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This thesis presents a systematic scheme to determine the optimal propulsive/axial force ratio of a single-sided permanent magnet axial-flux motor (SPMAM) along with its operational constraints on both the winding currents and the speed induced voltages. According to the rotating magnetic field theory with combining the recoil line characteristics of permanent magnet and the equivalent operational magnetic circuits, appropriate projection of the stator currents to achieve an optimal ratio of the machine propulsive/axial forces has been confirmed through detailed three-dimensional finite element analysis (3-D FEA) and numerical studies. From these evaluations, a feasible operational guidance for SPMAM field oriented control (FOC) scheme realizations can be suitably provided. Finally, based on the proposed optimal scheme, a DSP-based drive system has been successfully implemented, and the desired operational strategy realization can be achieved.

In an increasingly urgent climate crisis, the use of electric powertrains in smaller, purpose-built vehicles can expedite the global adoption of electrification. This thesis discusses the detailed design of an axial-flux switched reluctance motor for application in a light electric vehicle, such as an E-motorcycle. A vehicle application is studied based on typical driving conditions in an urban environment. The requirements of the propulsion motor are extracted, and a baseline machine topology is analyzed for its performance and manufacturability, towards the goal of a functional prototype. The prototype design includes a self-supporting foil winding, designed to maximize the use of axial space and allow for good conductive heat transfer to the machine casing. The rotor structure is found to be a limiting factor, where maximum speed is limited by the mechanical stresses. The performance of the motor is analyzed in detail, beginning with a numerical iron loss model that is implemented to provide faster simulation time of the machine efficiency than FEA. The efficiency is found to peak at 90%, comparable with other traction motors of similar size on the market. The switching angles are studied, and the trade-offs between torque quality and efficiency are quantified over the drive cycle. It was determined that the vehicle could save 19.6 Wh/km by accepting poor torque quality and operating with the most efficient control parameters. Thermal analysis is performed to determine the realistic performance limitations. The machine was found to have power ratings of 7.12 kW instantaneous and 4.76 kW continuous. The final temperature of the winding during the drive cycle was predicted not to exceed the temperature ratings of the insulation system. Finally, the prototype is assembled, and a test plan is outlined for qualification of the motor. / Thesis / Master of Applied Science (MASc) / This thesis documents the design of a new type of electric motor that is intended to be used in a small electric vehicle. The electric motor is different from the majority of motors used in this application for two reasons: firstly, the motor is a switched reluctance motor, which means that it does not contain any permanent magnets, offering cost savings and additional robustness. Secondly, the machine takes the form of a disk, where the magnetic interface between rotating and stationary components is on the face perpendicular to the axis of rotation. Normally, electric motors have the magnetic interface on the cylindrical surface which is parallel to the axis of rotation. The disk form factor presents multiple design challenges, which when coupled with the switched reluctance motor type, are addressed. A series of mathematical models are built to predict the performance of the motor in the vehicular application. Finally, a prototype of the motor is constructed.

This work is an investigation into the curvature related potential for flux to flow in the radial direction in the back-iron of laminated axial flux machine cores. Analytical and numerical models are presented. Analysis based on these models has shown that, in practical axial flux machines, the radial component of the flux density can be neglected with respect to the flux density distribution in the core back-iron. It has also been found that if the core permeability, core conductivity and number of poles are sufficiently high then power loss due to curvature related cross-lamination flux is negligible compared to normal eddy current losses. A closed form expression to predict losses due to curvature related radial flux is also presented. This expression allows axial flux machine designers to make quick assessment of the need to consider these losses when designing axial flux machines.

