Stator Holder

Design 1: Axial Flux Stator Lamination Core 19

Design 2:

Design 3:
Design 4: Axial-Flux motor firm Magnax

Design 5:
Axial Flux Motor Machine Design : 20
https://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=6352898

Fig. 2(a) shows an example of a

non-overlapping, fractional-slot
concentrated drum winding;

Fig. 2(b). As shown in Fig. 1, ring

windings are only used for Torus
structures and are generally the
preferred choice since they
maximize the active portions of the
winding and minimize the end
connections.

Classification based on Structure :-

● The single stator—single rotor, or single-sided machine, is the most elementary structure,
from which both the Kaman and Torus type machines derive.
● Multi-stack machines are made by stacking a number of Kaman type or Torus type
structures.

Second level of classification is based on the stator core material :-

1. An iron core
2. An ironless core
1. Iron Core :-

● Within the iron core category, stators made of non-traditional ferromagnetic material, such
as soft magnetic composite (SMC), amorphous metal (amorphous magnetic material
(AMM)), or charged polymers are also included.

Presence or absence of stator slots

Type of winding

1. The drum winding

2. The ring winding.

These windings differ in the end connections. The drum winding’s end connections are placed
circumferentially along the outer and inner radii; such a winding can be either overlapping or
non-overlapping such a winding can be either overlapping or non-overlapping.

When the stator is slotted, drum windings are also known as tooth-wound windings. On the
other hand, ring windings, also known as back to back, toroidal or core-wound windings have
end connections placed axially on the outer and inner radii of the machine; this type of
winding is always non-overlapping.

Polarity

The fourth level of segregation is based on polarity of opposing magnets

● The lowest hierarchical level of the tree diagram distinguishes the polarity of
opposing magnets and is used only for Torus structures.

● NN indicates that opposing magnets are of the same polarity, while NS indicates
that they are of opposite polarity.

● Some examples of AFPM machine topologies are shown in Figs. 3–5.

● Fig. 3(a) shows the structure of a slotted Kaman machine; due to the particular flux
paths for these structures, the rotor is usually ironless.
● Fig. 3(b) shows an ironless Torus type topology; in general, the stator windings are
encapsulated by thermally conducting epoxy resin.

● Fig. 4(a) shows a slotted current, and so on.

 MACHINE DESIGN

● The first step in this process is to develop a good estimate of the required
dimensions of the machine, in particular, the inner and outer diameters of the stator
and of the rotor and the active axial length of the machine.

● Two types of sizing equations for AFPM machines can be found in the scientific
literature, [3]. A first one is the classical D^2oLe equation, also known as Essen’s
Rule and was first adapted for AFPM machines by Huang et al., [4]. It relates the
output power (either mechanical power for motors or apparent power for
generators, e.g., [43]) to the principal geometrical, electrical, and magnetic
parameters of an AFPM machine.

● A compact form of this equation, expressed here in terms of mechanical power, is

the following:

Pmec = CmecfD2 0Le. (1)

Equation (1) is also often used in terms of power density, by dividing it either by
the total volume (W/m3) or by the total mass of active material (W/kg).

● The most general expression for Cmec, which also takes into account the
possibility of using wound excitation, is:

Cmec = 1 1 + Kφ m m1 π 2 KeKiKLKpηBgAavg 1 p (1 − λ2) 1 + λ 2 (2)

● In [4], two design examples illustrate how the various parameters of this sizing
equation can be determined. It is shown that the only really independent term is λ,
i.e., the ratio between the outer and inner diameters of the machine, since all of the
other parameters either depend on λ or have a very limited range of variation.

● The second type of sizing equation relates the electromagnetic torque to the
principal geometrical, electrical, and magnetic parameters:

Tem = π 4 BaveAinKdλ(1 − λ2)D3 0.

● Information on the magnetic shear stress can be obtained by dividing this equation
by the total active rotor surface. Torque density can be calculated by dividing (3) by
the total weight of active parts (Nm/kg) or the total volume (Nm/m3).
 ● For the same reasons as in (1), the only independent term here is λ.

● Values of λ that optimize torque density are to be found in the 0.65–0.75 range.

ELECTROMAGNETIC MODELING :-

● Due to their Geometry, AFPM machines represent 3-D electromagnetic problems, with two
separate 3-D effects standing out.

● One is the radial dependency of the flux density distribution, caused by the radial
dependency of the slot, tooth, and magnet pole pitches, and is widely known as the
curvature effect.

