Winding Losses in Coreless Axial Flux PM Machines with Wave and Spiral PCB Stator Topologies

Yaser Chulaee; Donovin Lewis; Greg Heins; Dean Patterson; Dan M. Ionel

doi:10.1109/ECCE50734.2022.9947897

Winding Losses in Coreless Axial Flux PM Machines with Wave and Spiral PCB Stator Topologies

Yaser Chulaee, Donovin Lewis, Greg Heins, Dean Patterson, Dan M. Ionel

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

11 Scopus citations

Abstract

Printed circuit board (PCB) stators in coreless axial flux permanent magnet (AFPM) machines have been proposed, designed and studied for utilization in multiple industries due to their design flexibility and reduction of manufacturing costs, volume, and weight compared to conventional stators. This paper investigated loss mechanisms and multiple methods of approximating winding supplementary losses in PCB stators with example wave and spiral winding topologies for a dual rotor, single stator configuration using 3D FEA models with a 15 hour runtime. The effect of rotor magnet placement, end windings, and active conductor path on eddy current is studied for both topologies. A hybrid FEA/analytical approach is proposed for the approximation of circulating current within layers of a planar PCB conductor using the equivalent circuit model. A coreless AFPM motor prototype is created and its power losses tested using multiple PCB stators with the findings being comparable to hybrid analytical methods results.

Original language	English
Title of host publication	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022
ISBN (Electronic)	9781728193878
DOIs	https://doi.org/10.1109/ECCE50734.2022.9947897
State	Published - 2022
Event	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022 - Detroit, United States Duration: Oct 9 2022 → Oct 13 2022

Publication series

Name	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022

Conference

Conference	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022
Country/Territory	United States
City	Detroit
Period	10/9/22 → 10/13/22

Bibliographical note

Publisher Copyright:
© 2022 IEEE.

Funding

This paper is based upon work supported by the National Science Foundation (NSF) under Award No. #1809876. Any opinions, findings, and conclusions, or recommendations expressed in this material are those of the authors and do not necessarily reflect the views of the NSF. The support of University of Kentucky, the L. Stanley Pigman Endowment, ANSYS Inc., and Regal Rexnord Corp. is also gratefully acknowledged.

Funders	Funder number
Regal Rexnord Corp.
U.S. Department of Energy Chinese Academy of Sciences Guangzhou Municipal Science and Technology Project Oak Ridge National Laboratory Extreme Science and Engineering Discovery Environment National Science Foundation National Energy Research Scientific Computing Center National Natural Science Foundation of China	1809876
U.S. Department of Energy Chinese Academy of Sciences Guangzhou Municipal Science and Technology Project Oak Ridge National Laboratory Extreme Science and Engineering Discovery Environment National Science Foundation National Energy Research Scientific Computing Center National Natural Science Foundation of China
University of Kentucky
ANSYS

Keywords

Axial-flux
FEA
PCB stator
circulating current
coreless machines
eddy current
permanent-magnet machines
winding losses

ASJC Scopus subject areas

Electrical and Electronic Engineering
Mechanical Engineering
Safety, Risk, Reliability and Quality
Energy Engineering and Power Technology
Renewable Energy, Sustainability and the Environment
Control and Optimization

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1109/ECCE50734.2022.9947897

Cite this

@inproceedings{47fc3212ca4e4ef48b830095684dd29d,

title = "Winding Losses in Coreless Axial Flux PM Machines with Wave and Spiral PCB Stator Topologies",

abstract = "Printed circuit board (PCB) stators in coreless axial flux permanent magnet (AFPM) machines have been proposed, designed and studied for utilization in multiple industries due to their design flexibility and reduction of manufacturing costs, volume, and weight compared to conventional stators. This paper investigated loss mechanisms and multiple methods of approximating winding supplementary losses in PCB stators with example wave and spiral winding topologies for a dual rotor, single stator configuration using 3D FEA models with a 15 hour runtime. The effect of rotor magnet placement, end windings, and active conductor path on eddy current is studied for both topologies. A hybrid FEA/analytical approach is proposed for the approximation of circulating current within layers of a planar PCB conductor using the equivalent circuit model. A coreless AFPM motor prototype is created and its power losses tested using multiple PCB stators with the findings being comparable to hybrid analytical methods results.",

keywords = "Axial-flux, FEA, PCB stator, circulating current, coreless machines, eddy current, permanent-magnet machines, winding losses",

author = "Yaser Chulaee and Donovin Lewis and Greg Heins and Dean Patterson and Ionel, \{Dan M.\}",

note = "Publisher Copyright: {\textcopyright} 2022 IEEE.; 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022 ; Conference date: 09-10-2022 Through 13-10-2022",

year = "2022",

doi = "10.1109/ECCE50734.2022.9947897",

language = "English",

series = "2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022",

booktitle = "2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022",

}

Chulaee, Y, Lewis, D, Heins, G, Patterson, D & Ionel, DM 2022, Winding Losses in Coreless Axial Flux PM Machines with Wave and Spiral PCB Stator Topologies. in 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022. 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022, 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022, Detroit, United States, 10/9/22. https://doi.org/10.1109/ECCE50734.2022.9947897

Winding Losses in Coreless Axial Flux PM Machines with Wave and Spiral PCB Stator Topologies. / Chulaee, Yaser; Lewis, Donovin; Heins, Greg et al.
2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022. 2022. (2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Chulaee, Yaser

AU - Lewis, Donovin

AU - Heins, Greg

AU - Patterson, Dean

AU - Ionel, Dan M.

PY - 2022

Y1 - 2022

N2 - Printed circuit board (PCB) stators in coreless axial flux permanent magnet (AFPM) machines have been proposed, designed and studied for utilization in multiple industries due to their design flexibility and reduction of manufacturing costs, volume, and weight compared to conventional stators. This paper investigated loss mechanisms and multiple methods of approximating winding supplementary losses in PCB stators with example wave and spiral winding topologies for a dual rotor, single stator configuration using 3D FEA models with a 15 hour runtime. The effect of rotor magnet placement, end windings, and active conductor path on eddy current is studied for both topologies. A hybrid FEA/analytical approach is proposed for the approximation of circulating current within layers of a planar PCB conductor using the equivalent circuit model. A coreless AFPM motor prototype is created and its power losses tested using multiple PCB stators with the findings being comparable to hybrid analytical methods results.

AB - Printed circuit board (PCB) stators in coreless axial flux permanent magnet (AFPM) machines have been proposed, designed and studied for utilization in multiple industries due to their design flexibility and reduction of manufacturing costs, volume, and weight compared to conventional stators. This paper investigated loss mechanisms and multiple methods of approximating winding supplementary losses in PCB stators with example wave and spiral winding topologies for a dual rotor, single stator configuration using 3D FEA models with a 15 hour runtime. The effect of rotor magnet placement, end windings, and active conductor path on eddy current is studied for both topologies. A hybrid FEA/analytical approach is proposed for the approximation of circulating current within layers of a planar PCB conductor using the equivalent circuit model. A coreless AFPM motor prototype is created and its power losses tested using multiple PCB stators with the findings being comparable to hybrid analytical methods results.

KW - Axial-flux

KW - FEA

KW - PCB stator

KW - circulating current

KW - coreless machines

KW - eddy current

KW - permanent-magnet machines

KW - winding losses

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Y2 - 9 October 2022 through 13 October 2022

ER -

Winding Losses in Coreless Axial Flux PM Machines with Wave and Spiral PCB Stator Topologies

Abstract

Publication series

Conference

Bibliographical note

Funding

Keywords

ASJC Scopus subject areas

UN SDGs

Access to Document

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