Asymmetric Bar Winding for High-Speed Traction Electric Machines

A new asymmetric bar winding concept along with the analysis and benefits for high-speed traction electric machines is presented. The objective is to reduce the ac losses, especially at high speeds, utilizing optimized and asymmetric conductor heights within a slot for bar-wound stators. Detailed winding diagram, height optimization, ac loss analysis, and thermal performance are presented for both symmetric, i.e., conventional, and asymmetric bar windings. The proposed idea is validated using the closed-form analytical equation and 2-D time-stepped finite-element analysis (FEA). A substantial reduction of ac losses and improvement in continuous power over the wide operation range is achieved as demonstrated for a 12-pole, 100-kW high-speed (15 000 r/min) PM traction machine. Thermal performance analysis using forced liquid cooling is also included. The design and analysis methodology is presented to support high-speed traction electric machine designers meet the ever-increasing demand on efficiency and performance with bar-type windings.