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It is desired to reduce stator end winding length and mass to reduce associated resistive losses, increase efficiency and power density of an induction motor. With recent advancements in additive manufacturing technology, it is possible to deposit copper conductive paths and insulation layers in a selective controlled manner. This enables more compact end winding designs. The objective of this paper is to present a topology optimization based approach for design of stator end winding to minimize its overall length, volume and mass. Design approach and parametric study results for a representative stator design are presented in this paper. By reducing length of end winding, efficiency and power density of the induction motor can be increased enabling benefit realization for weight critical aerospace applications, incorporation in electric vehicle market and potentially reducing rare-earth dependency.

Auto transformer rectifier units (ATRUs) are commonly used in aircraft applications such as electric actuation for harmonic mitigation due to their high reliability and relative low cost. However, those components and the magnetic filter components associated to it are the major contributors to the overall size and weight of the system. Optimization of the magnetic components is essential in order to minimize weight and size, which are major market drivers in aerospace industry today. This requires knowledge of the harmonic content of the current. This can be obtained by simulation, but the process is slow. In order to enable fast and efficient design space exploration of optimal solutions, an algebraic calculation process is proposed in this paper for multi-pulse ATRUs (e.g. 12-pulse and 18-pulse rectifiers), starting from existing solution proposed for 6 pulse rectifier in the literature.