| 1. |
- Frogner, Kenneth, et al.
(författare)
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A new concept of coil design for industrial induction heating
- 2011
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Ingår i: Proceedings of the Swedish Production Symposium 2011, SPS11.
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Konferensbidrag (refereegranskat)abstract
- Abstract in UndeterminedThe demands for energy efficent heating solutions for the manufacturing industry can be met by a new induction heating platform, presented in this article. A new concept and technology to design and manufacture induction heating units is explained, evaluated and tested with successful results. The so called Greenheat technology relies on inductors built on Litz wiring moulded in soft magnetic composite; a flux conducting material produced using rotational casting methods. The aim of the article is to present and verify a hyphotesis of greatly improved induction heating results when modifying a traditional inductor design in four dependent steps. The verification is done using analytic solutions and FEM simulations as well as by experimetal work, clearly showing higher heating efficiency, no requirement for advanced cooling and a higher geometrical flexibility compared to existing heating solutions.
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| 2. |
- Frogner, Kenneth, et al.
(författare)
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Industrial heating using energy efficient induction technology
- 2011
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Ingår i: Proceedings of the 44th CIRP International Conference on Manufacturing Systems.
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Konferensbidrag (refereegranskat)abstract
- Abstract in UndeterminedThe demands for energy efficent heating solutions for the manufacturing industry can be met by a newinduction heating platform, presented in this article. A new concept and technology to design andmanufacture induction heating unit is presented, as well as a prototype induction heater, evaluated and testedin an industrial environment. Improvements compared to existing heating solutions can be clearly shown, e.g.higher heating efficiency, no requirement for advanced cooling, a higher geometrical flexibility and alsoenvironmental gains. The Greenheat platform is built on Litz wiring, SMC flux conductors, and a castingtechnology which is outlined in the article.
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| 3. |
- Lundström, Fredrik, et al.
(författare)
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Cooling of Litz Wires in Industrial Induction Heating Applications
- 2016
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Konferensbidrag (refereegranskat)abstract
- Induction heating has the potential to be a very efficient heating method and by using litz wires instead of copper tubes the losses can be significantly reduced. The drawback with litz is the fact that it comprises insulation materials with low temperature resistance, typically in the range 150 – 200 °C. In order to solve this problem a solution is to create channels in the litz structure in which a cooling medium can flow. In order to investigate the possibility with cooled litz wires a number of litz wires were manufactured with different types of internal cooling channels and infiltration materials. The experiments showed that it was possible to maintain a steady state temperature of the litz wire below 25 °C at a current density of 10 A/mm2 and frequency of around 20 kHz. A thermal FEM model was developed in order to calculate the equivalent thermal conductivity of the litz structure based on the measurements. The induced losses in the cooling tube was also investigated with an electromagnetic FEM model showing that the choice of dimensions and material for the cooling tube might be crucial for the heating efficiency.
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| 4. |
- Reinap, Avo, et al.
(författare)
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Design and development of a roller with embedded heating for uniform temperature generation
- 2014
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Ingår i: [Host publication title missing].
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Konferensbidrag (refereegranskat)abstract
- This paper provides design experience based on 2D FE electromagnetic and heat transfer analysis that are used to support product development. An induction in-roll heater is analyzed, tested and verified. The scientific challenge is to develop fast and fair models to provide design guidelines for layout specification, material selection and performance estimation. The transferred energy capability and efficiency are the essential performance figures focused on the first hand in prior to temperature distribution and profiles.
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| 5. |
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| 6. |
- Siesing, Leif, et al.
(författare)
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Alternative production process for electric machine windings
- 2012
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Ingår i: 2012 2nd International Electric Drive Production Conference (EDPC). - 9781467330060 ; , s. 161-167
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Konferensbidrag (refereegranskat)abstract
- The development of production methods, research on material engineering and analysis tools for energy conversion processes establish a powerful design environment for any unconventional electromagnetic or electromechanical device. The design for manufacturability becomes the one of the main goals of the design apart from cost and performance improvement. The main focus of this paper lies on the development of production methods, the design of the product, a wave-winding, and the component assessment in an electrical machine. The production of non-complex coil with maximized performance capability of the molded core machine is the target for the design of the winding and also the design for the winding machine. Four different types of wave-windings are described and evaluated. One of them, wind and bend with conventional wire, has main focus in this work, and a prototype of the winding machine is built to produce the single-layer whole-lap wave-winding. The production method, manufacturing process and the processed component features are analyzed in this paper.
