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Design of a PCB Statorcoreless Axial Flux Permanent Magnet 414 Wang et al. / Front Inform Technol Electron Eng 2019 20(3):414-424 Frontiers of Information Technology & Electronic Engineering www.jzus.zju.edu.cn; engineering.cae.cn; www.springerlink.com ISSN 2095-9184 (print); ISSN 2095-9230 (online) E-mail: [email protected] Design of a PCB stator coreless axial flux permanent magnet * synchronous motor based on a novel topology Halbach array Xiao-yuan WANG, Xiang LI†‡, Chun-peng LI, Si-jia XU, Le-tao LING College of Electrical Engineering and Automation, Tianjin University, Tianjin 300072, China †E-mail: [email protected] Received June 2, 2017; Revision accepted Sept. 13, 2017; Crosschecked Mar. 14, 2019 Abstract: A novel topology Halbach permanent magnet array is proposed and applied to the design of a printed circuit board (PCB) axial flux permanent magnet (AFPM) motor. Compared with the traditional coreless AFPM motor, this novel topology for a Halbach permanent magnet array PCB stator AFPM motor has larger air-gap magnetic flux density and air-gap flux per pole. The magnetic flux leakage is effectively reduced, and the air-gap magnetic density is close to the sine wave. Results of the finite element analysis and prototype experiments verify the feasibility and effectiveness of the novel Halbach permanent magnet array PCB stator motor. A reference basis and practical value for the design of the PCB AFPM motor are provided. Key words: Axial flux permanent magnet synchronous motor; Printed circuit board; Halbach permanent magnet array; Finite element method https://doi.org/10.1631/FITEE.1700345 CLC number: TM351 1 Introduction 2011); thus, the motor servo is good and conducive for batch production (Wu, 2012). However, flux in the An axial flux permanent magnet (AFPM) motor stator coils will be reduced because of the coreless is different from a radial flux permanent magnet stator structure (Zhu et al., 2013); thus, there are many motor because the air-gap flux is along the axial di- design requirements for the air-gap magnetic flux rection and the air gap is in-plane (Tang, 1997). Be- density, and the air-gap magnetic density is close to cause its axial dimension and the armature winding the sine wave. In contrast to the traditional AFPM inductance are small (Dutta and Rahman, 2008), motor, stator winding of the PCB stator is directly AFPM has received increased attention (Wang et al., printed on the PCB. In a certain area of PCB, the 2007). AFPM motor performs well as a servo motor numbers of turns of stator winding, line width, and and is widely used in electric vehicles (Kumar et al., line distance are different. To give the PCB a certain 2014), wind power (Neethu et al., 2010), aerospace, flow capacity, considering heat dissipation, the PCB and other fields (Fan and Wu, 2010). A printed circuit plate must have a certain thickness; thus, the air-gap board (PCB) stator coreless AFPM motor can greatly length is not too small. Considering the weight of the reduce the weight of the motor with no cogging motor, the cost, and axial length of the rotor stator, the torque (Kumar et al., 2015) or stator iron loss, and can PCB motor should not be too thick. Optimizing the achieve an accurate position of the coil (Yu et al., distribution of poles on the rotor magnetic steel has become a preferred method to improve the perfor- ‡ Corresponding author mance of a PCB stator motor (Cao et al., 2014). * Project supported by the National Natural Science Foundation of A Halbach permanent magnet array has been China (No. 51577125) ORCID: Xiang LI, http://orcid.org/0000-0002-3022-617x widely used in the design of permanent magnet mo- © Zhejiang University and Springer-Verlag GmbH Germany, part of tors (Galea et al., 2015), and some researchers have Springer Nature 2019 studied this array (Huang et al., 2017). Jiao et al. Wang et al. / Front Inform Technol Electron Eng 2019 20(3):414-424 415 (2017) studied the applicability of the Halbach array central fan shapes, and the main and auxiliary pole on the AFPM motor, the influence of the magnetiza- distributions of the magnet are reasonable. Assume tion angle of this array on air-gap flux density, and the that the amount of permanent magnetic materials does performance of the AFPM motor. A coreless AFPM not change. Thus, the performance of the coreless motor was designed using a Halbach permanent AFPM motor stator of a PCB is optimized. A model magnet array (Zheng et al., 2010). Two-dimensional with 3D electromagnetic field was established using a (2D) simulation results were compared with 3D ones. finite element method (FEM) method to simulate the The influences of 45°, 60°, and 90° Halbach perma- air-gap magnetic flux density and magnetic flux nent magnet arrays on