CAD OF AXIAL FLUX PMBLDC MACHINE

A Minor Project Report

Submitted in Partial Fulfillment of the Requirements for the Degree Of

BACHELOR OF TECHNOLOGY
IN ELECTRICAL ENGINEERING

By Avi Krishna Gupta (10BEE063) Vipul Kumar Jain (10BEE067) Under the Guidance of Prof. Amit N. Patel

DEPARTMENT OF ELECTRICAL ENGINEERING INSTITUTE OF TECHNOLOGY, NIRMA UNIVERSITY AHMADABAD -382 481 NOVEMBER 2013 I

INSTITUTE OF TECHNOLOGY NIRMA UNIVERSITY DEPARTMENT OF ELECTRICAL ENGINEERING AHMEDABAD 382481

CERTIFICATE
THIS IS TO CERTIFY THAT THE MINOR PROJECT REPORT ENTITLED CAD OF AXIAL FLUX PMBLDC MACHINE
SUBMITTED BY

MR. AVI KRISHNA GUPTA (10BEE063) AND VIPUL KUMAR TECHNOLOGY (ELECTRICAL ENGINEERING) NIRMA

JAIN (10BEE067) TOWARDS THE PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF
THE DEGREE IN

BACHELOR

OF

OF

UNIVERSITY IS THE RECORD OF WORK CARRIED OUT BY HIM UNDER OUR SUPERVISION AND GUIDANCE. THE
WORK SUBMITTED HAS IN OUR OPINION REACHED A LEVEL REQUIRED FOR BEING ACCEPTED FOR EXAMINATION.

DATE:

PROF. AMIT N. PATEL

HOD(EE)

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ABSTRACT
Permanent magnet machines are finding increased application in electric vehicles because of increasing population and also as the cost of the oil products are on the rise. The main feature of this type of machine is compactness of their size compared to a normal machine. These types of machines are most efficient because of the fact that field excitation losses are eliminated resulting in significant rotor loss reduction. Thus motor efficiency is greatly improved and high power density is achieved. PM motors are compact and suitable for special operations where limited space and weight are available.

Permanent magnet motors are two types: Radial Flux and Axial Flux machines. In the axial flux machines, the air gap is axial and active current carrying conductor is radial. The axial flux machines can be designed to have a higher power to weight ratio resulting in less core material and less inertia. In axial flux machines adjustment of air gap is simpler. Axial flux permanent machines are smaller in size and disc shaped rotor and stator.

The objective of this project is to develop a design method for axial flux machines used for electric vehicles, propulsion purpose in naval ships, etc. It focuses on development of a Computer Aided Design program for the axial flux machine. It also aims at optimizing the parameters in order to increase the efficiency using the software package MATLAB.

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Acknowledgement
We are pleased to present report on the project CAD Of Axial Flux PMBLDC Motor. We are indebted to our guide Prof. Amit Patel sir for guiding us from time to time whenever we were in needed his help. We also are grateful to our seniors from M. Tech. for helping us through the Magnet software. We are also helpful to Prof. Tejas Panchal sir for guiding us in preparing the report.

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Nomenclature/Abbreviations
BLDC CAD PM RFPM AFPM KW Brushless Direct Current Computer Aided Design Permanent Magnet Radial Flux Permanent Magnet Axial Flux Permanent Magnet Kilowatt

List of Figures
1.1: Schematic diagram of AFPM 2.1: Dimensions of AFPM motor 2.2: Fleming Left Hand Rule 2.3: Derivation of Torque Equation 2.4: Slot Pole Overlap 2.5: Overlap of two back emfs 2.6: Graph of Is Vs Dout Vs Efficiency 2.7: Bg Vs Dout Vs Lm 2.8: Differential slice of rotor pole

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CONTENTS
Abstract Acknowledgement Nomenclature/Abbreviations List of Figures/Tables (II) (III) (IV) (V)

