Experimental Validation of Manufacturable Edgewise Winding Solutions Considering Parallel Slot and Parallel Tooth Stator Structures

High-power-density electric machines play a key role in decarbonising transportation technologies. A critical component of the movement towards high-performance machines is the structure and manufacture of the windings, as this is the dominant source of machine loss. Manufacturing time is important to the effectiveness of the production line, with equivalent importance to the electromagnetic and thermal characteristics. Edgewise windings are increasingly considered to have high potential to be quickly and automatically manufactured. However, they are rarely studied considering all the aspects, these being electromagnetic, thermal, and manufacturing characteristics. This paper will experimentally assess the performance of edgewise machines compared to a stranded winding machine, covering all the aforementioned aspects. Two edgewise winding types are considered, parallel slot and parallel tooth. Firstly, a baseline 11 kW stranded winding machine will be introduced, then two edgewise type machines are proposed to be compared to the baseline machine. These comparisons will initially be made based on simulated torque and thermal performance, then the manufacturing time and quality are assessed for each of the coil structures, showing the achievable time reduction by using edgewise coil structures. Motorettes are used to validate thermal performance of the structures, which are used to calibrate simulation models and evaluate the performance of a full machine equivalent model. Under the thermal limit condition, it is shown that the edgewise parallel tooth windings can achieve a torque increase of 27.8% compared to stranded and 24% compared to edgewise parallel slot.