Thesis (MScEng)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: This thesis is a description of how the first magnetically geared axial flux permanent magnet generator (MGAFG) is designed, constructed and experimentally evaluated. Magnetic gears (MGs) allow for contact-less power transfer and lubricant free operation, which may solve the reliability concerns with current mechanically geared wind energy converters. However, the complex structure of MGs may present serious challenges to its design. Thus, special care should be given to the mechanical layout and the electromagnetic influence of every component. The MGAFG can be configured to be magnetically coupled or decoupled. In the coupled configuration the permanent magnets (PMs) of the MG contribute to the total flux linkage in the PM generator (PMG). The coupled configuration is therefore more efficient. The processing time required to optimise the decoupled configuration is however much faster, since the MG and the PMG can be optimised separately. The optimised results show that a torque density in excess of 100kNm/m3 could be achieved, which is significantly higher than any of known electrical machines. However, owing to excessive losses in the mechanical support structures, the prototype exhibited lower torque density and poor efficiency. The design related aspects and issues are analysed and discussed in detail in an attempt to outline problem areas in the design process. Relevant recommendations are also given for future design improvements. The costs of magnetic material accounts for over fifty percent of the total cost of the prototype. Therefore to make the manufacturing of the MGAFG more economically viable magnetic material should be minimised in the design process. / AFRIKAANSE OPSOMMING: In hierdie tesis word die eerste magnetiese geratte aksiale vloed permanente magneet generator (MGAVG) ontwerp, vervaardig en eksperimenteel geëvalueer. In magnetiese ratte (MR) is daar geen kontak tussen werkende dele nie, daarom word geen smeermiddels benodig nie. Dit dra by tot die betroubaarheid van die ratkaste in wind energie generators en kan onderhoud grotendeels uitskakel. Die komplekse struktuur van magnetiese ratte kan egter die betroubaarheid van die ontwerp juis verswak. Daarom moet die meganiese uitleg noukeurig beplan word sodat dit nie die elektromagnetiese werking ondermyn nie. Die magnetiese rat (MR) en die permanente magneet generator (PMG) van die masjien kan magneties of sonder magnetiese koppeling verbind word. In die gekoppelde konfigurasie dra all die permanente magnete van die MR gesamentlik by tot die totale vloed-koppeling in die PMG. Wat die magnetiese gekoppelde konfigurasie meer doeltrefend maak. Minder tyd word benodig om die nie magnetiese gekoppelde konfigurasie te optimaliseer omdat die MR en die PMG apart geoptimaliseer kan word. Die optimale resultate toon dat ’n wringkrag van meer as 100kNm/3 bereik kan word, wat aansienlik beter is as die van bekende elektriese masjiene. Maar as gevolg van oormatige verliese in die meganiese strukture, toon die prototipe lae wringkrag digtheid en swak doeltreffendheid. Die ontwerp probleme word ontleed en bespreek in ’n poging om probleem areas in die ontwerp te identifiseer. Relevante aanbevelings word gegee vir toekomstige ontwerp verbeterings. Die koste van die magnetiese material verteenwoordig meer as vyftig persent van die vervaardigings koste van die prototipe. Koste kan bespaar word op die vervaardiging van die MGAVG deur die hoeveelheid magnete wat gebruik word te beperk.

This thesis aims to design a motor with axial magnetic flux, which could be used as a direct propeller of heart replacement pump. It is divided into several parts, first of which deals with describing possible axial motors construction design. Next follows up the description of possible motor designs, from which the non-ferrous one was chosen. After that, an analytic calculation of motor’s properties is conducted. Calculated parameters are thereafter verified by software tools using finite element method. Finally, the whole motor was manufactured and had its parameters tested and verified.

In reference to IEEE copyrighted material which is used with permission in this thesis, the IEEE does not endorse any of McMaster University's products or services. Internal or personal use of this material is permitted. If interested in reprinting/republishing IEEE copyrighted material for advertising or promotional purposes or for creating new collective works for resale or redistribution, please go to http://www.ieee.org/publications_standards/publications/rights/rights_link.html to learn how to obtain a License from RightsLink. / The need for reductions in global greenhouse gas emissions, coupled with rising fuel prices, has motivated intense research in the area of hybrid and fully electric crafts for commercial applications in the aviation sector. This thesis explores implementation of Halbach arrays in high-speed radial flux machines (RFMs) and low-speed axial flux machines (AFMs) for aerospace applications. Highly accurate analytical equations are developed for quickly predicting the magnetic field in the latter (both for coreless and steel core stators) due to the complex three dimensional axial flux paths which make traditional finite element analysis time-consuming. Electromagnetic design and optimization of two aerospace machines that use Halbachs are detailed. The first is a ~14 kW AFM intended to replace an existing high lift motor RFM concept in NASA’s Maxwell X57 all-electric plane. Two design variants are selected which achieve a 10 % increase in torque/power and a 10 % decrease in mass/volume, respectively. The second machine is a 20,000 RPM surface permanent magnet RFM capable of 150 kW peak power output that is intended as a proof-of-concept for the later development of a megawatt machine for a hybrid and/or all-electric aircraft. / Thesis / Master of Applied Science (MASc)

The objective of this thesis is to determine the feasibility of a novel axial flux variable reluctance machine design. The design aims to compete with prevalent rare-earth permanent magnet machines while also implementing an innovative torque ripple minimization strategy. Given the fundamental operating principles, a selection of dimensions, materials, and excitations are prepared for the machine. Special attention is given to the rotor profile which is crucial to operation. Finite element analysis software is used to evaluate a three-dimensional model in terms of inductance and torque. The ultimate potential of the machine is discussed and recommendations for improvement are proposed.

