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I. INTRODUCTION
In the recent years the Axial Flux Motors (AFMs) have been
object of numerous research studies. Different motor
structures and geometries have been proposed, for different
applications, as an alternative to the conventional Radial Flux
Motors (RFMs).
Beside the technological and manufacturing differences, it
seems interesting to compare AFMs and RFMs to understand
when and where the AFMs show potential advantages.
A general comparison of AFMs versus RFMs is not possible,
due to the large number of possible technical solutions; thus
the comparison is focused on two specific types of surface
mounted PM synchronous motors:
the axial flux motors with two external stators and one
internal rotor.
1611
L
Lcore
De
Dfc
Di
Dr
Dri
Da
Lm
g
wm
m
TABLE II
MAIN AFM DIMENSIONS
Axial motor length, [m]
Outer motor diameter, [m]
Inner end winding connection diameter, [m]
Inner stator core diameter, [m]
Outer stator core diameter, [m]
Shaft diameter, [m]
Slot axial length, [m]
Stator yoke axial length, [m]
Stator axial length, [m]
Half magnet axial length, [m]
Airgap radial thickness, [m]
Polar pitch occupation of the magnets, constant
with the radius, [p.u.]
L
De
Di
D1
D2
Da
Ls
Ly
Lc
Lm
g
m
Forewords
The comparison between electric motors, is often performed
using the sizing equations, that link the motor
electromagnetic torque to the active motor length and to the
motor reference diameter. For the RFMs, the most frequently
encountered sizing equation is in the form:
Te = r D 2r L
(1)
1612
(2)
TABLE III
COMPARISON CONSTRAINS
SW = De L + e
2
(3)
This takes into account the flanks and the framework lateral
surface as thermal dissipation ways. The thermal gradients
into external motor surfaces have been neglected. This
approximation introduce a minor error when the axial length
is very short for the AFMs and when the outer stator diameter
is very small for the RFMs.
A Starting data and motor design
In order to calculate the dimensions of each motor part, the
related electric and magnetic load and the delivered
electromagnetic torque, a suitable computer program has
been realized. A list of the design input quantities and of their
related values, that are adopted in the present comparison, is
reported in Tables III and IV. The same values are used for
AFMs and RFMs. The airgap induction value is not directly
reported in Table III, but it can be calculated through the
Eq.11.
The selected speed value, equal to 1,000 rpm, is relativity low
because the authors want to focus their study on direct drives
applications (i.e. gearless wind energy system, in-wheel
motor for electric vehicles, etc.). Hence the parameters and
the selected coefficients choices are typical for low speed PM
motor applications.
1613
0.01
1000
2500
1.8
1.44
0.004
the half of
TABLE IV
CONSTANT VALUE PARAMETERS
Airgap length, [m]
PMs polar pitch occupation, [p.u.]
Permanent magnet remanence, [T]
Magnet recoil permeability, [p.u.]
Carters factor, [p.u.]
Lamination specific losses, [W/kg]
Lamination stacking factor, [p.u.]
Slot fill factor, [p.u.]
Iron specific weight, [kg/m3]
Copper specific weight, [kg/m3]
Magnet specific weight, [kg/m3]
Copper resistivity @ 20 C, [m]
0.001
0.75
1.1
1.05
1.05
2.3
0.93
0.4
7800
8900
7500
1.72 10-8
TABLE V
MOTOR DESING OUTPUT DATA
Motor active weight, [kg]
Wasting surface, [m2]
Height of slots, [m]
Length of end winding connection, [m]
Maw
Sw
hs
Leq
2 Di + h s
2
2p
(4)
stator sector, the iron losses are evaluated through the Eq.10.
Instead, for the stator yoke design, it has been assumed that
the flux density in the yoke is uniform in the radial direction.
The windings Joule losses are evaluated as the difference
between the total motor losses and the iron losses. The skin
effect is not considered here. This means that some errors
may appear in the Joule losses calculation if the stator slots
are relatively deep. To take into account the skin effect,
further hypothesis onto the windings should be necessary (i.e.
the slots number, the number and the size of the conductors
in the slot, etc.). This would involve a major complexity of
the comparison procedure not useful to the aims of this paper.
