Additive Manufacturing for Electrical Machines and Power Converters Design
Organizers
Bulent Sarlioglu, Jean van Bladel Associate Professor, University of Wisconsin
Ayman El-Refaie, Werner Endowed Chair, Marquette University
Will Sixel, NASA Glenn Research Center in Cleveland
Abstract
In aircraft electrification, increasing the specific power and efficiency of electrical components is critical to make more electric/hybrid/electric propulsion physically and economically feasible. Additive manufacturing enables unique geometries that conventional manufacturing techniques cannot achieve. Additively-manufactured applications in electric machines and power electronics include permanent magnets, shafts, and housing designs, thermal management systems, integrated motor drives, additively manufactured coils, and highly optimized traditional designs. Additive manufacturing techniques also allow for increased design flexibility and co-design of related components and subcomponents, allowing for greater system-level performance optimization.
Short Bio of Organizers
Bulent Sarlioglu is a Jean van Bladel Associate Professor with the University of Wisconsin-Madison and the Associate Director of the Wisconsin Electric Machines and Power Electronics Consortium. From 2000 to 2011, he was with Honeywell International Inc.’s Aerospace Division, Torrance, CA, USA, most recently as a Staff Systems Engineer.
His expertise includes electrical machines, drives, and power electronics, and he is the inventor or co-inventor of 20 U.S. patents and many international patents. In addition, he has more than 200 technical papers that are published in conference proceedings and journals. Dr. Sarlioglu was the recipient of the Honeywell’s Outstanding Engineer Award in 2011, the NSF CAREER Award in 2016, and the 4th Grand Nagamori Award from Nagamori Foundation, Japan, in 2018.
Dr. Sarlioglu involves in many IEEE activities. He is currently one of the IEEE IAS distinguished lecturers. He serves as the Chair of the IAS Transportation Committee, Chair of PES Motor Subcommittee, one of the co-editors of the IEEE Electrification Magazine. Dr. Sarlioglu was the general Chair of ITEC 2018 and Technical Program Co-Chair for ECCE 2019, and special session chair in ECCE 2020. Dr. Sarlioglu is the recipient of IEEE PES Cyril Veinott Electromechanical Energy Award in 2021.
Ayman M. El-Refaie received the M.S. and Ph.D. degrees in electrical engineering from the University of Wisconsin Madison in 2002, and 2005 respectively. Between 2005 and 2016 he has been a principal engineer and a project leader at the Electrical Machines and Drives Lab at General Electric Global Research Center. Since January 2017 he joined Marquette University as the Werner Endowed Chair for Energy Sustainability. He has over 150 journal and conference publications. He has 48 issued US patents. His interests include electrical machines and drives with special focus on renewable energy and transportation electrification. He was the chair for the IEEE IAS Transportation Systems committee and an associate editor for the Electric Machines committee. He was a technical program chair for the IEEE 2011 Energy Conversion Conference and Exposition (ECCE). He was the general chair for ECCE 2014 and 2015 ECCE steering committee chair. He was the general chair of IEMDC 2019. He is the past chair of the IEEE IAS Industrial Power Conversion Systems Department and member of the IEEE Industry Applications Society executive board. He is an IEEE Fellow.
William Sixel received the B.S. degree in Engineering Mechanics in 2017 and the M.S. degree in Mechanical Engineering both from the University of Wisconsin-Madison in Madison, WI, USA. From 2017 to 2019, he worked as a research assistant with the Wisconsin Electric Machines and Power Electronics Consortium (WEMPEC). Mr. Sixel’s master thesis was about 3-D additive manufactured heat exchanger for direct cooling of stator windings in electrical machines. His research interests include high power density electric machines for traction and electric aircraft applications and thermal management topologies for electric machines. He currently works as Aerospace Engineer at NASA Glenn Research Center in Cleveland, OH where he is responsible for thermal designs, prototype, and testing.
Speakers and Presentations
1. Peter de Bock, ARPA-E, US Department of Energy
Exploring Potential of Additive Manufacturing for Next Generation Electrical Machines and Power Electronic systems
2. Alex Plotkowski, Oak Ridge National Laboratory
Additive Manufacturing of Fe-Si Soft-Magnetic Alloys
3. Shanelle N. Foster, Assistant Professor, Department of Electrical and Computer Engineering, Michigan State University
3D Printed Magnetic Cores for Electrical Machines
4. Ozge Taskin, Ricardo
Developing the supply chain for the next generation high-speed, high voltage synchronous reluctance motor
5. Nick Simpson, Senior Lecturer, University of Bristol
Additive Manufacturing of Next Generation Electrical Machine Windings
6. Max Liben, Chief Technology Officer, H3X Technologies Inc.
Design of a highly saturated high-frequency electric machine with additively manufactured coils