Rapid Prototyping of Three-Phase AC Machine Drive System with Subtractive and Additive Manufacturing

We propose a method for rapid prototyping of a three-phase AC drive system for educational purposes. The proposed method allows college students to design and manufacture a drive system comprising three-phase inverters, a permanent-magnet (PM) machine, a controller, and sensors within a semester. The rapid prototyping process, which requires less than a day, enables efficient iteration and testing during the development process. In addition to addressing the electrical design considerations, this study also addresses the mechanical aspects of the drive system, including the use of coreless PM machines fabricated, using additive manufacturing technology, and the inverter manufacturing process, utilizing an auto-milling machine. Finally, we provide details of the rapid prototyping of closed-loop control, based on sensor feedback to regulate the rotating magnetic fields and output torque.