Additive Manufacturing Overlapping Winding for Enhanced Performance of a Coreless Permanent Magnet Synchronous Linear Motor

This paper proposes an additive manufacturing overlapping winding adopting tangentially place flat conductors in coreless permanent magnet linear synchro-nous motors to reduce eddy current and improve motor performance. The differences among AM overlapping winding with radially or tangentially placed flat conductors and traditional concentrated winding are analyzed in terms of copper fill rate, winding factor, copper loss, and output characteristics. Moreover, the effect of winding structure parameters and material conductivity on copper loss and output thrust is conducted for preparation of further opti-mization. Finally, the winding samples are printed to verify the theoretical analysis, providing experience for application of additive manufacturing in motors.