● The other is the flux fringing that occurs at the inner and outer radii and is known as the
edge effect.
● Both effects produce a certain amount of radial flux in the machine. In order to take both of
these into account, 3-D models are necessary.

● Without any doubt, 3-D FEA (finite element analysis) is the most accurate numerical tool
that can be used; however, it is time consuming and can require very large amounts of
memory.

● For these reasons, analytical models are used in the initial stage of a design, where less
precise, but quick simulations are generally preferred.

● In the following, recent contributions to 2-D and 3-D analytical electromagnetic modeling of
AFPM machines are analyzed. The models presented in all of these contributions assume
infinitely permeable iron.

● The simplest 2-D model for an AFPM machine is the mean radius model: this is equivalent
to the model of a linear PM machine without any lateral flux fringing effects. Such an
approach inherently neglects both curvature and edge effects.

● Within this category of models, Bumby et al., [8], present an analytical mean radius model
for the calculation of the magnetic field in the air-gap of a slotless machine. Armature
reaction is also taken into account.

● An analytical function derived by 3-D FEA (finite element analysis) is used to account for
the curvature effect. Chan et al., [10], propose an analytical mean radius model for an
ironless single-sided machine. Solutions for both the no-load field and the armature
reaction field are given.

● Iron losses are also calculated by using a separate, nonlinear reluctance network.

LOSS ANALYSIS AND THERMAL MODELING :-

● The stator of the machine is entirely made of SMC.

● The slots are open, and the machine is air-cooled.

● Cooling is achieved by means of the centrifugal airflow in the air-gap generated by the
PMs.
 MATERIALS :-

● The need on one hand for machines with ever increasing performances, such as reduced
weight, reduced losses, increased power density, and on the other for ease of fabrication
and mass production, has pushed researchers to investigate the utilization of
non-traditional materials both for active and structural parts in AFPM machines.

● Use of SMC, charged polymers, AMM, grain-oriented steel, superconductors, and even
plastic has been investigated by many, and the key publications in this area are addressed
in this section.

● In [25], Jack et al. design and build a FSCW, six pole pair, q = 0.25 Kaman type machine,
with stator teeth made of SMC material.

● The stator core is made of strip laminations, within which purposely designed ligaments
are obtained in order to firmly join the stator core with the teeth.

● SMC is used for the teeth due to the possibility of obtaining 3-D shapes by compacting the
SMC powder with ad-hoc designed molds.

● This sectional-core-building technique allows a high slot fill factor to be achieved even with
round-wire conductors, i.e., over 65% compared to 35% obtained with traditional
construction methods. The rated torque density (at the steady-state thermal limit) is 3.6
Nm/kg.

● In [26], [27], Khan et al. present a 220 W FSCW, Kaman type generator with seven pole
pairs and q = 5/14.

● The structure of the machine is similar to the one presented by the previous authors. A
significant difference in the fabrication rests in the fact that the teeth have been obtained
by milling SMC core samples.

● The authors have found that the smearing on the SMC teeth introduced by this method
leads to high superficial eddy current losses; the use of acid treatment successfully
removes the smearing; however, due to the removal of iron from the tooth surfaces, it
results in a reduced no-load back-emf and increased core losses, which offset the
reduction in eddy current losses.

● Woolmer and McCullogh, [28], design a yokeless and segmented armature topology motor
with five pole pairs and q = 0.4.
● The stator teeth are entirely made of SMC, pressed to separately form the shoes and
central part of the teeth. The peak overload torque density of the machine is 10 Nm/kg.

Amorphous materials have a very high relative permeability (in the 100 000 range)
and have low hysteresis losses.

● In [38], Masson et al. design a 450 kW, high temperature superconducting, ironless, two
stage, six pole machine for aircraft propulsion.

● The peculiarity of this machine is that the excitation is obtained by using six
superconducting yttrium barium copper oxide (YBCO) pellets instead of conventional PMs.

● It is expected that, by using YBCO pellets, the air-gap flux density reaches 3 T allowing
for very high torque density (≈ 18 Nm/kg) and very high efficiency (potentially over
99%).

● In order to function correctly, a cryostat is necessary to cool the pellets up to about 20 K.

● De Donato et al., [48], [49], design and construct a 10 kW 800 r/min, ten pole pairs, q =
0.2, FSCW Torus machine.
● In [48], core-wound coils are compared to tooth-wound coils, and it is shown that for this
topology, the former are generally preferable in terms of lower end connections.