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| 7. |
- Siesing, Leif
(författare)
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Development and Implementation of a Mouldable Soft Magnetic Composite
- 2016
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Doktorsavhandling (övrigt vetenskapligt/konstnärligt)abstract
- Electrical machines, chokes and induction heaters are found in most homes,offices and factories all over the world. They are used to create movement, filtrate the power or to generate heat. A typical unit consist of a coil and a flux conductor material. Some of the materials have been established for over 100 years, while others are only a couple of decades old.A new flux conductor material has been developed at the Division of Production and Materials Engineering at Lund University. The material is called soft magnetic mouldable composite (SM2C). This thesis is focused on investigating the potential of this material and lay a knowledge foundation, wherein the material properties and manufacturing process of the material is tested and further developed, as well as the material composition. In order to use the full potential of the material a holistic view of all the materials involved is necessary. Both coil and insulation suitable for the mouldable soft magnetic composite are therefore studied. Tests are performed both on the separate materials, but also together in applications. Several motors and induction heaters were built and tested in different projects.Results from the work show that by changing from solid copper tubes to litz wire and by using a flux conductor an increase of efficiency from 50-80 % to 98 % is possible. This is due to lower losses in the current conductor and higher flux linkage.The possibility to mould the soft magnetic composite has interesting potential. It is shown that sensors, current conductors and other soft magnetic materials can be integrated directly into the composite. Also, the technology will provide a good thermal contact between the materials. This is especially important for the current conductor, which is usually the main heat source. A good contact will help conduct away the heat if the device is designed properly.Other opportunities are opened with the new technology as well. The size of a moulded part has no limit, unlike for other soft magnetic composites that are usually pressed. It is possible to mould parts into almost any geometry, but it is also easy to machine the material if wanted.
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| 8. |
- Siesing, Leif, et al.
(författare)
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Electrical isolation of coils in Soft Magnetic Composite applications
- 2011
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Konferensbidrag (refereegranskat)abstract
- Soft Magnetic Composites (SMC) based on iron powder have a strong potential for improving both the performance and the manufacturing of various electromagnetic components and devices, such as inductors, induction heaters and electrical machines. A new casting or moulding method we have developed makes use of a modified composite, termed SM2C, or soft magnetic mouldable composite. Use of it makes it possible to design very complex shapes of magnetic flux conductors and also to achieve a better thermal coupling between electromagnetic components, primarily coils and flux conductors. The latter also creates a new type of problem, concerning the electrical isolation between the coil and the flux conductor. Use of SM2C, increases the demands on the isolation layer, since the molding compound penetrates every single pinhole, potentially creating leak currents or short circuiting. A comprehensive study of suitable coating materials and processes were carried out, an evaluation of the electrical strength of different configurations being made. A model of the wetting of rough surfaces is introduced here and is applied in the test analysis. This model makes it possible to explain why a certain isolation layer can be insufficient, even if the nominal requirements are fulfilled. Multi layer coatings and certain application adjustments are shown to be necessary, in order for the technical demands placed on isolation to be met.
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| 9. |
- Siesing, Leif, et al.
(författare)
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New manufacturing methods for electric motors using different soft magnetic material combinations
- 2012
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Ingår i: [Host publication title missing]. - 9781467330060 ; , s. 366-372
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Konferensbidrag (refereegranskat)abstract
- This paper presents the manufacturing experience of an outer rotor permanent magnet synchronous machine with four different stators. The advantageous features of powder technology and molding techniques are tested when constructing and manufacturing the stators for a 28-pole 30-slot machine. The selected machine configuration is taking advantages of the concept of the modular windings and at the same time facing the challenges of undemanding winding production, which is suitable for injection and rotation molded magnetic cores. The geometric tolerances of the modular winding segments and the requirements for the electric insulation system have the main influence on the selection of alternatives methods for manufacturing powdered magnetic cores. The tight connection between the material engineering, research on the production techniques and the modeling of energy conversion processes have positively influenced the machine design towards improved electromagnetic and thermal characteristics of the product. The main outcomes of the manufacturing methods and electromagnetic design are discussed when combining the modular windings together with compression and molded soft magnetic composite powders.
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| 10. |
- Siesing, Leif, et al.
(författare)
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Soft magnetic moldable composites: Properties and applications
- 2012
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Ingår i: Journal of Magnetism and Magnetic Materials. - : Elsevier BV. - 0304-8853. ; 324:18, s. 2717-2722
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Tidskriftsartikel (refereegranskat)abstract
- A new type of electromagnetic soft magnetic material (SMM) is introduced, based on spherical iron powder particles and a suitable polymer binder. A key feature of this material is that it can be cast or molded into almost any 3D shape, hence the denotation soft magnetic moldable composite ((SMC)-C-2). The SM2C is compared with a set of reference materials, such as ferrites, laminated steels, and soft magnetic composites, in terms of primary properties such as permeability and loss, and other properties, such as thermal conductivity and manufacturability. The SM2C has the obvious disadvantage of relatively low permeability, but offers benefits such as relatively low losses and high potential for close integration into electromagnetic circuits. Some recent SM2C applications are illustrated, and design and manufacturing aspects are discussed. (C) 2012 Elsevier B.V. All rights reserved.
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