Increasing the torque density of permanent-magnet synchronous machines using innovative materials and winding technologies

Due to the progress of system integration, the increase of energy efficiency and device mobility it is worthwhile to investigate alternative materials for electrical machines and methods of producing electric windings. In this paper the influence of innovative materials on the machine behaviour as well as the machine design are discussed. This includes FeCo, FeNi and SMC. For each of these materials design guidelines are defined. Beyond this the screen printing technology - so far used since a couple of years especially for producing cheap windings for small-power electrical motors - is generalized to a wide range of machine sizes. A possible benefit over classic copper wire windings regarding torque density is determined.