● Key design aspects, verified by 2-D FEA, include the use of SMC wedges to keep no-load
losses at bay and the use of conventional, sintered non segmented NdFeB magnets since
the rotor losses are kept sufficiently small for every load condition.

● Experimental tests on a full-scale prototype confirm the design predictions.

PULSATING TORQUE :-

● AFPM machines are inherently suitable for high performance applications, such as
direct-drive systems, where low noise and smooth torque are imperative requirements.

● Both components of pulsating torque, [52], i.e., cogging torque and torque ripple produced
by non sinusoidal armature mmf (magnetomotive force) and field distribution, should
therefore be minimized.

● Appropriate AFPM machine design allows a strong reduction in pulsating torque and has
been the subject of numerous papers.

● In the following, the papers that have specifically addressed this topic as the main focus of
the research have been reviewed.

● In [52], Aydin et al. propose a new cogging torque reduction method for multiple
rotor machines.

● The method is based on the principle of alternating magnet pole-arcs:

● consequent magnets on a same rotor are designed with different magnet pole-arc ratios,
and the magnets on the opposite rotor are the same, but in reversed order; in this way
some cogging torque harmonic components produced in each air-gap are phase-shifted
and cancel out, thus reducing the peak cogging torque.

● The authors design a 3 kW, four pole pair, q = 1, slotted NN Torus machine and analyze
the proposed method by 3-D FEA; trapezoidal magnets with radial edges are used.

● With this technique only, peak cogging torque as low as 8.8% of the rated torque is
reported.
● In [53], Caricchi et al. perform an experimental campaign to evaluate the reductions in
cogging torque and no-load losses obtained by using various methods on a 7 kW, 12 pole,
q = 1, slotted NN Torus machine.

● The authors investigate the use of magnetic wedges versus PVC wedges to close the
stator slots; magnet skewing; angular shifting between rotor discs; variation of the magnet
pole arc to pole pitch ratio; shortening of magnet pitch. They also investigate the adoption
of combinations of these methods. The key conclusion that is made is that among all of
the analyzed methods, the shortening of the magnet pitch is the most effective, allowing to
obtain peak cogging torques as low as 1% of the rated torque.

● In [54], Aydin et al. analyze the pulsating torque of 150 kW, three pole pair, q = 1,
single-stator double-rotor, and double stator single-rotor designs.

● Both cogging torque and torque ripple components are considered. In order to reduce
cogging torque, magnet skewing is considered, while in order to reduce torque ripple
different winding arrangements are analyzed for the slotless designs.

● The analyses are performed both numerically and analytically. Key conclusions are: slight
variations in the skew angle or in the magnet pole-arc ratio cause noticeable fluctuations in
the torque ripple; slotless designs have lower torque ripple; use of pie-shaped wingdings
instead of core wound windings reduces torque ripple in slotless designs.

● In [55], Aydin et al. review various techniques that can be applied in AFPM machines to
reduce cogging torque. FEA analyses are performed on a four pole pair, q = 1,
single-stator, double-rotor machine.

● The following methods are analyzed individually: fractional slot windings, dummy slots in
the stator teeth, magnet-pole-arc to pole-pitch ratio optimization, stator slot skew, magnet
skew, magnet displacement, variable magnet pole arc, circumferential displacement of the
rotors/stators, displaced slots, and displaced slot openings.

● The above methods show how it can be more or less effective in reducing cogging torque,
but do not analyze the effects of the adoption of combinations of the proposed methods.

● They conclude that selection of the optimal ratio of magnet pole arc to pole pitch and
skewing are among the most effective ways of reducing cogging torque in AFPM
machines.
● Aydin et al., [59]–[62], present the concept, the sizing equations, the design, the 3-D FEA
analysis/optimization, and the experimental testing of an original axial-flux topology which
allows flux control and weakening without the use of a negative d-axis current component.

● This topology is known as the field controlled machine (FCAFPM). Fig. 9 shows an
exploded view of the machine. It has two slotted concentric stators and two rotors.

● The stators have two sets of three phase windings, not shown in the figure (one for each
air-gap), and a dc winding is placed between the two stators.

● The rotors carry NdFeB magnets and arc-shaped iron pieces.

● Each rotor pole consists of a PM and an iron piece.

● Two concentric rings can be seen on each rotor, alternatively formed by PMs and iron
pieces.

● The upper PMs of one rotor are all N-poles, while the lower PMs are S-poles; on the
opposite rotor the PMs have opposite magnetization, so that the machine can be classified
as a particular version of the slotted NS Torus topology.

