Design and multiphysics analysis of a 3D printed winding with fluid cooling channels in a multi-three-phase motor

The work focuses on the design and multiphysics analysis of a 3D-printed winding with fluid cooling channels for a multi-three-phase surface permanent magnet motor. The main objective is to reduce the motor's supply voltage from 400 V to 20 V while maintaining a power output of 20 kW. To manage the increase in Joule losses, an internal cooling solution was developed within the windings, with channels designed for the passage of a coolant fluid. The winding was manufactured using powder bed fusion (PBF-LB/M) technology with AlSi10Mg material. The multiphysics simulations, conducted through Finite Element Analysis (FEA) using COMSOL software, were compared with measurements taken from a printed prototype. This work demonstrates how 3D printing and FEA simulations can optimize the design and thermal efficiency of electrical windings.