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Comparison of Electrically Excited Synchronous Machines Using Copper and Aluminum Windings in Stator and Rotor
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CES Transactions on Electrical Machines and Systems | 2026, 10(1) : 16 - 27
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CES Transactions on Electrical Machines and Systems | 2026, 10(1): 16-27
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Comparison of Electrically Excited Synchronous Machines Using Copper and Aluminum Windings in Stator and Rotor
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Tianzheng Xiao1, Zi Qiang Zhu2, Ziad Azar3
Affiliations
    1 the School of Electrical and Electronic Engineering, the University of Sheffield, Sheffield, S1 3JD, UK;
    2 the Department of Electrical and Electronic Engineering, the Hongkong Polytechnic University, 11 Yuk Choi Rd, Hung Hom, Hong Kong, China;
    3 Siemens Energy Industrial Turbomachinery Ltd., Ruston House, Waterside South, Lincoln, LN5 7FD, UK
About Author:
Tianzheng Xiao: Tianzheng Xiao (Graduate Student Member, IEEE) was born in Jiangxi, China, in 1998. He received the B. Eng. and M. Sc. degrees in electrical engineering from Huazhong University of Science and Technology, Wuhan, China in 2019 and 2022, respectively. He is currently working toward the PhD degree since 2022 in electrical engineering at the University of Sheffield, Sheffield, UK.
His research interests include design and analysis of permanent magnet and electrically excited synchronous electrical machines, as well as the study of losses in electrical machines.
Zi Qiang Zhu: Zi Qiang Zhu (M’90, SM’00, F’09) received the B.Eng. and M.Sc. degrees from Zhejiang University, Hangzhou, China, in 1982 and 1984, respectively, and the Ph.D. degree from the University of Sheffield, Sheffield, UK, in 1991, all in electrical engineering.
From 1988 to 2025, he was with the University of Sheffield, as Professor (1997–2025), Royal Academy of Engineering/Siemens Research Chair (2014–2023), and Head of the Electrical Machines and Drives Research Group (2008–2025). Since 2025, he has been a Chair Professor at the Hong Kong Polytechnic University, Hong Kong, China. He is Founding Director of four industrial research centers, including the Sheffield Siemens Gamesa Renewable Energy Research Centre and Midea Shanghai Electric Machines and Control Systems Research Centre. His current major research interests include design and control of permanent magnet machines and drives for applications ranging from electrified transportation through renewable energy to domestic appliance, robots, and automation. He is a Fellow of the Royal Academy of Engineering, UK, the Institute of Electrical and Electronics Engineers (IEEE), USA., the Institute of Engineering and Technology (IET), UK, and the Chinese Society for Electrical Engineering (CSEE) and China Electrotechnical Society (CES).
Ziad Azar: Ziad Azar received the B.Eng. degree in electrical engineering from the University of Damascus, Damascus, Syria, in 2003, and the M.Sc. degree in electronic and electrical engineering and the Ph.D. degree in electrical engineering from the University of Sheffield, Sheffield, UK, in 2008 and 2012, respectively.
From 2008 to 2012, Ziad was a Research Associate at the University of Sheffield, with major research interests covering modelling, design, and analysis of permanent magnet, as well as magnetless brushless machines for automotive applications. From 2012 to 2024, Ziad was with Siemens Gamesa Renewable Energy, and the last role was the Technology Development Manager with a focus on the development and validation of generator technologies and topologies to enhance the capability, efficiency, and reliability of direct-drive wind power turbines. Ziad is currently the Head of Portfolio Strategy Management at Siemens Energy Industrial Turbomachinery, with the responsibilities of the product development and ownership, product life-cycle management, and strategy development.
doi: 10.30941/CESTEMS.2026.00008
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In this paper, electrically excited synchronous machines (EESMs) using copper (Cu) and aluminum (Al) windings are compared for the feasibility of replacing Cu windings with Al windings in electric vehicle (EV) applications since Al windings have lower mass density and cost per weight, but higher resistivity and lower thermal conductivity than Cu windings. The EESMs with four winding configurations are optimized with an electromagnetic-thermal co-optimization method. The optimized EESM with only Cu windings is considered as the baseline in this study. Results show that the EESM with stator-Cu/rotor-Al windings has the least torque reduction (12.1%) compared to the baseline among the three EESMs with Al windings and the highest torque mass density among all EESMs. Meanwhile, although the new European driving cycle efficiency of the stator-Cu/rotor-Al EESM is 1.8% lower than that of the baseline, the torque per cost is 71% higher, and the maximum rotor mechanical stress is 8% lower. Therefore, the EESMs with stator-Cu/rotor-Al windings are prospective substitutions of those with only Cu windings for EV applications considering the trade-off between performance and cost.
Aluminum winding  /  Copper winding  /  Cost efficiency  /  Electrically excited synchronous machines  /  Torque density  /  Winding temperature
Tianzheng Xiao, Zi Qiang Zhu, Ziad Azar. Comparison of Electrically Excited Synchronous Machines Using Copper and Aluminum Windings in Stator and Rotor[J]. CES Transactions on Electrical Machines and Systems, 2026 , 10 (1) : 16 -27 . DOI: 10.30941/CESTEMS.2026.00008
Year 2026 volume 10 Issue 1
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doi: 10.30941/CESTEMS.2026.00008
  • Online Date:2026-06-12
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表12种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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