A
B2
D1
D2
De
D2 =
sin ( ) + cos( )
D1 =
(5)
Di
1
tan ( )
cos( )
(6)
outer
D 2 sen ( )
4
(7)
D
= 1 tan ( )
L eq
inner 2
2
(8)
B Losses calculation
The total allowable motor losses depend on the wasting
surface and on the losses/wasting surface ratio (KLosses)
adopted in the comparison constrain:
PTot = K Losses S W
(9)
f
PFe = C P Fe K st Vys B2ys + Vdt B2dt
50
(10)
1614
l m mr
4
= sen( m 90)
Br
l m m r + g'
B g1 =
(11)
A
3 k w1 2 N 1
I = k w1 Cu
D
D
(12)
Bg
-90
-60
-30
30
60
90
m p
p
Bg1
dF(,t)
B()
Kz(,t)
asse
160
120
=
asse
80
40
0
1.84
1.64
KZ(R,,t)
1.44
1.24
d2F(R,)
1.04
B(-)
= L / De
dR
R
0.70
0.44
0.50
D = Di / De
0.24
Te = 2 R 2 L Bg1 K S1
0.04
(13)
2
Te =
k w1 A Cu D 22 D12 B g1
8
0.10
1.00
0.75
0.50
0.25
0.00
1.84
1.64
1.44
1.24
1.04
(14)
= L / De
0.84
0.90
0.64
0.70
0.44
0.30
TSpecific =
0.90
0.64
0.84
(15)
IV. RESULTS ANALYSIS
1615
0.50
D = Di / De
0.24
0.30
0.04
0.10
160
8 poles
140
Electromagnetic torque [Nm]
12 poles
120
4 poles
100
80
16 poles
60
40
20 poles
20
= L / De
0
0.0
0.5
1.0
1.5
2.0
This means that the slots currents decrease and thus the
electromagnetic torque. This effect results more evident with
high pole numbers.
For very low values of the ratio, there are solution with
minimum iron (Fig.8). This fact brings to very small Di
diameters and yokes, the stator slots are deep and tooth are
very thin. These design solutions are thermally and
magnetically feasible with the adopted constrains, but they
are not practically realizable. It is important to remember that
is the ratio between the motor overall axial length and the
motor external diameter and it is very different by the
classical stator core length/rotor diameter ratio.
In general, it is possible to find out a better design dedicated
for each modifying some of the starting data, such as, for
example, the flux density in the stator core; but, as a
consequence, the proposed comparison approach would loss
its generality.
On the basis of the simulations results, the authors opinion is
that the RFMs designs are effectively realizable when 0.5
for motors with few poles and when 0.75 for motor with
several poles. For this reason, the curves in Fig.9 and in
Fig.10 are dashed for 0.5.
For each values of the ratio and for each different pole
number, the design solution that provides the maximum
torque is determined and the results, in absolute value, are
summarized in Fig. 9.
Fig.10 shows the RFMs torque density versus the ratio.
These curves have been obtained dividing the maximum
torque design solutions, shown in Fig.9, for their
correspondent active weights. The motor active weight
includes the stator and the rotor iron, the copper and the
permanent magnets weight. The torque density values result
in the range of 1.64 Nm/kg, according to the motor poles
number.
For each motor polarity, the outer stator diameter/inner stator
diameter (Di/De) ratio assumes different values according to
the motor axial length (Table VI).
16 poles
12 poles
4
3
8 poles
20 poles
1
4 poles
= L / De
0
0.0
0.5
1.0
1.5
2.0
200
150
100
50
0
1.84
1.64
1.44
TABLE VI
1.24
1.04
= L / De
Di/De
=1
0.42
0.55
0.67
0.82
0.90
=2
0.52
0.55
0.70
0.85
0.90
0.84
0.90
0.64
0.70
0.44
0.50
D = Di / De
0.24
0.30
0.04
0.10
1616
160
8 poles
1617
120
16 poles
20 poles
100
80
60
4 poles
40
20
= L / De
0
0.0
0.3
0.5
0.8
1.0
140
5.0
12 poles
8 poles
4.0
3.0
4 poles
2.0
1.0
= L / De
0.0
0.0
0.2
0.4
0.6
0.8
1.0
D = Di/De
0.15
0.22
0.30
0.47
0.60
D1/D2
0.51
0.44
0.48
0.68
0.80
VI. CONCLUSIONS
In this paper a method is provided to compare the two rather
different PM synchronous motors structures: the two-stators
one-rotor AFMs and the conventional RFMs.
The proposed procedure is based on simple thermal
considerations. The two motors structures are compared in
terms of provided electromagnetic torque and torque density,
when the overall motor volume, the losses per wasting
surface and the airgap flux density are kept constant. The
poles number influence and the ends windings encumbrances
are take into account.
The results are shown as function of the two main
dimensional ratios: (axial motor length/external motor
diameter) and D (internal motor diameter/ external motor
diameter).
The aim of the paper is to put in evidence when to use the
AFMs instead of RFMs. Low-speed, direct-drive motors (i.e.
gearless wind energy system, in-wheel motor for electric
vehicles, etc) are the reference applications. For high speed
motors, it could be necessary to choose a coefficient sets
different by those shown in Table III and Table IV (i.e. to
decrease the airgap flux density and to use a better lamination
material).
1618
[3]
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[5]
[6]
[7]