the air-gap magnetic flux den- leakage of the PCB stator coreless AFPM motor. The sity and torque density were analyzed (Ubani et al., fundamental frequency and sinusoidal distortion rate 2016). However, simulation analysis instead of ex- of the air-gap magnetic flux density were analyzed perimental verification was performed. The magnetic and compared with the counterparts of the main vector potential of the Halbach permanent magnet magnetic and auxiliary magnetic poles with different array magnetic field was analyzed and applied to the shapes. A finite analysis simulation verified the ac- coreless permanent magnet synchronous linear motor, curacy of the experimental results. Thus, our method showing that the harmonic was significantly weak- can provide a reference basis and practical value for ened and that the amplitude of the back electromotive the design of a magnetic steel structure for PCB stator force (EMF) slightly decreased (Zhang et al., 2013). coreless AFPM motors. The fundamental maximum/minimum amplitude hybrid with a global optimization algorithm for mul- tiple objectives and the sine distortion rate were dis- 2 A PCB stator coreless AFPM motor and a cussed, and the magnetic pole angle and magnetizing novel Halbach array angle of the air-gap flux density waveform of the 2.1 A PCB stator AFPM motor structure fundamental amplitude and harmonic distortion were studied (Fan et al., 2009). In addition, some works In this study, the PCB stator coreless AFPM improved the performance of the AFPM using Hal- motor is a single-stator double-rotor structure (Fig. 1), bach arrays by changing the permanent magnet ma- and the PCB stator is in the middle of the bilateral terials; however, this method will lead to a cost in- magnetic steel. The structure can overcome single- crease of the motor (Luise et al., 2016). The effect of side tension, reduce magnetic leakage, and effectively the motor’s permanent magnet array on different increase the air-gap magnetic flux density. The rotor lengths of the air gap and the thickness of the per- is made of type 45H neodymium iron boron perma- manent magnet on the application of the Halbach nent magnet material. The PCB stator winding uses a were studied by changing only the Halbach perma- three-phase winding with eight layers, and each layer nent magnet array angle instead of the Halbach per- contains 12 coils. manent magnet array shape (Li et al., 2015). Studies 2.2 Structure of a novel Halbach permanent of the Halbach permanent magnet array used in the magnet array AFPM motor focus on the magnetization angle of the magnet steel, the thickness ratio of the magnetic steel, The Halbach permanent magnet array can in- and the back iron. The influence of the shape of the crease the air-gap flux density and ensure the sine array on the air-gap magnetic flux density and mag- waveform of the air-gap density. It can make up the netic flux leakage, especially from the inner and outer negative influence of the coreless structure on the diameters of the rotor, has received little attention. main magnetic circuit flux and effectively increase In this study, we propose a design of a PCB the torque density of the motor. A traditional disk stator coreless AFPM motor rotor structure. Using a motor rotor using a Halbach permanent magnet array novel topology for a Halbach permanent magnet array, is shown in Fig. 2. This design uses a novel Halbach where the pole diameter and outer diameter of the permanent magnet array, which changes the tradi- polar angle parameters are independent, the main and tional Halbach permanent magnet array optimization auxiliary poles are optimized with different method by adjusting the main pole in the inner and 416 Wang et al. / Front Inform Technol Electron Eng 2019 20(3):414-424 outer diameters and the auxiliary pole in terms of arc Table 1 Basic parameters and design requirements of the length, i.e., the angle from the main pole in the inner motor and outer diameters to the center line, for an effect on Parameter Value the novel Halbach array’s motor performance. Com- Rated power 200 W pared with the traditional Halbach array, the novel Permanent magnet material model 45 H Halbach array makes the distribution of the main Thickness of the permanent magnet 8 mm magnetic and auxiliary magnetic poles more reason- Thickness of theback iron 5 mm able on the magnetic steel. The novel Halbach array is Rotor outer diameter 90 mm used in the design of the PCB stator coreless AFPM Rotor inner diameter 52 mm motor, which effectively improves the sine waveform Air- gap length 5 mm of the air-gap flux density and the no-load back EMF Number of turns 8 of the motor. Number of slots 12 Number of pole pairs 8 5 1 Coil 2 Permanent Back iron magnet 4 6 8 3 7 Fig.
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