Application of additive manufacturing processes to reduce the axial end-winding length of low-pole high-voltage machines

Abstract:
In this paper a new design approach of manufacturing end-windings for high-voltage electrical machines is presented. A viable winding structure is introduced and compared to a conventional one with double-layer form-wound coils. The application of several additive manufacturing processes - which have been significantly further developed in recent years - is presented and supported by previous investigations, e.g., in the area of Cold Sprayed copper conductors or innovative insulation methods. Finally, a workable variant of a complete machine design is illustrated.