● It is demonstrated by the authors that by commanding a positive or negative dc current in

the stator dc field winding, the linked flux with the stator windings can be increased or
decreased, i.e., both flux intensifying and flux weakening effects can be achieved.
● An important feature of this topology is that the flux density component due to the dc
excitation passes through the iron pieces and not through the PM, so there is no risk of
PM demagnetization during heavy flux weakening.

● In the design process, the authors pay particular attention to minimizing flux leakage, by
selecting appropriate distances between the PMs and the iron pieces and an appropriate
dc winding slot width between the concentric stators.

● A 1.2 HP, eight pole, 1200 r/min machine is designed, simulated and built. 3-D FEA shows
that the no-load air-gap flux density can be varied linearly between 0.75 T and 0.2 T. This
implies that a CPSR of up to 3.75 : 1 can be ideally achieved.

● Experimental results show a good accordance with the design and FEA predictions;
however, the actual CPSR of the machine is not verified.

APPLICATIONS :-

● AFPM machines are generally regarded as ideally suited whenever low speed and high
torque are required, such as in direct-drive applications, [78]–[83]. However, the axial
compactness of these machines and the relatively high moments of inertia that the rotors
can achieve have also pushed research in high speed applications, from hard disk drives
to flywheel energy storage systems all the way to axial magnetic bearings.

● In [81], Rahman et al. present a direct-drive wheel motor propulsion system for fuel cell
and hybrid electric vehicles, shown in Fig. 14. The proposed machine is a slotted NN
Torus machine, having 15 pole pairs, q = 1, a base rotational speed of 600 r/min, a CPSR
equal to 2:1 and a peak power equal to 25 kW.

● The machine is designed to fit into a 17 wheel for use in GM’s S10 mule vehicle. Key
construction aspects include the following: the use of reduced magnet pitch to keep
cogging torque low; the elimination of mass from the areas of low flux concentration in the
rotors’ back iron to reduce overall weight; the use of magnetic wedges to close the stator
slots in order to increase the CPSR; the use of a patented liquid cooling aluminum ring in
combination with high thermal conductivity epoxy resin to enhance the heat extraction
capability and to handle the reaction torque of the motor.

● Efficiencies above 85% are reported for the areas of the torque/speed plane where the
vehicle is intended to operate most of the time.
 PAPER 2 : AXIAL FLUX ELECTRIC MOTOR 21

https://www.emworks.com/ckfinder/userfiles/files/Axial%20Flux%20Motor.pdf

INTRODUCTION

● The electric motor is a machine that transforms the electrical energy into mechanical
energy, basing its principle of operation on the electromagnetic interactions of magnetic
fields generated by the coils and magnets, housed in the structure [1].

● Electrical machines are usually composed of one stator and one rotor.

● Typically the electric motors are designed and constructed in order to use the radial flux
distribution, where the rotor and stator have a small radial air gap between them (as
shown in Fig 1).

● In Axial flux motors, the winding can vary their geometric arrangement according to the
required design diameter, making it possible to considerably reduce the total volume
occupied by the machine.

● The axial flux electric motors have specific positioning of their magnets, which are in
planes parallel to the coils - Figure 2, which allows to create a flux of magnetic field over a
smaller rotary volume resulting in a decrease of the moment of inertia and the mass of the
rotor. [2]
● The topic of this project is the design and manufacturing of an axial flux electric motor
taking into account critical parameters such as size, electrical consumption and RPM.

● In order to conclude this project in the best way, all the development phases will be
presented - from the working principle, through all the phases of analysis and design, both
physical, electrical and electronic, to the control system.

IDEOLOGY

● The electric motor is a machine that transforms electrical energy into mechanical energy
by means of the action of the magnetic fields generated in its coils [3].

● They are usually called rotating electrical machines and are composed of a stator and a
rotor, some of which are reversible, and can function as motors or generators.

● On the other hand, electric traction motors used in locomotives or hybrid cars often
perform both tasks [3].

● Historically axial flux machines were the first to develop in 1821 Michael Faraday (British
Physicist and Chemist).

● This machine had the disadvantage that it had a very large peak in the magnetization
current due to the large air gap of the rotor disk, making it impossible to implement at that
time [4].

● As a principle of optimization and efficiency, the configuration of the axial flux motor
represents a significant advantage with respect to the radial flux motor, for which this type
of configuration is commonly used to ensure that the efficiency of the motor is greater than
90%.

