Characterisation of Compressed Windings via High Resolution X-ray Computed Tomography and Semi-Automatic Segmentation

Compressed windings can substantively increase the power density of electrical machines. However, the compression of coils can lead to significant deformation of the conductor lay, cross-sections and insulation coating, impacting the longevity, loss and thermal performance of such windings. This paper presents the use of high resolution X-ray Computed Tomography (XCT), along with 2D and 3D image segmentation techniques, to perform an initial characterisation of a compressed aluminium winding. From the XCT derived data, significant localised conductor deformation and strand insulation thinning has been observed.