Dieser Beitrag beschäftigt sich mit den zunehmend Verbreitung findenden Hairpin-Wicklungen unter den besonderen Randbedingungen elektrischer Fahrantriebe. Dabei wird bewusst auf den in der Literatur bekannten Vergleich zu konventionellen Wicklungen hinsichtlich Nutfüllfaktor und Kühlanbindung verzichtet. Stattdessen konzentriert sich der Beitrag zunächst auf die Stromverdrängung, ihre Abhängigkeiten sowie Möglichkeiten zur Reduzierung des Effekts, wobei ausschließlich Maßnahmen vorgestellt werden, die zum Stand der Technik großserientauglich sind. Darüber hinaus werden Potentiale im Layout der Spulenseiten und Wickelköpfe aufgezeigt, die weit über die Optionen von aus Endlosdraht hergestellten Wicklungen hinausgehen. / This paper examines the increasingly popular hairpin windings under the dedicated boundary conditions of electrical drivetrains. A comparison to conventional windings regarding slot filling and cooling link will consciously be omitted since it is well known from literature. Instead, the paper concentrates on current displacement, its dependencies and possibilities for its reduction – with only measures being considered that state-of-the-art are suitable for mass-production. Furthermore, potentials in the layout of coil sides and end-windings are shown, which are far beyond the options of windings manufactured from continuous wire.

To achieve higher power density, converters and components must be able to handle higher voltage and current ratings at higher percentages of efficiency while also maintaining low cost and a compact footprint. To meet such demands, medium-voltage resonant converters have been favored by researchers for their ability to operate at higher switching frequencies. High frequency (HF) operation enables soft switching which, when achieved, reduces switching losses via either zero voltage switching (ZVS) or zero current switching (ZCS) depending on the converter topology. In addition to lower switching losses, the converter operates with low harmonic waveforms which produce less EMI compared to their hard switching counterparts. Finally, these resonant converters can be more compact because higher switching frequencies imply decreased volume of passive components. The passive component which benefits the most from this increased switching frequency is the transformer. The objective of this work is to design a >400 kHz, 100 kW transformer which will provide galvanic isolation in a Solid-State Transformer (SST) based PEBBs while maintaining high efficiency, high power density, and reduced size. This work aims to present a simplified design process for high frequency transformers, highlighting the trade-offs between co-dependent resonant converter and transformer parameters and how to balance them during the design process. This work will also demonstrate a novel high frequency transformer insulation design to achieve a partial discharge inception voltage (PDIV) of >10 kV. / Master of Science / As the world's population expands and countries progress, the demand for electricity that is high-powered, highly efficient, and dependable has increased exponentially. Further, it is integral to the longevity of global life that this development occurs in a fashion that mitigates environmental consequences. The power and technology sectors have been challenged to address the state of global environmental affairs, specifically regarding climate change, carbon dioxide emissions, and resource depletion. To move away from carbon emitting, non-renewable energy sources and processes, renewable energy sources and electric power systems must be integrated into the power grid. However, the challenge lies in the fact that there is not an easy way to interface between these renewable sources and the existing power grid. Such challenges have undermined the widespread adoption of renewable energy systems that are needed to address environmental issues in a timely manner. Recent developments in power electronics have enabled the practical application of the solid-state transformer (SST). The SST aims to replace the current, widespread form of power transformation: the line frequency transformer (50/60 Hz). This transformer is bulky, expensive, and requires a significant amount of additional circuitry to interface with renewable energy sources and electric power systems. The SST overcomes these drawbacks through high frequency operation (>200 kHz) which enables higher power at a reduced size by capitalizing on the indirect proportionality between the two parameters. The realization of the SST and its implementation has the ability to greatly advance the electrification of the transportation industry which is a top contributor to carbon emissions. This work aims to demonstrate a >400 kHz, 100 kW SST with a novel magnetic design and insulation structure suited for electric ship applications.