COMPANY 1: MAGNAX

● This way the company MAGNAX has developed Next-Gene Axial Flux Motor / Generator
● Which is a motor / generator of direct assembly that offers an efficiency of 96% for such
specific purposes as wind turbines and electrical. machinery of large industrial proportions,
in addition to having a size of 140mm in length and 1600mm diameters, with a weight of
850kg, this engine / generator offers a torque of 16kNm.

● Permanent magnet axial flux motors allow the axial configuration to be maintained and the
position of the rotating part to be changed to the ends of the motor, the ELMO motor
-S112 Figure 10 [6] of the company ASHWOODS Electric Motor has developed an
engine of these characteristics maintaining a more compact design than that presented by
the company MAGNAX in order to provide alternatives for smaller spaces.

● This engine delivers a torque of 45Nm at a speed of 5000 rpm, which allows to obtain an
efficiency of 90%, the engine has a total weight of 13 kg.
 COMPANY 2: CKN

● EVO ELECTRIC motor Figure 11 [7] of the company CKN which consists of 3
configurations of permanent magnets each fed with a phase, which increases the
torque at the output due to the current density on the driven surface increases.

● UNIQUENESS: This company has more than 5 models that allow you to choose
between maximum speed (rpm), nominal torque (Nm), diameter (mm), length (mm)
and weight (kg) as the most important options when choosing any of these Models.

COMPANY 3: ALBUS TECHNOLOGIES

● As in Figure 12 the company ALBUS TECHNOLOGIES [8] implements a double rotor

motor making the ventilation on the stator is maximum, the innovation in the design
presented by this company lies in the way they miniaturize each section of the same,
allowing them to have a length between 2 and 5 mm with a maximum diameter between 8
and 15 mm, which facilitates its use in compact areas.

● With this design and its small size, this engine achieves a torque output between 5 and 8
Nm.
 COMPANY 4: LAUNCHPOINT TECHNOLOGIES, INC

● As we have seen so far, most of the designs presented handle the direct output of its axis
parallel to the ground, which for many cases is useful, however, the company
LAUNCHPOINT TECHNOLOGIES, INC [9] has managed to innovate in construction of
the HALBACH ARRAY ELECTRIC MOTOR model, which is an axial flux electric motor
with axis orientation perpendicular to the ground, as shown in Figure 13, which, in some
cases, simplifies mechanical assembly because it does not need any type of coupling to
change the direction of application of the torque.

COMPANY 5: EMRAX INNOVATIVE E-MOTORS

● Another example of the efficient use of space for electric Figure 16. Brushless DC Motor
BGA 22x2 d Core motors with axial flux with three-phase power is the EMRAX 188 motor
Figure 14 - Figure 15 developed by the company EMRAX INNOVATIVE E-MOTORS which
changes the way of winding generating a greater rotor permeability generating in this way
that the induced current density increases and a greater conduction and speed is
generated as well.

● This engine with 188mm diameter and 77mm length delivers a torque magnetic field
resulting from a Certain motor rotates of approximately 50 Nm ensuring this 98%
efficiency.
 COMPANY 6: DUNKENMOTOREN and AMETEK Advanced Motion Solutions

● As a last example, we present the brushless axial flux DC motor with air core coils,
developed by the company DUNKENMOTOREN and AMETEK Advanced Motion
Solutions, which directly implies that there is no induced field that generates any type of
vibration, this in mechanical design allows its efficiency to be greater than in other
previously presented designs.

● The principle of operation is the same, however, this has greater induced current density,
which allows it to maintain a greater robustness in terms of its electromagnetic
composition.

THEORETICAL BACKGROUND
● Within the category of electric motors we can find two [10], which changes the way of
winding generating a configurations; Radial flux motor (MFR) is characterized greater rotor
permeability generating in this way that the when the resulting magnetic field rotates like
the hands of induced current density increases and a greater a clock, superimposed
perpendicularly along the axis, and conduction and speed is generated as well.

● This engine axial flux motor (MFA) which is characterized when the magnetic field
resulting from a Certain motor rotates concentric to its axis, besides that these present
high values of motor torque at low speeds, high efficiency and high power density - Figure
17 - Figure 18 - Figure 19 - Figure 20 [2].
● The operation of an axial flux motor is based on the interaction of the magnets in the rotor
with the electromagnetic field flux produced by the coils, generating an induction of current
on the rotor to generate a rotational torque, the explanation of this phenomenon Physical
is based on the Lorentz Force, which dictates that "Any electric charge moving within
a magnetic field suffers a force" [12].
● With this principle is that the movement of the electric motor is achieved since maintaining
constant the polarity of the load and varying the direction of flux of the magnetic field can
generate the movement, due to the force rotations, for or against the hands of the clock.

