Topology Optimization for the Design of a Heat Sink in an Inductive Electrically Excited Synchronous Machine

An inductive electrically excited synchronous machine does not require permanent magnets or slip rings. It is therefore beneficial concerning its supply chain and has less wear. Compared to a permanent magnet synchronous machine, the wireless power transfer system introduces additional complexity. The heat generated by losses in the coils and rectifier of the wireless power transfer system must be taken out of the system by active cooling. In this work, we show how we used the method of topology optimization to create a design for the rectifier heat sink. The optimized heat sink makes use of its rotation to efficiently cool the rectifier diodes. In order to manufacture the heat sink, a manual redesign was necessary which altered the optimized design. Future work will look into manufacturing methods to better capture the design features of the optimized design.