The electromagnetic utilization of an electrical machine can be increased by raising the current density, with a limitation resulting from the maximum permissible temperature of the winding insulation. Conventional insulating materials only have a low specific thermal conductivity, which results in large temperature gradients in the winding cross section and consequently hotspots. This article presents the development and characterization of ceramic-like composite materials based on filled polysiloxanes for the dip coating of lamination stacks and the impregnation of the winding of electrical machines. The specific equivalent thermal conductivity is determined on composite winding samples, the thermal cycle stability is examined and the microstructure is analyzed with the scanning electron microscope. The manufacturability and the partial discharge behavior are examined based on test samples. The results of tests on an electric traction machine are used to show the potential for increasing the power density.

De l’avion plus électrique, en passant par l’hybridation de véhicules automobiles et jusqu’aux implants cardiaques d’assistance circulatoire, la compacité est devenue le graal de l’électrotechnique embarquée moderne. En effet, la densité de puissance des systèmes électromécaniques ne cesse de s’accroitre. Ainsi, pour répondre aux besoins de forte intégration, les convertisseurs en électronique de puissance trouvent un vecteur de développement dans l’augmentation de leur température et des fréquences de fonctionnement mais aussi dans la réduction des temps de commutation des interrupteurs, leur permettant de réduire leurs pertes thermiques et ainsi, de réduire leurs besoins en refroidissement. Les moteurs et générateurs électriques évoluent avec des topologies aussi diverses qu’innovantes pour répondre aux besoins d’intégration, robustesse et sureté de fonctionnement. Particulièrement, les bobinages des moteurs sont les premiers éléments sur le front de bataille. Au sein du bobinage s’effectuent les échanges entre moteur et convertisseur. L’augmentation des contraintes fréquentielles et transitoires sous forme de fronts de courant et tension issus des ensembles d’électronique de puissance constituent des défis en termes de compatibilité électromagnétique (CEM) pour les systèmes embarqués. Le travail présenté ici est le fruit d’une étroite collaboration entre la société NOVATEM et le laboratoire Génie de Production de l’ENIT de Tarbes au travers d’un financement CIFRE, en association avec la plateforme Labceem de l’IUT de Tarbes. Il propose d’apporter des modèles prédictifs permettant de déterminer les conséquences de ces contraintes d’intégration dans les systèmes mécatroniques de puissance dès les premières étapes de leur conception. Les perturbations conduites dont la source HF est au sein des interrupteurs de puissance du convertisseur, sont façonnées par les impédances caractérisant le chemin de couplage dont le moteur fait partie intégrante. Ce travail vise à élaborer des méthodes et outils pour contribuer à l’étude prédictive de la compatibilité électromagnétique (CEM) des ensembles mécatroniques en essayant de couvrir une plage de fréquence allant de 0 à 300 MHz. Dans une première partie, un état de l’art est détaillé afin de délimiter le contexte et les frontières de l’étude. Puis, un deuxième chapitre porte sur la modélisation analytique de bobinages concentrés de moteurs électriques. Les modèles analytiques établis permettent de déterminer les paramètres de réseaux de circuits pour effectuer des simulations dans le domaine temporel et harmonique. Contrairement aux modèles comportementaux de moteurs répandus dans la littérature, les modèles ici synthétisés prennent en compte les paramètres physiques des bobinages. Ils donnent la possibilité à l’utilisateur de paramétrer les architectures de bobinages concentrés en changeant des paramètres tels que la géométrie des bobines, les matériaux d’isolation ou encore la perméabilité des culasses. Un troisième chapitre, détaille l’établissement d’une méthode rationnelle d’extraction numérique de paramètres fonctionnels et parasites des PCB multicouches de puissance. Cette méthode, de par la prise en compte de paramètres physiques, s’inscrit dans une logique générique et prédictive. Finalement, dans le dernier chapitre, les outils et méthodes précédemment établis sont appliqués à l’étude d’un système réel de motorisation de véhicule électrique développé par la société partenaire Novatem. Le caractère physique et prédictif de ces outils vise à permettre l’expérimentation virtuelle sur l’ensemble moteur-convertisseur sans la nécessité de prototypes. Ce dernier chapitre illustre l’intérêt d’une approche physique en modélisation pour la compatibilité électromagnétique de systèmes mécatroniques. / From the more electrically operated aircraft, to the hybridization of motor vehicles, all the way to electromechanic cardiac implants, compactness has become the holy grail of modern embedded electrical engineering. Indeed, the power-to-weight ratio demands for electromechanical systems has greatly increased. To meet these high integration needs, power electronic converters find a vector of development by increasing their temperature and operating frequencies but also by reducing the switching time of power switches, thus enabling them to reduce their power losses and