Contents: Chapter 1: Axial Flux PMBLDC Motors 1.1 Introduction 1.2 Axial Flux PM motors 1.3 Applications of AFPM machines Chapter 2: Stator design of AFPM machine 2.1 Main Dimensions 2.2 Back Iron Width 2.3 Tooth Bottom Width (Wtbi) 2.4 Slot Bottom Width (Wsb) 2.5 Area of slot (As) 2.6 Slot Bottom Width 2.7 Conductor Slot Depth 2.8 Shoe Depth 2.9 Total Slot Depth 2.10 Slot Opening 2.11 Air Gap Area (3) (10) (11) (11) (12) (12) (12) (12) (12) (12) (12) (1) (1) (2)

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2.12 Length Of Magnet Chapter 3: Result Tabulation Using matlab Chapter 4: Analysis Of Design 4.1 Magnetic Circuit Analysis 4.2 Performance Analysis 4.3 Algorithm for developing CAD program Chapter 5: Result Tabulation Using matlab Chapter 6: Comparison with standard IEEE reference Conclusion and Future Scope

(12) (14)

(15) (18) (19) (20) (21) (22)

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CHAPTER 1 AXIAL FLUX PMBLDC MOTORS 1.1 Introduction

PM machines are increasingly becoming dominant machines with the cost competitiveness of high energy permanent magnets. These machines offer many unique features. They are usually more efficient because of the fact that field excitation losses are eliminated resulting in significant rotor loss reduction. Thus, the motor efficiency is greatly improved and higher power density is achieved. Moreover, PM motors have small magnetic thickness which results in small magnetic dimensions. As for the axial flux PM machines, they have a number of distinct advantages over radial flux machines (RFPM). They can be designed to have a higher power-to-weight ratio resulting in less core material. Moreover, they have planar and easily adjustable airgap. The noise and vibration levels are less than the conventional machines. Also, the direction of the main air gap flux can be varied and many discrete topologies can be derived. These benefits present the AFPMs with certain advantages over conventional RFPMs in various applications

1.2 Axial flux PM motors

Based on stator-rotor arrangement there are three types of AFPM motors: i) Single sided structure. ii) Double sided structure. iii) Multi disc structure.

Our project aims at developing design equations and algorithm for double sided AFPM motor. Advantages of using double sided AFPM motors over single sided motor are: i) More robust structure ii) Lower leakage reactance iii) Higher power density iv) Higher efficiency.

Figure 1.1: Schematic diagram of AFPM

The above picture shows double rotor single stator type AFPM motor. There are 2 rotors, on the rotor periphery there are magnet poles placed alternately as seen in Fig. 1.1. The stator has a slotted structure and the winding is wound on the stator in the pattern as shown above.

1.3 Applications of AFPM machines:

There are many existing applications of AFPM motors some of them are: i) Hybrid electric vehicle with flywheel-electrical machine combination. ii) High-speed generator driven by a gas turbine in a hybrid traction system. iii) Wheel direct drive for electric vehicles.

CHAPTER 2 DESIGN OF AFPM MACHINE

2.1 Main Dimensions

Figure 2.1: Dimensions of AFPM motor

The rotor and stator dimensions are identical to each other. As illustrated by fig. 1.2 we see that the inner diameter is the shaft radius. The difference in the inner and outer radii is the actual active length of the conductor on the stator winding. This length of conductor actually contributes to the production of useful torque. As we know that according to Flemings left hand rule the force applied on a current carrying conductor placed in a magnetic field is perpendicular to the plane containing the current and field vectors. The force is given by equation:

Figure 2.2: Fleming Left Hand Rule

We can see from the fig 1.1 that the direction of flux is axial i.e. it is perpendicular to the direction of the current in the stator winding. Thus in this case we can apply the Flemings rule and find the force acting on the conductor. Thus since the direction of current is perpendicular to the air gap flux (Bg) thus the magnitude of force is given by:

Figure 2.3: Derivation Of Torque Equation

Now consider the active conductor between Ro and Ri. Take a differential length dr at a distance r from the center of the shaft. Thus the force is given by , Tangential to the rotor

