Highly Manufacturable Edgewise Winding Design Integrating Cooling Solutions for High Power Density Applications

Edgewise winding is reported recently for high-performance electric machines. However, to achieve widespread uptake of electric machines, it is essential to consider the manufacturing time of the complete machine solution. For example, with different winding topologies, the cooling solutions for edgewise winding machines will be different compared to traditional round windings. This paper considers the manufacturability of edgewise windings through stator slot shape and winding cross section. A variety of cooling solutions are incorporated to increase power density, designed such that the high-quality thermal transfer pathways of edgewise windings are exploited. The contribution of the paper is the design and simulation of a manufacturable edgewise winding using finite element software for electromagnetic design and losses, as well as thermal analysis with a lumped parameter thermal network. The edgewise winding structure is developed and compared with various cooling solutions incorporated for high power density applications. The power density for the proposed, easier-to-manufacture parallel tooth edgewise winding topology is increased by 13.6% compared to the parallel slot edgewise winding with a slot opening duct cooling.