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Electrical machines with laminated winding for hybrid vehicle applications

This paper focuses on the experimental evaluation and design of a magnetic core of a modular segment for a synchronous machine with a laminated wave-winding. The advantageous features of laminated windings, which are the simple production and the high winding fill factor with a good net shape, are optimized towards high torque capability. The focus in this study lies on the design of soft magnetic core rather than the thermal design of an assembled system. The manufacturability and the electromagnetic energy conversion are compared and evaluated in a number of stator segments with both powder and laminated core. The evaluations of the energy conversion capability and manufacturability show the potential with a laminated winding/yoke and also with laminated winding/core segments configurations. The comparison shows that the design considerations in the modelling of the energy conversion match well with the measured results. The experimental results from the small alternator are used to propose a design strategy for a hybrid traction machine with the same topology.