Innovative Rotor Winding Geometry for Synchronous Machine By Means of Additive Manufacturing

This paper presents an innovative optimized rotor winding for an electrically excited synchronous motor by means of additive manufacturing (AM). The new coil geometry was designed with the purpose of maximizing the filling factor keeping the cross section area of the conductors constant as only constrain in the geometry definition. The proposed solution allow to increase the machine torque density for the same rotor Joule losses or to increase the efficiency of the machine for the same output torque. Then a fluid pole shaping was study to reduce the mechanical stresses in the most critical points taking advantage of the fact that with AM the windings can be design following any kind of theet profile.