Flat winding made of aluminum or copper sheet for axial flux machines

Abstract

Abstract A novel flat winding topology has been proposed as an alternative to conventional windings with stranded round wires and other bar wound windings. The proposed winding is manufactured from thin conductor sheets by industrial tools such as stamping press, laser cutter, or water jet. As these tools are widely used in the production of electric machines, the flat winding topology can provide ease of manufacturing without significant modification to the production line. Besides, superior current ratings, shortened end windings, and high fill factors are other advantages of flat winding. Its performance is measured by comparison study between flat wired prototype machine and the stranded wired machines with similar ratings presented in the literature. The proposed winding is implemented on an axial flux permanent magnet machine. Analytical modeling is presented, including field modeling, voltage, torque derivations, and loss modeling. Then, experimental verification of a 1.4‐kW and 26‐Nm prototype with copper and aluminum flat windings is presented, and the performances of two are compared.