EM1 - TopoMAG

In the project, a sample component is developed to demonstrate the feasibility of suitable 3D-printed slot and cooling structures in soft magnetic components. These enable maximum functionality of the components of a transverse flux machine (TFGM) and an increase in performance through a more efficient cooling concept.

A simulation-based topology optimization is carried out, taking into account the slot shapes that can be produced. The sample component is then realized using pure iron or ferrosilicon (a master alloy of steel or cast iron). On the one hand, the functionality of the sample component is verified by means of the magnetic resonance method. In addition, a specially designed test rig for measuring individual machine components will be developed and set up.

Approach

• Development of model samples and adaptation of the measurement and testing technology to characterize the material properties
• Evaluation of the effectiveness of slot geometries and arrangements in terms of loss minimization for best possible functionality in a TFM
• Simulative analysis and optimization of heat dissipation through integrated cooling channels
• Validation of the design through realistic simulations and measurements on additively manufactured test specimens