Multiphysics analysis of printed circuit board winding for high‐speed axial flux permanent magnet motor

Abstract

Gearless and compact motors rotating at speeds above 10,000 rpm are finding many applications nowadays. This study presents the multiphysics modelling and analysis of a multilayer printed circuit board (PCB) stator for high-speed, lowpower axial flux permanent magnet motor. The possibility of circulating current in the multilayer PCB is studied. The two major effects of eddy currents at high frequencies: skin effect and proximity effect are investigated for the PCB winding. The losses in the PCB stator are estimated, and thermal analysis is performed to ensure reliable operation of the motor. MagNet 3-D and COMSOL Multiphysics are used, respectively for the finite element analysis and optimisation of the motor; and the simulation results are presented. A prototype of the motor is fabricated and tested to validate the simulation results.

Design aspects, winding arrangements and applications of printed circuit board motors: a comprehensive review

“…The second as shown in Fig. 3 b has interior permanent magnets (IPMs), in which the PMs are embedded inside the rotor [1, 13, 20, 44]. Since the PMs are buried in the rotor iron, they are protected from corrosion and high centrifugal forces, which can make them a suitable option for high‐speed applications [45].…”

“…In [87] a linear motor has been developed for factory automation, consisting of a novel FPCB winding, it is shown that the proposed PCB winding is an appropriate solution for the slotless linear motor. An AFPM PCB motor for high speed, low‐power applications was described in [13, 22, 44], since the Halbach array configuration is used, the flux production and the motor performance is enhanced.…”

“…In the motors where the main flux does not flow through stator core circumferentially and just flows straight from one rotor to another, the presence of the stator core is no longer needed; hence it can be removed, which leads to a coreless stator composed of only windings. The coreless structure offers many specific features such as reduced weight, zero iron losses in the stator [22, 51], minimised torque ripple and axial attraction force in the axial‐flux motor [22, 44]; and also this improves the motor efficiency and power density [52]. Whereas, the core elimination results in a larger non‐magnetic air‐gap which reduces the stator flux linkage.…”

Multiphysics Analysis of an Axial-Flux In-Wheel Motor With an Amorphous Alloy Stator

“…In this paper, a novel YASA in-wheel motor with tapewound AMM segments for a solar-powered electric vehicle is proposed. During the design process, a multiphysics analysis including electromagnetic, thermal, and mechanical behavior is indispensable [35]- [38]. This paper describes the design, the study and the construction of the prototype of the YASA in-wheel motor with 24 poles and 27slots.…”

Analysis and Design of an Axial Flux Permanent Magnet Motor for in-Wheel System Using a Novel Analytical Method Combined With a Numerical Method

“…Research on all motors including AFPM motors can be largely categorized into analysis and design, materials, and control. Analysis and design research mainly focuses on multiphysics modeling, such as electromagnetic field, stress, vibration, noise, and heat, design through these analyses, and analytical methods to reduce the analysis time and cost of the motors [9]- [11]. Materials research is actively conducted for the purpose of improving performance or reducing manufacturing costs by using materials such as amorphous cores and ferrite magnets [12]- [14].…”