Search Results (17)

The effective part of the winding in a slotless motor varies across different axial sections of the motor, resulting in a three-dimensional structure. Therefore, it is not feasible to simply use the single-section simulation method of conventional radial field motors for motor simulation. Currently, the simulation of slotless motors primarily depends on three-dimensional electromagnetic fields, which present significant modeling challenges and require extensive simulation times, rendering them unsuitable for engineering applications. This paper introduces a method for analyzing slotless motors using a two-dimensional electromagnetic field, based on the electromagnetic field simulation software EasiMotor (R2025). The study elucidates the principle of employing a two-dimensional electromagnetic field to analyze slotless motors and applies this method to the design of a slotless motor with a diameter of 4.5 mm. Through the fabrication of prototypes and performance testing, experimental results validate the accuracy and efficiency of this method. Full article

In slotless machines, the winding conductors are exposed to the magnetic air gap field, which causes additional eddy current losses, thus decreasing efficiency and affecting thermal utilization. This is the case, inter alia, for axial flux motors equipped with printed circuit board windings, where the winding is made of copper–fiberglass epoxy laminations and located in the air gap. The dominant influencing factors are primarily the width of the conducting tracks and the magnetic air gap flux density and frequency. The evaluation time is a crucial constraint when calculating thousands of different designs for design space exploration or performing multi-objective optimizations. Finite element simulations can achieve very precise results, but unlike semi-analytical approximation functions, they are very time-consuming and therefore not the method of choice for design space exploration. This publication provides a comprehensive overview of a selection of different eddy current loss calculation techniques that are applicable for rectangular tracks and round wire windings. A comparison of the calculated results for a finite element simulation is presented for a slotless axial flux machine with printed circuit board windings and rectangular tracks. The calculation time consumed is also compared. The current density distribution of planar conductors of air gap windings differs from that in electrical steel sheets. In contrast to the methods based on steel sheets, only the adapted methods for conductors in air gaps offer acceptable accuracy. A recommendation is provided for the method that offers the best balance between accuracy and computation time for the early-stage design of slotless axial flux machines. Full article

A PCB stator axial flux permanent magnet (AFPM) motor is presented that overcomes the manufacturing challenges associated with the complex geometry of conventional stators by employing a PCB substrate. Traditionally, AFPM motors are produced by winding coils around the stator teeth, a process that requires specialized winding machinery and is both labor intensive and time consuming, ultimately incurring considerable manufacturing costs and delays. In contrast, PCB substrates offer significant advantages in manufacturability and mass production, effectively resolving these issues. Furthermore, the primary material used in PCB substrates, FR-4, exhibits a permeability similar to that of air, resulting in negligible electromagnetic cogging torque. Cogging torque arises from the attraction between permanent magnets and stator teeth, creating forces that interfere with motor rotation and generate unwanted vibration, noise, and potential mechanical collisions between the rotor and stator. In the PCB stator design, the conventional PCB circuit pattern is replaced by the motor’s coil configuration, and the absence of stator teeth eliminates these interference issues. Consequently, a slotless motor configuration with minimal vibration and noise is achieved. The PCB AFPM motor has been applied to a vehicle-mounted electric water pump (EWP), where mass production and space efficiency are critical. In an EWP, which integrates the impeller with the motor, it is essential that vibrations are minimized since excessive vibration could compromise impeller operation and, due to fluid resistance, require high power input. Moreover, the AFPM configuration facilitates higher torque generation compared to a conventional radial flux permanent magnet synchronous motor (RFPM). In a slotless AFPM motor, the absence of stator teeth prevents core flux saturation, thereby further enhancing torque performance. AC losses occur in the conductors as a result of the magnetic flux produced by the permanent magnets, and similar losses arise within the PCB circuits. Therefore, an optimized PCB circuit design is essential to reduce these losses. The Constant Trace Conductor (CTC) PCB circuit design process is proposed as a viable solution to mitigate AC losses. A 3D finite element analysis (3D FEA) model was developed, analyzed, fabricated, and validated to verify the proposed solution. Full article

Accurate calculation of the flux and the magnetic field distribution of fractional slot concentrated winding permanent magnet synchronous motor (FSCW PMSM) is the basis for motor performance analysis, and rapid calculation is key. In this paper, to solve the problem of difficult modeling and accuracy guarantee of the flux linkage differential method, a method is proposed to calculate the flux and the no-load back EMF by the slotless subdomain model. By introducing the leakage flux calculation link, the calculation accuracy is improved, the analytical method results are compared with the finite element method results, and the effectiveness of the proposed method is verified. On this basis, the nonlinear variations of the magnetic field and the no-load back EMF with rotor permeability are determined, and the influence mechanism of rotor length and rotor permeability on the main magnetic circuit is revealed. Finally, an experiment of the prototype is carried out, and the correctness and accuracy of the analytical method and the finite element method is verified by comparing with the experimental results. Full article

