Enhanced Design and Electromagnetic Analysis of Synchronous Reluctance Machines Using Multi-Material Additive Manufacturing

This article comprehensively investigates the design and simulation of synchronous reluctance machines (SynRMs) using multi-material additive manufacturing (MMAM) methods. The main goal is to improve the electromagnetic performance of the machine by strategically utilizing various materials in the rotor's edge bridges to reduce quadrature inductance L<inf xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">q</inf>. A comparative analysis is led on various combinations of magnetic and non-magnetic materials, examining conventionally built machines with single materials alongside additively manufactured machines with both single and multiple materials. A demonstrator machine is built to analyze and determine essential performance parameters, emphasizing the optimization of the rotor. The research establishes an optimized rotor model to enhance electromagnetic performance and examines the operational impacts on electromagnetic torque and torque oscillations. Analytical and simulation findings illustrate the capability of multi-material additive manufacturing to improve the performance of conventional electric machines.