Design Optimization Of Winding For Disc-Type Permanent Magnet Synchronous Motor With PCB Stator

Disc-type permanent magnet synchronous motor with a PCB(Printed Circuit Board)stator,a type of coreless axial fux permanent magnet motor,has the merits of uncomplicated processing,high working efficiency and high power density.This motor with coreless achieves the goal of lightweight,and has the characteristics of small torque ripple and operation stability.The armature winding of coreless disc-type motor is mostly poured with resin,which makes the installation and fixing of the coil more difficult.Machining precision is difficult to meet the demand.Disc-type electric motor with a PCB stator can solve these problems above better.This kind of motor has the strong point in small torque ripple and low noise,The armature production is greatly simplified,and it is suitable for mass production.In this paper,the analysis and design of the rotor and stator of PCB stator disc-type motor are deeply studied.Firstly,the characteristics of the motor structure and the magnetic circuit of the motor are analyzed,and the features on different kinds of common windings also are compared and analyzed.Besides,the 3D finite element solution domain model of stator and rotor is established.The key parameters of the stator and rotor are analyzed and designed by the analytical model while the characteristics of the main magnetic circuit and the no-load working point of the permanent magnet are studied.Then the inner and outer diameter and magnetization length of the rotor are analyzed and designed,and the pole number and the pole arc coefficient of the motor are selected.Secondly,the motor stator winding is optimized.The stator linewidth has an important influence on the performance of the motor.Because of the PCB stator disc-type motor without the iron core,the winding cannot be placed in the stator slot like the motor with an iron core.Its winding is directly exposed to the magnetic field in the air gap,there would have eddy loss in the winding.Considering the eddy current loss of stator winding,stator current,copper loss and the process capability of PCB,the stator linewidth of PCB is optimized,which not only reduces the eddy current loss,but also meets the requirement of large stator current,and the copper loss of the stator is small.The stator ends is analyzed and designed after that.A new type of winding used in PCB stator motor is designed,compared with the traditional PCB stator winding.The characteristics and advantages of the new PCB winding are analyzed from the aspects of no-load back EMF,output power,efficiency and winding loss.Finally,the finite element method is used to simulate the motor under no load and load.The simulation results are consistent with the theoretical analysis.In addition,based on the results of design and optimization,the prototype is made to verify the correctness of simulation analysis.The simulation values are in good agreement with the tests data,which shows that the three-dimensional finite element calculation model established in this paper is reasonable,that has a certain reference value for the design of disc-type permanent magnet motor with a PCB stator.