When magnetic saturation occurs during the operation of a permanent magnet (PM) slotless brushless DC motor, the material permeability will no longer be a constant value, and the neglected magnetic saturation model used for motor optimization will no longer be applicable. And considering that the increase in motor torque will lead to a high temperature rise of the winding, therefore, an electromagnetic heat coupling model applicable to the occurrence of magnetic saturation in the motor is established, and the model is utilized in combination with the particle swarm algorithm to enhance the maximum output torque of the motor. Firstly, a 100 W, 16,400 r/min high-speed PM slotless DC brushless motor is taken as the object of study, and its electromagnetic–thermal coupling model is established to derive the analytical equations for the electromagnetic torque with respect to the split ratio, the thickness of the stator yoke, the PM thickness, and the copper loss. Secondly, based on the modeling, the motor was optimized using a particle swarm algorithm to maximize the output torque and minimize the copper loss. Finally, a prototype was fabricated and verified with the prototype through no-load and load experiments. The difference between the theoretical maximum output torque and the experimental maximum output torque is less than 8%. The results show that this method can effectively predict the maximum output torque of the motor in the case of magnetic saturation, and the model is suitable for increasing the maximum output torque of slotless brushless DC motors under space constraints. Full article

In this paper, the design of novel slotless permanent magnet synchronous motor (PMSM) for a collaborative robot was studied considering the manufacture process of winding. The winding manufacture process of novel slotless PMSM was proposed in three steps. First, the two types of coil units were manufactured based on the winding jig to assemble the coil units. Second, the coil unit was manufactured using the injection molding based on the plastic material such as polyphenylene sulfide (PPS). Third, the units of the coil were assembled to form a stator winding. Considering this manufacture process of winding, the slotless motor design was studied for the collaborative robot. For the design and analysis of slotless motor, finite element analysis (FEA) was performed through ANSYS Maxwell. The electromagnetic performance was analyzed according to the pole-slot combination. Considering the space of the collaborative robot, the basic model was designed. Based on the basic model, the electromagnetic performance was analyzed according to the design parameters such as the thickness of magnet and yoke and turns per slot. Considering the torque and current density, the final model was designed. To verify the FEA results, the slotless motor was manufactured and the experiment and FEA results were compared. Full article

A slotless self-bearing motor (SSBM) is a new type of electric motor, with its levitating and rotating capability as a drive system. In the design of motor, the iron core of stator was removed, it could have many advantages such as small size, light, no friction loss, low losses, high speed. Besides, disturbance and uncertainty factors are the unexpected values, which impacting strongly to the output of the control system. In this paper, to reject the effects of these factors, an optimal Lyapunov-based (OLB) sliding mode control (SMC) was proposed to control the movements and rotation of SSBM system. First, the mathematical model with uncertainty and disturbance factors of the SSBM system was rewritten to show the detail configuration of the proposed motor. Second, the OLB-SMC controllers were designed for the control of displacements on $x$-, y-axes, rotor speed on $\omega$-axes, respectively. Third, the stability analysis of control algorithm was demonstrated via the Lyapunov stability theory. Finally, the experimental test was implemented to prove the high performance of the OLB-SMC for SSBM system. The practical results show that the effectiveness of OLB-SMC controller for SSBM system. The novelty of the proposed method is that the stability condition was newly proposed based on the transformation from scalar equation to state-space equation, where the gains of controller were found based on the linear matrix inequality. Full article

The slotless self-bearing motor (SSBM) is a motor with its self-bearing function. The mechanical structure of the motor is six symmetrical hexagonal shapes. The main control problem for this motor is disturbance and uncertainty rejection. Therefore, this paper proposes a new disturbance observer (DOB) based on an optimal fixed-time state observer (OFTSOB) and adaptive sliding mode control (SMC) for the motor. Firstly, the optimal state observer was used to construct to obtain the information of the states of the bearing-less motor system. Second, a new disturbance observer base on the fast speed reaching law is proposed for estimating the unknown dynamics and unpredicted uncertainty of the motor system. Third, the adaptive fast-reaching law-sliding mode control is designed to control the positions and rotational speed. Fourth, the proposed control system is proved via the Lyapunov theorem. Finally, the corrections of proposed method once again tested by using MATLAB simulation. The obtained results figured out that the proposed method is good at rejection disturbance and uncertainty and precision in control the movement and rotation. The novelties of the proposed method are that the gains of fixed-time observer were met by the support of optimal pole placement method, the disturbances were mostly rejected by a new reaching law of unknown input observer. Full article

In this paper, an axial slot-less permanent magnet synchronous motor (ASFPMSM) was designed to increase the power density. The iron core of the stator was replaced with block coils, and the stator back yoke was removed because 3D printing can provide a wide range of structures of the stator. The proposed model also significantly impacts efficiency because it can reduce iron loss. To meet size and performance requirements, coil thickness and number of winding layers in the block, the total amount of magnet, and pole/slot combinations were considered. The validity of the proposed model was proved via finite elements analysis (FEA). Full article