Now,

Thus,

Integrating w.r.t r from Ri to Ro:

Thus,

(i)
Where,

Nc = No. of coils conducting simultaneously = 2 Is = Slot Loading = NsI

Taking different constants the equation (i) becomes: So,

.(ii)
Here, Nm = No. of magnet poles.
NO. OF POLES SLOTS PER POLE WINDING PITCH 2 12 12 4 6 6 8 3 3 10 2.4 2 16 1.5 1 20 1.25 1

The best design would probably be the 8 pole because the winding pitch will be pitch and inherent detent of cogging torque is small due to the fact that only 2 out of 8 poles aligned with stator slot opening as rotation occurs. So we select no, of poles for one rotor =8. Thus for two rotors Nm = 16. Also Slots per pole = 3 so slots per pole per phase =1 for 3 phase. Thus Nspp = 1

The Distribution Factor (Kd ):

It is important to note that the peak back emf is equal for Nspp = 1 and for Nspp = 2 because the peak values of the individual back emfs overlap. In reality, some reduction in peak back emf usually occurs because the peak values of the individual back emfs do not coincide as they do in Fig. 1.6. Clearly, the amount of reduction is highly dependent on the shape of the back emf distribution. When the back emf is a pure sinusoid, the decrease in back emf is given by the distribution factor Kd . So for Nspp = 1 the Kd = 1.

Figure 2.4: Slot Pole Overlap

Figure 2.5: Overlap of two back emfs

The Pitch Factor (Kp ):

Pitch factor Kp is the ratio of coil pitch to pole pitch and in our cade the no. of slots per pole per phase is 1 so pole pitch is equal to coil pitch and so Kp = 1

The Skew Factor (Ks ):

The skew factor is the measurement of the skewing of the pole edges with respect to the edges of stator slots. In our design we are not considering the skewing of rotor poles so for our design Ks =1

Slot Loading (Is ):

Here motor armature has (Slot = Nspp * Poles * No. of phases = 1*3*16 = 48) slots as per the dimension. And for that each slot has loading within some limit. It should be less than 200 A/m for optimum design. If slot loading is very much lower than main dimensions are drastically changed. There are some limitation for selecting motor with very much higher aspect ratio (aspect ratio = Dout/L). If aspect ratio is very much higher than material used for the same rating is higher and also watt / kg ratio is decreases (it should be less than 250). Here in fig. 1.7 the variation of slot loading on main dimension is given. As slot loading decreases the outer diameter (Dout) increases and as Dout increases, core losses increase but efficiency of the motor increases which is advantageous, for the all designers. But if the change in dimension is more than 30%, the efficiency will increase only by 1% then it should not be an optimum design. So, here, on the bases of Dout and efficiency slot loading is finalized at 130

Is Vs Efficiency Vs Dout
93.4 93.2 93 Efficiency 92.8 92.6 92.4 92.2 92 91.8 0 25 50 75 100 125 150 175 200 225 Slot Loading 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 Efficiency Dout

Figure 2.6

Air Gap Flux Density (Bg ) :

Air gap flux density should be as high as possible, is needed for the desired torque production. For the permanent magnet motor flux is produced by the magnet. Length of the magnet highly affects flux density at air gap. Also higher length of magnet cause to increase overall cost of the motor and that is not permissible. Lower length of magnet cause to decreases mechanical strength of the magnet. Here in fig 1.8 variation of Bg v/s Dout given. If Bg varies between 0.45 to 0.85 then change in Dout is linear. Figure 1.8 shows variation of Bg v/s Lm (length of magnet) is given. If Bg is greater than 0.7 then change in length of magnet is much higher. And Bg < 0.75 will give lower Dout which is quite helpful to increase efficiency and W/kg ratio is also increases on the basis of that Bg=0.66 is finalized for this topology.