● Figure 22 and Figure 23 show the two cases that can be presented according to the
direction of the movement that is generated, in this case the direction of the current on the
winding Figure 30. The change of direction of the current must be generated in order to
attract the poles of the magnets distributed according to Figure 20 so as to generate
attraction and repulsion forces on each section of magnets.
● The advisable way to make all the changes in the direction of the magnetic fields can be
described according to the shape of the wave in Figure 24, in which during half a cycle the
wave maintains positive values of current that generate a positive magnetic change and in
its other half cycle it takes negative values that invert the sense of the magnetic field, in
general it could be said that the available three-phase power of the public network can be
used but the main problem with this power supply is that the frequency that is handled, 60
Hz, for basic applications it is difficult to control, for which reason another means of
feeding must be available.

● In order to simplify the prototype model developed in this project, it was proposed to use
the configuration (a), shown in [2], facilitating the development of the electronic part since
it is not necessary to have control over both rotors to synchronize the stages with the
sending of the necessary sequences for the movement of the motor, nor to develop more
electrical power if the configuration of double stator is handled.

● Taking into account both the physical and electromagnetic aspects of the system,
emphasis is placed on the following parameters;
• Magnitude of the electromagnetic
• Induced magnetization force
• Stator dimensions for coil design
• Geometrical structure of the winding to maximize the induced field
• Resistivity, inductance, reluctance and impedance of the windings
● In order to have these parameters as a basis, it is necessary to know how the principles of
magnetization work on a solenoid and for this the following information is exposed; The
composition of the coils can be modeled as an Nturn solenoid, forming a configuration of
length L, distributed one after the other with one or several layers as shown in Figure 26.

● Taking into account that the coils are going to be solenoids, with a defined shape, the
magnetic field on these can be described in [13] as :-

● Equation 2. Magnetic field equation of a solenoid, where:

• μ, magnetic vacuum permeability coefficient
• N, total number of turns in the solenoid.
• I, magnitude of the current fluxing in the solenoid.
• L, total winding length.

● Once the magnetic field generated by the coil supply in one direction is known, the
magnitude of the dipole magnetic moment on each loop can be known in the following way
described in [13] as:

● Equation 3. Magnetic dipole moment equation in a solenoid loop. Where;

• B, magnetic field present in the solenoid.
• I, magnitude of the current fluxing in the solenoid.
• A, induction area of the magnetic field.
 • ∅, angle of incidence of the magnetic field with respect to the perpendicular of the plane
of the turn.

● Knowing that the solenoid is composed of N contiguous spiers, we can determine that the
magnitude of the total torque on the solenoid is the sum of each of the moments
generated by each turn, therefore, the dipole moment on a solenoid is:

● Equation 4. Magnetic dipole moment equation in one loop of the solenoid, where:

• B, magnetic field present in the solenoid.

• I, magnitude of the current fluxing in the solenoid.
• A, induction area of the magnetic field.
• ∅, angle of incidence of the magnetic field with respect to the perpendicular of the plane
of the turn.
• N, total number of turns in the solenoid.

● In this way it is possible to quantify the magnitude of both the force and the attraction as
well as the repulsion which are necessary for the movement of an electric axial flux motor
to be generated.

● In conclusion, the phenomenon that occurs for the existence of electromagnetic induction
motors is that both the winding field Figure 26, generally solenoids, and the field generated
by the permanent magnet attempt to align so that their magnetic fields form a single loop.

● Repeating this process again and again, changing the direction of the magnetic field
induced in the coil, generates the forces of attraction and repulsion that manifest the
movement of the rotors in the motors.

● Having clear the phenomena that make the operation of the proposed project is presented
in Figure 29 the shape of the coils that are going to be implemented in the assembly.

● This geometric configuration was chosen in order to distribute the magnetic field in a
directed manner over each magnetic field of the magnets resulting in the reduction of the
electromotive force that must be generated to attract each pair of magnets.

● The structure of the winding is made in a malt cross configuration with the intention of
generating a wave of sinusoidal magneto-motive force [2].
● Projecting an expected speed that has our axial flux electric motor, we apply Equation 5
that correlates the frequency with the number of poles to estimate the maximum
revolutions that can reach our system.

where:
• f, magnetic circuit inductance
• f, working frequency
• R, resistance of the electrical circuit.

