Optimization Design Of PCB Winding For Axial Flux Permanent Magnet Synchronous Motor

One of the distinctive features of coreless Axial Flux permanent magnet(AFPM)machine is it works under axial magnetic field.These kinds of machines have several advantages as high efficiency,simple and compact structure,high power density and so on.The application of the non-iron core greatly reduces the weight of the machine,making the motor running more smoothly at low speed.The PMs of the permanent magnet motor are arranged and designed through the method of Halbach array structure,this scheme can not only increase the air gap flux density of the motor to a certain extent,but can also guarantee the An ideal sinusoidal distribution of magnetic flux density.The design and manufacture of the stator armature winding of the coreless disc type motor is a very important part in the design of the machine.Traditionally,wound-rotor type machine,whose coil is sealed by epoxy resin casting,are more widely used in these days,although the processing technology is not mature enough,and coil is arranged with too much difficulty,with low positioning accuracy.Under these circumstances,the shape and size of the coil is difficult to meet the requirements,and these problems will intensified with the loop size,or maybe even result in winding disc's running out axially.The application of PCB(Printed Circuit Board)technology in AFPM greatly simplifies the manufacturing process of the motor.The specific structure parameters and the distribution of the winding directly affect the output power of the machine.In order to improve the power density of the axial flux permanent magnet synchronous motor(PMSM),a series schemes were presented in this article to optimize winding by considering of several characteristics of PCB coil.A three-dimensional analytical model of the motor was established first;then the expression of back EMF and other parameters such as winding resistance,winding inductance and winding loss were showed and calculated respectively.3D FEM simulation method was carried out in order to explore and verify the relationship between features of PCB and the output power.Simulation results have verified the correctness of the analysis mentioned before.Finally,the power density of the motor was optimized by appropriately increasing the conducting bar width which was verified by a prototype machine later in this paper,which provided a reference and practical engineering value for the design of the PCB axial flux PMSM.