Design Optimization Considering a Detailed PCB Stator Layout for Coreless AFPM Machines with Minimal Eddy and Circulating Current Losses

Yaser Chulaee, Greg Heins, Ben Robinson, Mark Thiele, Dean Patterson, Dan M. Ionel

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

This paper proposes a multi-objective design optimization approach for printed circuit board (PCB) stator coreless axial flux permanent magnet (AFPM) machines based on a detailed PCB stator layout. The process begins with the machine envelope design optimization based on an evolutionary algorithm and 3D finite element analysis (FEA) models and continues with the detailed design of a PCB stator aimed at minimizing eddy and circulating current losses. This approach employs different open circuit loss mitigation techniques while taking into account PCB manufacturing limitations and standards. The process is explained through the design of an integral horsepower PCB stator coreless AFPM machine, which was prototyped and tested. The experimental results indicate negligible open circuit losses and 96% efficiency at the speed of 2,100rpm and an output torque of 19Nm, thereby validating the efficacy of the proposed approach.

Original languageEnglish
Title of host publication2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023
Pages3753-3758
Number of pages6
ISBN (Electronic)9798350316445
DOIs
StatePublished - 2023
Event2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023 - Nashville, United States
Duration: Oct 29 2023Nov 2 2023

Publication series

Name2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023

Conference

Conference2023 IEEE Energy Conversion Congress and Exposition, ECCE 2023
Country/TerritoryUnited States
CityNashville
Period10/29/2311/2/23

Bibliographical note

Publisher Copyright:
© 2023 IEEE.

Keywords

  • Axial-flux
  • FEA
  • PCB stator
  • circulating current
  • coreless machines
  • differential evolution
  • eddy current
  • optimization
  • permanent-magnet machines
  • winding losses

ASJC Scopus subject areas

  • Energy Engineering and Power Technology
  • Renewable Energy, Sustainability and the Environment
  • Electrical and Electronic Engineering

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