CONCLUSION:-

● The geometry of the coil is of great importance since it defines the level of magnetic field
that can be generated, thereby influencing the torque capability.
● The materials chosen for the structure that will serve to support the engine must have
strength, flexibility, low weight, low conductivity, in order to reduce the inertia exerted
inside the engine as much as possible, the magnetic losses and the generation of parasitic
currents induced in the support structure.

● The use of acrylic material for the entire support structure of the engine was supported
and defined according to its engineering properties, which allowed us to disregard the
variables of weight and magnetic conductivity of the material.

● In addition, the use of acrylic allowed us to also neglect the inertia and vibrations
generated by the movement of the engine at high speeds.

● The use of a three-phase inverter is based on the premise that a DC source is going to be
used as an external power source, in order that, in each coil, a sinusoidal power is
generated. And so you can, changing the frequency, change the speed of the engine
without altering the developed power of it.

● The axial flux electric motor with respect to other conventional motors offers a much higher
level of efficiency, torque generation and low presence of vibration due to its geometric
topology, distribution of its components affecting the center of mass and its behavior, and
mainly that the use of the coils allows mechanical movements to have minimal friction with
maximum torque development.

● With the implementation of an axial flux electric motor it is expected to create a path for a
better use of the available resources in order to develop a movement towards the
optimization of the complete drive system.
 YASA AXIAL FLUX MOTOR:
https://www.yasa.com/technology/

The core advantage of an axial-flux motor is that the spinning rotor has a larger diameter,
because it turns alongside the stator, rather than inside it. Torque equates to force
multiplied by radius. With an axial-flux design there’s a larger radius than in a
conventional radial motor, you get more torque for the same force. This means for the
same permanent magnet and copper winding provision, you get more torque.
However, the YASA motor topology also removes the stator yoke, which reduces the
stator iron mass by up to 80%. This innovation provides a significant power density
advantage and a 5-10% range benefit over the radial electric motors on which most of
today’s mass-market Electric Vehicles depend.
Uniquely, our axial-flux electric motors feature a proprietary ‘Yokeless And Segmented
Armature’ (which, incidentally, is where we get the name YASA).
Electromagnetic Design Characterization of a Dual Rotor
Axial Flux Motor for Electric Aircraf t (IEEE)
https://ieeexplore.ieee.org/document/9449611

Exploded view of the motor topology with 12 slots and 5 pole pairs.

2D flux lines distribution of a symmetrical fraction of an example “unrolled” motor

design with 30 slots and 14 pole pairs.
(a) Transverse-section (with red arrows illustrating flux direction) and (b) Prototype
stator of YASA motor with GOES in [10] used to validate FEA models.

Axial Flux Permanent Magnet Motor:

https://ieeexplore.ieee.org/abstract/document/4957798
https://ieeexplore.ieee.org/abstract/document/9627679

AFPM machine structures.

Schematic design of a proposed AFPM motor and design parameters related to tooth and PM.

Stator, rotor, and assembly of AFPM motor: (a) stator core with skew angle 0°, (b) stator
core with skew angle 4°, (c) AFPM motor assembly.
Dimensions and Parameters of the AFPM Motor
 Rotor poles with magnets and soft iron piece

AFPM stator construction: (a) Strip-punched core, SMC teeth and a coil, (b)
Completed stator halves with laminated back iron
 ● The AFPM machine is an attractive solution for high power density applications which
have strict restrictions on motor axial length, whereas the RFPM counterpart is attractive
for a long motor shaft.
● Among all AFPM machines, the double-sided AFPM structure including both TORUS and
AFIR types is most promising for high-performance drive applications due to high power
density and high efficiency.
● YASA motor is a premium AFPM structure which has been widely investigated for
direct-drive EVs, due to high torque density, compact structure and low weight. However,
the manufacturing and assembly are still challenging.
● The tooth-wound CWs are increasingly adopted in AFPM machines as it reduces
end-winding length and allows a segmented stator structure and pre-wound coils to ease
the manufacture process and achieve a high slot fill factor.
● Sizing equations are used in the initial design stage of an AFPM machine to estimate the
required motor dimension, and the quasi-3-D model is adopted in the design process to
reduce the computation cost of 3-D FEA.
● The diameter ratio is considered as the most important design parameter for AFPM
machines which cannot be designated as a simple numeric value and should be optimized
under specific geometry, electric and magnetic loadings.
● Power losses, torque ripple and CPSR are important design considerations for EV motors.
Corresponding techniques are introduced, among which adding magnetic wedges at the
slot opening is a global way to improve the motor performance.
● SMC material has been widely applied in AFPM machines for the production of cores or
teeth due to the advantages of 3-D isotropic magnetic properties and low eddy-current
loss.