thereby reducing their cooling requirements. Electric motors and generators operate with various innovative topologies that meet integration, robustness and reliability needs. Motor windings, particularly, are the first motor components on the battle front. It is at the heart of the winding that occur the exchanges between motor and converter. In terms of electromagnetic compatibility (EMC) for embedded systems, the increased frequency and transient stresses in the form of current and voltage edges from the power electronic assemblies are considered steep challenges. The work presented herein is the result of a close cooperation between the company Novatem and the laboratory Génie de Production of ENIT de Tarbes, through CIFRE funding, in combination with the Labceem platform of IUT of Tarbes. Its aim is to develop predictive models that will serve to determine the consequences of such integration constraints in power mechatronic systems that are in the early stages of design. Conducted disturbances whose HF source is located at the inverter power switches are shaped by the impedances characterizing the coupling path of which the electrical machine is an integral part. This work proposes to develop methods and tools to support the predictive study of electromagnetic compatibility (EMC) of mechatronic assemblies, by attempting to cover a modeling frequency range that goes from 0 to 300 MHz’s. In the first chapter of this work, a literature review is detailed for the definition of the context and boundaries of the study. A second chapter focuses on the analytical modeling of concentrated windings in electric motors. The analytical models that are established allow determination of circuit networks settings to perform time- and frequency- domain simulations. Unlike the widespread behavioral models of electrical machine in the literature, the models that are synthesized here take into account the physical parameters of the coils. The user of such models is offered the opportunity to account for the different winding architectures, by changing core parameters such as geometry, insulation materials or permeability. A third chapter describes the establishment of a rational method for extraction of functional and parasitic parameters in multilayer Power PCBs. This method being of a generic and predictive logic aims to account for physical parameters. Finally, in the last chapter, the previously established tools and methods are applied to the study of a real electric vehicle drive system developed by the company Novatem. The physical and predictive value of these tools allows for execution of virtual experimentations on the motorconverter assembly without the need for prototypes. This chapter illustrates the value of a physical approach to modeling the electromagnetic compatibility of mechatronic systems.

<p>Electromagnetic transients impinging on electromagnetic power devices - such as electric machines, transformers and reactors - can stress the design severely. Thus the magnitudes of the transients are often decisive for the design of the devices. Further, the operation of a device can be transient in itself. This is the case for the explosive magnetic flux compression generator (EMG) and a ferromagnetic actuator. </p><p>Models are presented that are mainly intended for transients in the millisecond range and faster. Hence, eddy currents and the related skin and proximity effect become significant in windings, magnetic cores and in the armatures of the devices. These effects are important for, e.g., the damping of the transients. Further, the displacement current in the insulation of the winding is significant. It changes the response of the windings dramatically, as it manifests the finite velocity of propagation of the electromagnetic fields. Under such circumstances, reflections and excited resonances can make the transient voltage and current distribution highly irregular. </p><p>Induced voltages are modelled with self and mutual inductances or reluctances combined with winding templates. The displacement currents are modelled with capacitances or coefficients of potential. Cauer circuits and their dual form are used to model eddy currents in laminated cores and in conductors. The Cauer circuit enables one to consider hysteresis and the non-linear response of a magnetic core. It is also used to model the eddy currents in the moving armature of an EMG. </p><p>A set-up is presented that can be used to study the transient voltage and the current distribution along a coil. </p><p>The transient response of coaxially insulated windings is analysed and modelled in detail. A lumped circuit model is developed for a coil, Dryformer^TM - the new high-voltage transformer - and Powerformer^TM, the new high-voltage generator. An alternative model, a combined lumped circuit and FEM model, is presented for a coaxially insulated winding in two slot cores.</p>