0.25 0.24 0.23

0.008 0.007 0.006

0.22 0.21 0.2 0.19 0.18 0.002 0.17 0.16 0.15 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.001 0 0.005 0.004 0.003 Dout Lm

Figure 2.7: Bg Vs Dout Vs Lm

By using Kr = Ro/Ri = 3

Output Power Supply Voltage Speed Angular Speed Air Gap Flux Density No. Of Magnet Poles No. of Coils Conducting Simultaneously Slot Loading No. of slots per pole per phase Pitch Factor Skew Factor Max. flux density in stator back iron Distribution Factor

Po V N Bg Nm Nc Ns Nspp Kp Ks Bmax Kd

250W 48 V 150 rpm 15.71 rad/sec 0.66 16 2 130 A 1 1 1 2.12 1

Table 2.1: Constants and Assumptions

By this data we can find Ro and Ri by using equation (ii). So,

2.2 Back Iron Width:

The flux entering the stator from a differential slice is

Figure 2.8: Differential slice of rotor pole

In the stator, this flux splits in half in the back iron to return through adjacent magnets. Therefore, if Bmax is the maximum allowable flux density in the back iron, the back iron flux is

from which the required back iron thickness is obtained by equating both equations as:

. (iii)

Pole pitch at inner and outer radii is given as respectively:

And

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The Stacking Factor (Kst):

Due to laminated core the laminations are separated from each other by insulating material so the effective length of the magnetic core is less than the actual value so Kst is require to compensate this decrease in length, Normally,

Kst = 0.9
By substituting values from table 1 into equation (iii) we get,

2.3 Tooth Bottom Width (Wtbi):

. (iv)

By putting value from table 1 in equation (iv) we get

2.4 Slot Bottom Width (Wsb):

si= Distance between two consecutive slots or inner slot pitch

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2.5 Area of slot (As):

Kcp = Conductor packing factor = .40 Jmax = Maximum current density = 107 A/m2 By this we can conclude area of slot

m2 2.6 Slot Bottom Width (Wsb):

= Distance between two consecutive slots or inner slot pitch m

2.7 Conductor Slot Depth:

By putting value in equation we get conductor slot depth

M

2.8 Calculation of shoe depth:

sd = Shoe depth fraction sd is confined between 0.25 to 0.5 [6] So, 0.0015 m

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2.9 Calculation of total slot depth: Total slot depth

ds= d1+d2+d3 0.0176 m

2.10 Calculation of slot opening (Ws):

The slot opening is 1.8 times larger than the air gap length [6] As we know air gap length =.5mm
M

And

Wt =

0.0132 m

2.11: Air gap area:

m = Magnet Fraction

2.12: Length of magnet:

Bcr = Flux density of disc core (Ranging between 1.6 to 1.8 T ) By this 0.0021 m

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CHAPTER 3 RESULT TABULATION BY CALCULATION:

Output Power Supply Voltage Speed Angular Speed Air Gap Flux Density No. Of Magnet Poles No. of Coils Conducting Simultaneously Slot Loading No. of slots per pole per phase Pitch Factor Skew Factor Max. flux density in stator back iron Distribution Factor Stator inner radius Stator outer radius Stacking factor Back iron width Tooth bottom width Slot bottom width Area of slot

Po V N W Bg Nm Nc Is Nspp Kp Ks Bmax Kd RI Ro Kst Wbi Wtbi Wsb As

250W 48 V 150 rpm 15.71 rad/sec 0.66 16 2 130 A 1 1 1 2.12 1 .0767 .1328 .9 .018 .007 .0031 3.25*10-5

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CHAPTER 4 ANALYSIS OF DESIGN

4.1 Magnetic Circuit Analysis

The effective magnet Permeance

is : = +4 =KMLPM

Where the magnet leakage factor kml is:

The air gap permeance must be approximated since the magnet flux crossing the air gap travels through an increasing cross-sectional area. Using the average of the areas, the air gap permeance is:

where ge = kcg is the effective air gap length in there kc =carter coefficient Ag is air gap cross-section area:

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So by this

So

and that the permeance coefficient is

since there are two air gaps in series

By this

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4.2 Performance Analysis

1) Resistance As stated earlier, the windings on the two stators are assumed to be connected in series. Therefore, factor of 2 are required since Nm, Nsm, Nspp and Ntpp are defined per stator. The slot resistance per slot is given by

Resistance of end turn

So total resistance per phase R= (NS/NPH) (RS+RE) 2) Copper Loss

By this Pr=16.7595 3) Core Loss:

(
So

)
vst = 6.0774e-004 Pcl= 5.3466

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4) Stray Loss: Stray loss is 20% of core losses PS= 1.0693

5) Efficiency:

So efficiency = 0.9152

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CHAPTER 5 RESULT TABULATION BY MATLAB

Output Power Supply Voltage Speed Angular Speed Air Gap Flux Density No. Of Magnet Poles No. of Coils Conducting Simultaneously Slot Loading No. of slots per pole per phase Pitch Factor Skew Factor Max. flux density in stator back iron Distribution Factor Stator inner radius Stator outer radius Stacking factor Back iron width Tooth bottom width Slot bottom width Area of slot Slot Bottom Width Depth Of Slot Depth Of Shoe Stator Axial Length

Po V N W Bg Nm Nc Is Nspp Kp Ks Bmax Kd RI Ro Kst Wbi Wtbi Wsb As Wsb D3 Ds L

250W 48 V 150 rpm 15.71 rad/sec 0.6623 16 2 130 A 1 1 1 2.12 1 0.0761 0.1319 0.9 0.0179 0.0069 0.0126 1.75*10-5 0.0031 0.0014 0.0034 0.0206

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CHAPTER 6 COMPARISION WITH STANDARD IEEE TRANSACTION PAPER

REFERENCE:

FE Analysis and Computer-Aided Design of a Sandwiched Axial-Flux Permanent Magnet Brushless DC Motor Parameter
Voltage Speed Power No. Of Stator Slots No. Of Magnets Outer Diameter Inner Diameter Inductance Per Phase

Our Design
230 V 1450 rpm 2200 W 24 16 226.8 mm 130.1 mm 7.3 mH

Reference Design
230 V 1450 rpm 2200 W 24 16 224 mm 129 mm 10.76 mH

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CONCLUSION AND FUTURE SCOPE

The project has been concluded with successful development of design equations and algorithm for developing an Axial Flux PMBLDC machine. Also the CAD program for calculation and optimization of design parameters has been made to simplify and speed the process of design. The future scope of the project is the design of motor on FE analysis software like MAGNET and conforming the design parameters and physical realization of the motor.

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REFERENCES:
[1] J.R. Hendershot Jr. and T.J.E Miller: Design of brushless permanent magnet motor, Clarendon Press, Oxford, 1994
[2] T.J.E. Miller: Brushless Permanent Magnet and Reluctance Motor Drives, Oxford University Press ,1989 [3] D. C. Hanselman, Brushless Permanent Magnet-Motor Design. New York: McGrawHill, 1994. [4] P. R. Upadhyay and K. R. Rajagopal.; A Novel Integral-Force Technique for the Analysis of an Axial-Field Permanent-Magnet Brushless DC Motor Using FE Method, IEEE Trans. on Magnetics, vol. 41, 2005, pp. 3958-3961. [5] Jacek F. Gieras, Rong-Jie Wang, Maarten J. Kamper: Axial flux permanent magnet brushless machines, Kluwer Academic Publications,2004. [6] Caricchi F.; Crescimbini F.; Honorati O.; Santini E.: Performance evaluation of an axial flux PM generator, Proc. Of ICEM 92, 1992, pp. 761-765. [7] Yee-Pien Yang, Yih-Ping Luh, and Cheng-Huei Cheung: Design and Control of AxialFlux Brushless DC Wheel Motors for Electric Vehicles Part I: Multi objective Optimal Design and Analysis

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