AFPM machines have much larger electromagnetic interaction between the stator and PMs of the
rotor than RFPM machines, which requires accurate thermal and mechanical analysis during the
design process, as well as strict manufacturing and assembly to avoid eccentricity and asymmetry.
Future research can be focused on the following aspects:

1. Efficient and accurate modeling of AFPM machines to minimize the gap between the
predicted and actual performances.
2. Cost-effective manufacturing and assembly methods for AFPM machines with less side
effect.
 3. Relations between lamination properties (including thinner laminations) and motor
performances, to develop motor design with tailored laminations.
4. New processing methods including stacking, cutting and stamping for laminations, to
minimize the side effects by manufacturing.

Axial Flux Induction Motors :

https://ieeexplore.ieee.org/abstract/document/6517530

A two-speed, single-phase, squirrel-cage AFIM with laminated single side cores for
use as an evaporative cooler motor is considered. The objectives of this paper are as
follows:

1. A comprehensive design algorithm is proposed to design the single-phase

capacitor-run AFIMs.
2. All geometrical dimensions and electrical equivalent circuit parameters of the
designed motor are analytically calculated.
3. A new construction technique, which allows designers to decrease air-gap length
to the desired value, without any concern about high axial force between stator
and rotor and locking of the rotor, is presented. It should be mentioned that
there is some manufacturing difficulty associated with the axial force acting on
the rotor and bearings of the AFIMs caused by the one-sided magnetic pull [1],
[18]. The value of this force increases in the smaller air-gap length, while an
increase in air-gap length will lead to a decrease in the power factor and
deterioration of other performance characteristics of the motor. The typical
air-gap length in single-side AFIMs is more than 2 mm, but by using the
proposed technique, it can be decreased to even 0.1 mm.
4. A multiobjective and multivariable optimization MOMVO was carried out to
achieve maximum efficiency and power factor simultaneously with minimum
core volume.
5. A 3-D time-stepping finite-element analysis (TSFEA) was employed to verify the
design and optimization process.
6. Optimal motor is practically constructed and tested.
Studied AFIM: (a) stator and (b) rotor.
Geometry of (a) stator slots and (b) rotor slots.
Fabricated AFIM: (a) stator, (b) rotor, (c) the whole motor, (d) motor installed on the evaporative
cooler, and (e) experimental test circuit.
Axial flux motor with Halbach-type permanent magnet
rotor and SMC cores :
https://ieeexplore.ieee.org/abstract/document/6556181

Details of the AFPM prototype; (a): partially assembled motor showing the configuration of the
stator pole shoes and of the disk rotor; (b): test rig adopted for static and dynamic
measurements.
Axial-Flux Permanent-Magnet Disk Motors :
https://ieeexplore.ieee.org/abstract/document/6603341#full-text-header

AFPM disk motors with (a) one stator and one rotor, (b) one stator and two rotors
(also called slotted TORUS type), (c) coreless one stator and two rotors, (d) slotless
TORUS, and (e) two stators and one rotor (also called AFIR type)

The AFPM motor used in this study has a two-rotor–one-stator configuration with 24 slots and 8
poles. This motor is designed so that the cogging torque is maximum with
q=1 slot/pole/phase. The designed motor, also called reference motor as given in Fig. 2, has a
cogging profile of 8-
N⋅m peak. The motor has conventional fan-shaped magnets used in the design
Fig. 2. Cogging torque profile of the 8-pole 24-slot axial gap experimental (reference) motor and
the picture of the prototype

Key Design Parameters of the Reference AFPM Motor

 Electromagnetic design procedure for AFPM motors

Summary of cogging torque minimization techniques in AFPM disk motors.

 Planer AFPM disk rotor with different magnets.

Manufacturing stages of the slotted double-rotor–single-stator AFPM motor prototype (only a

triangular rotor is illustrated).
Manufactured and tested rotors of the AFPM motor prototype. (a) Rotor with fan-shaped magnets
(unskewed structure); prototype. (b) Rotor with triangular magnets. (c) Rotor with conventional
skewed magnets.