A regular vehicle of today is equipped with an internal combustion engine that runs on either gasoline or diesel, which are fossil fuels from oil reserves that are millions of years old. In all types of combustion processes carbon dioxide and several other emissions are produced. There are none known technologies of today that can reduce the emissions of carbon dioxide from combustion, but the amount that is produced is mainly dependent on the fuel that is used. Combustion of fossil fuels increases the contamination of carbon dioxide in the atmosphere and diminishes the oil resources. The results are global warming and empty oil reserves within a few decades with the current production tempo, in addition to many other pollution effects that are harmful to the environment. A transition towards a society based on sustainable transportation is therefore urgent. The hydrogen fuel cell powered car with an electric propulsion system has the potential to be the car of the future that possesses the required characteristics of no harmful tailpipe emissions. There are some obstacles in the way for an early commercialisation, including the expensive catalysts used today and the lack of an infrastructure based on hydrogen, though. The hybrid electric vehicle, with both a conventional as well as an electric drivetrain, is a natural candidate for making the transition from the conventional car towards the car of the future. This thesis is focused on the design and analysis of permanent magnet machines for a novel hybrid electric vehicle drive system called the Four Quadrant Transducer. A number of electrical machine aspects are identified, including cores of soft magnetic composites, fractional pitch concentrated windings, core segmentation, novel machine topologies and cost effective production methods. The main objective is to analyse and judge the many unconventional machine aspects of which some may have the potential to improve the performance and reduce the cost of permanent magnet machines. Another objective is to study the effects of the use of fossil fuels and describe them with a new perspective and thereby make one small contribution to the debate about energy issues. Much focus has been spent on the theory of concentrated windings for permanent magnet machines. The potential parasitic effects and methods to improve the torque performance have been described. Other topics that have been given a high priority are material and power loss studies. An important contribution to the understanding of iron losses during field-weakening operation has been presented. A comprehensive use of finite element modeling has been done in the analysis combined with measurements on several laboratory prototypes. The Four Quadrant Transducer drivetrain and its two electrical machines intended for a midsized passenger car has been studied. The gearbox can be of a simple single stage type, which reduces the mechanical complexity and makes the traction performance of the vehicle smooth, without gear changes and drops in power. Simulations on a complete hybrid system show that fuel savings of more than 40% compared to a conventional vehicle can be achieved at citytraffic driving. The savings are modest at highway driving, since the engine is required to operate at high power during such conditions, and the support from the electrical system is negligible. The laboratory prototypes have shown that it is possible to manufacture high performance electrical machines with high material utilization and potential for automated production. The described concepts offer cost effective solutions for future drive systems in automotive and industrial applications. A number of weaknesses with the presented constructions have also been characterized, which should serve as guidelines for creating more optimized machines.

Electromagnetic transients impinging on electromagnetic power devices - such as electric machines, transformers and reactors - can stress the design severely. Thus the magnitudes of the transients are often decisive for the design of the devices. Further, the operation of a device can be transient in itself. This is the case for the explosive magnetic flux compression generator (EMG) and a ferromagnetic actuator. Models are presented that are mainly intended for transients in the millisecond range and faster. Hence, eddy currents and the related skin and proximity effect become significant in windings, magnetic cores and in the armatures of the devices. These effects are important for, e.g., the damping of the transients. Further, the displacement current in the insulation of the winding is significant. It changes the response of the windings dramatically, as it manifests the finite velocity of propagation of the electromagnetic fields. Under such circumstances, reflections and excited resonances can make the transient voltage and current distribution highly irregular. Induced voltages are modelled with self and mutual inductances or reluctances combined with winding templates. The displacement currents are modelled with capacitances or coefficients of potential. Cauer circuits and their dual form are used to model eddy currents in laminated cores and in conductors. The Cauer circuit enables one to consider hysteresis and the non-linear response of a magnetic core. It is also used to model the eddy currents in the moving armature of an EMG. A set-up is presented that can be used to study the transient voltage and the current distribution along a coil. The transient response of coaxially insulated windings is analysed and modelled in detail. A lumped circuit model is developed for a coil, DryformerTM - the new high-voltage transformer - and PowerformerTM, the new high-voltage generator. An alternative model, a combined lumped circuit and FEM model, is presented for a coaxially insulated winding in two slot cores.