The slotless permanent magnet motor (SPMM) has low phase inductance due to the larger physical air gap, which will adversely affect motor control and current harmonics. In this paper, the method of forming an extra magnetic circuit by endcap around the outer stator is proposed. The advantage of this method is that a restrained flux path is formed without increasing the motor structure and cost, and the inductance of the motor is effectively improved without causing a significant decrease in torque. The preliminary simulation analysis and corresponding experimental content are carried out. The experimental results and the simulation content showed good consistency, which verified the correctness of the theory and simulation analysis. Full article

The end force of North-South permanent magnet linear synchronous motor (NS-PMLSM) fluctuates symmetrically with a period of one pole. Different from it, the end force’s fluctuation cycle of the consequent-pole permanent magnet linear synchronous motor (CP-PMLSM) is usually two poles and asymmetrical. Especially, within two half cycles, the end force presents complex asymmetric characteristics. In this paper, a piecewise function model of the end force of CP-PMLSM is established. Then a primary segmented design method for adjusting the period, symmetry and phase of the end force waveform is proposed. The two-segment and grouped four-segment modular distances are combined and matched to eliminate the odd-numbered harmonics of the end force and suppress the thrust ripple. A slotless primary core experimental platform and a slotted CP-PMLSM prototype are manufactured and tested to verify the theoretical analysis and simulation results. Full article

In this study we developed a brushless DC (BLDC) slotless motor with toroidal winding. The proposed toroidal winding is a method of winding a coil around a ring-type stator yoke in the circumferential direction. As there is no need for a slot or tooth structure, it can be designed with a slotless motor structure that is advantageous for vibration and noise. The basic principle of operation and motor characteristics of a slotless motor with toroidal winding were explained using an analytical method and finite element analysis (FEA). Further, the air gap flux density, winding factor, and back electromotive force (EMF) for changes in the winding angle and number of coil turns were calculated using the analytical method and compared with the FEA results. Finally, the resistance, back EMF, cogging torque, and performance of the prototype were measured and compared with the FEA results. The results show that the air gap flux density and winding factor were approximately the same with an error of <2%, while the back EMF had an error of ~10% from the analysis result. Thus, the proposed slotless motor provides a basic design for conveniently manufacturing brushless DC (BLDC) slotless motors with toroidal windings. Full article

The implications of the end effect for flux linkage and thrust ripple in a slot-less long-stator permanent magnet linear synchronous motor (LSPMLSM), are analyzed in this paper. Since it is affected by the end effect, the air-gap magnetic field density under the end permanent magnet is different from that under the non-end permanent magnet, leading to asymmetry in the thrust ripple. For this reason, we establish a dynamic permanent magnet flux linkage model, which proves that the end effect leads to sub-harmonics in the permanent magnet flux linkage. The motor’s magnetic field distribution in the left and right parts is symmetrical. A thrust model taking into account the flux linkage sub-harmonics is established, from which the amplitude and period of the thrust ripple caused by the end effect can be calculated. There is no detent force for the slot-less LSPMLSM, and the end effect is the primary origin of the motor thrust ripple. In order to suppress the end effect, a method of increasing the end iron length is proposed, as a result of which the sub-harmonics in the flux linkage and the motor thrust ripple are effectively suppressed. Experimental and simulation results verify the results of this paper. Full article

Small sized electric motors providing high specific torque and power are required for many mobile applications. Air gap windings technology allows to create innovative lightweight and high-power electric motors that show low phase inductances. Low inductance leads to a small motor time constant, which enables fast current and torque control, but requires a high switching frequency and short sampling time to keep current ripples and losses in an acceptable range. This paper proposes an optimal torque feedforward control method, minimizing either torque ripples or motor losses, combined with a very robust and computation-efficient modal current feedback control. Compared to well-known control methods based on the Clarke-Park Transformations, the proposed strategy reduces torque ripples and motor losses significantly and offers a very fast implementation on standard microcontrollers with high robustness, e.g., against measurement errors of rotor angle. To verify the accuracy of the proposed control method, an experimental setup was used including a wheel hub motor built with a slotless air gap winding of low inductance, a standard microcontroller and GaN (Gallium Nitride) Power Devices allowing for high PWM switching frequencies. The proposed control method was validated first by correlation of simulation and experimental results and second by comparison to conventional field-oriented control. Full article

Different from the design of conventional permanent magnet (PM) motors, high-speed motors are primarily limited by rotor unbalanced radial forces, rotor power losses, and rotor mechanical strength. This paper aimed to propose a suitable PM motor with consideration of these design issues. First, the rotor radial force is minimized based on the selection of stator tooth numbers and windings. By designing a stator with even slots, the rotor radial force can be canceled, leading to better rotor strength at high speed. Second, rotor power losses proportional to rotor frequency are increased as motor speed increases. A two-dimensional sensitivity analysis is used to improve these losses. In addition, the rotor sleeve loss can be minimized to less than 8.3% of the total losses using slotless windings. Third, the trapezoidal drive can cause more than a 33% magnet loss due to additional armature flux harmonics. This drive reflected loss is also mitigated with slotless windings. In this paper, six PM motors with different tooth numbers, stator cores, and winding layouts are compared. All the design methods are verified based on nonlinear finite element analysis (FEA). Full article