Precompressed and Stranded Aluminum Motor Windings for Traction Motors

James Widmer; Richard Martin; Barrie C.  Mecrow

doi:10.1109/TIA.2016.2528226

Precompressed and Stranded Aluminum Motor Windings for Traction Motors

James Widmer, Richard Martin, Barrie C. Mecrow

Newcastle University

Research output: Contribution to journal › Article › peer-review

44 Citations (Scopus)

1537 Downloads (Pure)

Abstract

There are benefits if copper windings are replaced with aluminum in applications that are cost- and mass-sensitive, such as automotive traction; these include the low cost of aluminum, low mass of aluminum, and the ease of motor recycling at the end of life. However, the relatively low electrical conductivity of aluminum compared to copper needs to be overcome. Precompressed motor coils have been shown to produce very high fill factors (> 75%), reducing dc-winding losses, therefore enabling the use of aluminum conductors. However, the single-stranded conductors used can be prone to high ac losses due to skin and proximity effects. Therefore, a method of manufacture of precompressed coils made from stranded/Litz wire is needed, allowing ac losses to be reduced to low levels. This paper describes the development and test of stranded, precompressed aluminum coils, which have been developed for use in an automotive traction application.

Original language	English
Pages (from-to)	2215 - 2223
Number of pages	9
Journal	IEEE Transactions on Industry Applications
Volume	52
Issue number	3
Early online date	11 Feb 2016
DOIs	https://doi.org/10.1109/TIA.2016.2528226
Publication status	Published - 1 May 2016
Externally published	Yes

Bibliographical note

© 2016 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any
copyrighted component of this work in other works.

Keywords

Windings
Aluminum Conductors
Electric Machines

Access to Document

10.1109/TIA.2016.2528226

Post-PrintAccepted author manuscript, 1.13 MBLicence: Unspecified

James Widmer
- Centre for E-Mobility and Clean Growth - Professor in Electric Propulsion Systems
Person: Teaching and Research

Cite this

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title = "Precompressed and Stranded Aluminum Motor Windings for Traction Motors",

abstract = "There are benefits if copper windings are replaced with aluminum in applications that are cost- and mass-sensitive, such as automotive traction; these include the low cost of aluminum, low mass of aluminum, and the ease of motor recycling at the end of life. However, the relatively low electrical conductivity of aluminum compared to copper needs to be overcome. Precompressed motor coils have been shown to produce very high fill factors (> 75%), reducing dc-winding losses, therefore enabling the use of aluminum conductors. However, the single-stranded conductors used can be prone to high ac losses due to skin and proximity effects. Therefore, a method of manufacture of precompressed coils made from stranded/Litz wire is needed, allowing ac losses to be reduced to low levels. This paper describes the development and test of stranded, precompressed aluminum coils, which have been developed for use in an automotive traction application.",

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AU - Mecrow, Barrie C.

N1 - © 2016 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting/republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other works.

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N2 - There are benefits if copper windings are replaced with aluminum in applications that are cost- and mass-sensitive, such as automotive traction; these include the low cost of aluminum, low mass of aluminum, and the ease of motor recycling at the end of life. However, the relatively low electrical conductivity of aluminum compared to copper needs to be overcome. Precompressed motor coils have been shown to produce very high fill factors (> 75%), reducing dc-winding losses, therefore enabling the use of aluminum conductors. However, the single-stranded conductors used can be prone to high ac losses due to skin and proximity effects. Therefore, a method of manufacture of precompressed coils made from stranded/Litz wire is needed, allowing ac losses to be reduced to low levels. This paper describes the development and test of stranded, precompressed aluminum coils, which have been developed for use in an automotive traction application.

AB - There are benefits if copper windings are replaced with aluminum in applications that are cost- and mass-sensitive, such as automotive traction; these include the low cost of aluminum, low mass of aluminum, and the ease of motor recycling at the end of life. However, the relatively low electrical conductivity of aluminum compared to copper needs to be overcome. Precompressed motor coils have been shown to produce very high fill factors (> 75%), reducing dc-winding losses, therefore enabling the use of aluminum conductors. However, the single-stranded conductors used can be prone to high ac losses due to skin and proximity effects. Therefore, a method of manufacture of precompressed coils made from stranded/Litz wire is needed, allowing ac losses to be reduced to low levels. This paper describes the development and test of stranded, precompressed aluminum coils, which have been developed for use in an automotive traction application.

KW - Windings

KW - Aluminum Conductors

KW - Electric Machines

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DO - 10.1109/TIA.2016.2528226

M3 - Article

SN - 0093-9994

VL - 52

SP - 2215

EP - 2223

JO - IEEE Transactions on Industry Applications

JF - IEEE Transactions on Industry Applications

IS - 3

ER -

Precompressed and Stranded Aluminum Motor Windings for Traction Motors

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