<p>A regular vehicle of today is equipped with an internal combustion engine that runs on either gasoline or diesel, which are fossil fuels from oil reserves that are millions of years old. In all types of combustion processes carbon dioxide and several other emissions are produced. There are none known technologies of today that can reduce the emissions of carbon dioxide from combustion, but the amount that is produced is mainly dependent on the fuel that is used. Combustion of fossil fuels increases the contamination of carbon dioxide in the atmosphere and diminishes the oil resources. The results are global warming and empty oil reserves within a few decades with the current production tempo, in addition to many other pollution effects that are harmful to the environment. A transition towards a society based on sustainable transportation is therefore urgent. The hydrogen fuel cell powered car with an electric propulsion system has the potential to be the car of the future that possesses the required characteristics of no harmful tailpipe emissions. There are some obstacles in the way for an early commercialisation, including the expensive catalysts used today and the lack of an infrastructure based on hydrogen, though. The hybrid electric vehicle, with both a conventional as well as an electric drivetrain, is a natural candidate for making the transition from the conventional car towards the car of the future. </p><p>This thesis is focused on the design and analysis of permanent magnet machines for a novel hybrid electric vehicle drive system called the Four Quadrant Transducer. A number of electrical machine aspects are identified, including cores of soft magnetic composites, fractional pitch concentrated windings, core segmentation, novel machine topologies and cost effective production methods. The main objective is to analyse and judge the many unconventional machine aspects of which some may have the potential to improve the performance and reduce the cost of permanent magnet machines. Another objective is to study the effects of the use of fossil fuels and describe them with a new perspective and thereby make one small contribution to the debate about energy issues. Much focus has been spent on the theory of concentrated windings for permanent magnet machines. The potential parasitic effects and methods to improve the torque performance have been described. Other topics that have been given a high priority are material and power loss studies. An important contribution to the understanding of iron losses during field-weakening operation has been presented. A comprehensive use of finite element modeling has been done in the analysis combined with measurements on several laboratory prototypes. </p><p>The Four Quadrant Transducer drivetrain and its two electrical machines intended for a midsized passenger car has been studied. The gearbox can be of a simple single stage type, which reduces the mechanical complexity and makes the traction performance of the vehicle smooth, without gear changes and drops in power. Simulations on a complete hybrid system show that fuel savings of more than 40% compared to a conventional vehicle can be achieved at citytraffic driving. The savings are modest at highway driving, since the engine is required to operate at high power during such conditions, and the support from the electrical system is negligible. The laboratory prototypes have shown that it is possible to manufacture high performance electrical machines with high material utilization and potential for automated production. The described concepts offer cost effective solutions for future drive systems in automotive and industrial applications. A number of weaknesses with the presented constructions have also been characterized, which should serve as guidelines for creating more optimized machines. </p>

Thesis (MScEng)-- Stellenbosch University, 2013. / ENGLISH ABSTRACT: The objective of this project is to develop an electromagnetic model that can be used to accurately calculate the voltage distribution in a transformer winding structure when excited with standard impulse excitation waves. This voltage distribution is required during the design stage of a power transformer to ensure that the insulation is capable of withstanding the occurring electric field stresses during these tests. This study focuses on the modelling of a single disk-type power transformer winding without the presence of an iron-core. Methods of calculating self- and mutual-inductances of transformer windings are presented and validated by means of finite element method software simulations. The same is done for the calculation methods used for calculating the capacitances in and around the winding structure. The calculated and FEM-simulated results are compared