibilities for developing nonsymmetrical electrical machines (EM) with compact structures, reduced mass density, high torque, better power density, and minimal material waste during fabr...
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| Format: | Article |
| Language: | English |
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IEEE
2024-01-01
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| Series: | IEEE Open Journal of the Industrial Electronics Society |
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| Online Access: | https://ieeexplore.ieee.org/document/10772070/ |
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| author | Zahoor Ahmad Ants Kallaste Toomas Vaimann Muhammad Usman Naseer Shahid Hussain Anton Rassolkin |
| author_facet | Zahoor Ahmad Ants Kallaste Toomas Vaimann Muhammad Usman Naseer Shahid Hussain Anton Rassolkin |
| author_sort | Zahoor Ahmad |
| collection | DOAJ |
| description | Additive manufacturing (AM) enables the creation of parts with exceptional geometric versatility, creating new possibilities for developing nonsymmetrical electrical machines (EM) with compact structures, reduced mass density, high torque, better power density, and minimal material waste during fabrication. This review highlights the current state of AM methods and their critical role in the production of EM. The impact of the additively built EM components concerning performance indices, including torque, power density, and efficiency, is highlighted. In addition, an overview of the constraints associated with the traditional production process of EM-specific components and the role of AM in addressing those limitations is emphasized. As per the current state of AM in the context of EM production, the nonconventional structures of the stator and rotor core of EMs are feasible to fabricate to accomplish improved utilization of magnetic flux. Moreover, AM enables the fabrication of windings/coils of any profiles with integrated functionality, including the design of thermal management mechanisms to enhance EM performance and achieve thermally controlled EM. However, the current state of AM technology is not very advanced and requires additional improvement, particularly in areas of EM production, which are minimizing eddy current losses, high-quality surface refinement, build volume restrictions, and simultaneous multimaterials processing. |
| format | Article |
| id | doaj-art-159a0eddf0e146dc9f439eb510188a55 |
| institution | Kabale University |
| issn | 2644-1284 |
| language | English |
| publishDate | 2024-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Open Journal of the Industrial Electronics Society |
| spelling | doaj-art-159a0eddf0e146dc9f439eb510188a552025-01-18T00:01:34ZengIEEEIEEE Open Journal of the Industrial Electronics Society2644-12842024-01-0151300132310.1109/OJIES.2024.350954710772070Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical MachineZahoor Ahmad0https://orcid.org/0000-0001-6914-4174Ants Kallaste1https://orcid.org/0000-0001-6126-1878Toomas Vaimann2https://orcid.org/0000-0003-0481-5066Muhammad Usman Naseer3https://orcid.org/0000-0002-1682-9169Shahid Hussain4https://orcid.org/0000-0003-3773-166XAnton Rassolkin5https://orcid.org/0000-0001-8035-3970Department of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Tallinn, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Tallinn, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Tallinn, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Tallinn, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Tallinn, EstoniaDepartment of Electrical Power Engineering and Mechatronics, Tallinn University of Technology, Tallinn, EstoniaAdditive manufacturing (AM) enables the creation of parts with exceptional geometric versatility, creating new possibilities for developing nonsymmetrical electrical machines (EM) with compact structures, reduced mass density, high torque, better power density, and minimal material waste during fabrication. This review highlights the current state of AM methods and their critical role in the production of EM. The impact of the additively built EM components concerning performance indices, including torque, power density, and efficiency, is highlighted. In addition, an overview of the constraints associated with the traditional production process of EM-specific components and the role of AM in addressing those limitations is emphasized. As per the current state of AM in the context of EM production, the nonconventional structures of the stator and rotor core of EMs are feasible to fabricate to accomplish improved utilization of magnetic flux. Moreover, AM enables the fabrication of windings/coils of any profiles with integrated functionality, including the design of thermal management mechanisms to enhance EM performance and achieve thermally controlled EM. However, the current state of AM technology is not very advanced and requires additional improvement, particularly in areas of EM production, which are minimizing eddy current losses, high-quality surface refinement, build volume restrictions, and simultaneous multimaterials processing.https://ieeexplore.ieee.org/document/10772070/3-D printingadditive manufacturing (AM)conventional manufacturing limitationselectric machine designsoft magnetic materialsthermal management system |
| spellingShingle | Zahoor Ahmad Ants Kallaste Toomas Vaimann Muhammad Usman Naseer Shahid Hussain Anton Rassolkin Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical Machine IEEE Open Journal of the Industrial Electronics Society 3-D printing additive manufacturing (AM) conventional manufacturing limitations electric machine design soft magnetic materials thermal management system |
| title | Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical Machine |
| title_full | Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical Machine |
| title_fullStr | Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical Machine |
| title_full_unstemmed | Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical Machine |
| title_short | Review of Design Freedom Offered by Additive Manufacturing for Performance Enhancement of Electrical Machine |
| title_sort | review of design freedom offered by additive manufacturing for performance enhancement of electrical machine |
| topic | 3-D printing additive manufacturing (AM) conventional manufacturing limitations electric machine design soft magnetic materials thermal management system |
| url | https://ieeexplore.ieee.org/document/10772070/ |
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