to measured values as a final stage of validation. The methods used to calculate the various model parameters seem to produce results that agrees well with measured values. The non-linear frequency dependant dissipative nature of transformer windings is also investigated and a methodology to take this into account is proposed and implemented. The complete modelling methodology proposed in this thesis, which includes the calculation of the model parameters, model synthesis and solver algorithm, are applied to an actual case study. The case study is performed on an air-core reactor manufactured using a disk-type power transformer winding. The reactor is excited with standard lightning impulse waves and the voltages along the winding are measured. The calculated and measured voltage wave forms are compared in both the frequency and time-domain. From the comparison it is found that the model accurately represents the actual transient voltage response of the testunit for the frequency range of interest during standard factory acceptance tests. / AFRIKAANSE OPSOMMING: Die doel van hierdie projek is om 'n elektromagnetiese model te ontwikkel wat gebruik kan word om die spanningsverspreiding in 'n transformatorwindingstruktuur te bereken as standaard weerligimpulstoetse toegedien word. Hierdie spanningsverspreiding word vereis tydens die ontwerpstadium van ‘n kragtransformator om te verseker dat die isolasie in staat is om die elektriese veldsterkte tydens hierdie toetse te weerstaan. Hierdie studie fokus op die modelering van 'n enkele skyftipe-kragtransformatorwinding sonder die teenwoordigheid van 'n ysterkern. Metodes van berekening van self- n wedersydse-induktansie van transformatorwindings word aangebied en getoets deur middel van Eindige-Element-Metode (EEM) simulasies. Dieselfde word gedoen vir die metodes wat gebruik word vir die berekening van die kapasitansies in en rondom die windingstruktuur. Die berekende en EEM-gesimuleerde resultate word vergelyk met die gemeete waardes as 'n finale vlak van bekragtiging. Die metodes wat gebruik word om die verskillende modelparameters te bereken vergelyk goed met gemete waardes. Die nie-lineêre frekwensie-afhanklike verliese van transformatorwindings word ook ondersoek en 'n metode om hierdie in ag te neem is voorgestel en geïmplementeer. Die volledige voorgestelde modeleringsmetodiek in hierdie tesis, wat die berekening van die modelparameters, modelsintese en oplosingsalgoritme insluit word toegepas op 'n werklike gevallestudie. Die gevallestudie is uitgevoer op 'n lugkern-reaktor wat 'n skyftipe-kragtransformatorwinding. Die reaktor word onderwerp aan die standaard weerligimpuls golwe en die spanning al langs die winding word gemeet. Die berekende en gemete spanning golf vorms word met mekaar vergelyk in beide die frekwensie- en tyd-vlak. Uit die vergelyking blyk dit dat die model die werklike oorgangspanningsweergawe van die toetseenheid akkuraat verteenwoordig vir die frekwensie reeks van belang tydens standaard fabriekaanvaardingstoetse.

Une machine électrique utilisée pour un entraînement à vitesse variable est généralement alimentée par un convertisseur statique dont les composants électroniques de puissance commutent extrêmement rapidement. De ce fait, chaque enroulement statorique de la machine est soumis à des fronts raides de tension dont la répartition sur les différentes spires qui le constituent dépend notamment des capacités parasites entre spires ou entre spires et carcasse. Des zones locales de fort champ électrique apparaissent dans le bobinage conduisant souvent la création d'une activité de décharges partielles. Ce travail de thèse a pour but de fournir des informations quantifiées et précises quant aux risques encourus lorsque divers paramètres liés à l'alimentation de la machine et la topologie du bobinage varient permettant de contribuer à acquérir une expertise vis à vis des problèmes liés à l’apparition de décharges partielles au sein des bobinages, et à en déduire des règles de conception. / Electrical machine used in variable speed drives are usually fed by a converter using fast switching power electronics devices. Thus, each stator winding of the machine is subjected to steep-fronted voltage pulses whose distribution over its various turns depends on the parasitic capacitances between turns or between turns and slot walls. Therefore, local areas of high electric field appear within the coil, often resulting in partial discharges activity. This thesis aims to provide accurate and quantified information regarding partial discharge inception when various parameters related to the machine power supply and winding topology so as to help develop expertise with respect to problems related to partial discharges, as well as to deduce machine design rules in this regard.