The growing demand of electrified light duty trucks, including sports utility vehicles (SUV) require high performance motors to surpass form their internal combustion engine counterparts. The Axial Flux Permanent Magnet (AFPM) Motor is expected to be one of the leading technologies to meet the demands of these industries due to its efficenct and high torque and power density. Designing a robust thermal management system for this motor is key to utilizing these performance benefits. To meet these demanding conditions, additive manufacturing is expected to play a critical role in enhancing performance. Additively manufactured hollow coil is a cooling strategy to extract heat directly from the hottest part of the motor, the stator. The following research assesses the viability of the design in a prototype motor. ANSYS CFX is used to characterize the pressure drop and flowrate, and a test setup is used to validate the results. The challenges associated with integrating the solution into a motor is highlighted as well as design issues during design development. Finally, the integration of a parallel hybrid SUV using an AFPM motor is documented and the challenges with integration into a vehicle is explained. / Thesis / Master in Advanced Studies (MAS)

A Thesis Submitted to the School of Graduate Studies in Partial Fulfillment of the Requirements for the Degree of Master of Applied Science in Mechanical Engineering / In the wake of the rising global demand for more electric transportation, aerospace electrification is becoming a highly active research area as commercial fully electric aircrafts are becoming a reality. The transportation electrification industry is challenged to develop powerful, safe, and compact-sized machines that can replace fossil fuel powered engines in aircrafts. Axial Flux Permanent Magnets (AFPM) machines are currently being intensively developed as a great candidate for this purpose due to their inherently higher power density compared to other machine electric machines topologies. The efforts of further increasing AFPM machines power density add more thermal challenges as intensive cooling is required at a relatively small machine package to avoid machine failure. One of the most concerning failure modes in these machines is power output reduction due to overheating of the rotor-mounted permanent magnets or even complete failure due to irreversible demagnetization. This research discusses the design process of an integrated rotor air cooling system for a 100 kW AFPM machine designed for an electric aircraft propulsion system. The embedded cooling system allows the rotor to be self-cooled at a sufficient cooling rate while minimizing the impact on machine efficiency due to windage power losses. The presented design process includes several stages of cooling enhancement including the addition and fine-tuning of rotor fan blades and rotor vents design. These enhancements are done by studying the air flow over the rotor surfaces in conjunction with heat transfer through Conjugate Heat Transfer (CHT) Computational Fluid Dynamics (CFD) analyses. In an initial study, different rotors with different combinations of rotor cooling features are studied and their thermal performance is compared. The results show that using rotor embedded fan blades in throughflow ventilated rotor geometry offers the best performance balance, achieving sufficient rotor cooling rate within a reasonable increase of windage power loss. A parametric study is performed to improve the rotor blade geometry for a higher ratio of heat transfer to windage losses. Another study is performed where the rotor and the enclosure geometries are fine-tuned simultaneously to reduce the negative effect on rotor heat transfer imposed by the enclosure. The final geometry of the rotor enclosure assembly is generated based on the research results and the design is integrated into the final machine prototype to be tested. / Thesis / Master of Applied Science (MASc) / Axial-flux permanent magnets (AFPM) machines are gaining the transportation electrification industy attention as a greener alternative to combustion engines in aircraft propulsion systems due to their high power and torque density. The intense endeavors of the current research to further improve AFPM machines power densities brings thermal design challenges to ensure the safe operation of the machine. Rotor permanent magnets failure due to demagnetization as a result of overheating can impose a great risk to the machine operation and safety. Accordingly, special attention should be paid to rotor thermal management. This research discusses the design process of an integrated rotor air cooling system for an AFPM machine designed for an electric aircraft. The machine mechanical and thermal design parameters are used to set an initial rotor design with different rotor cooling features based on literature findings. Rotor fan blades and air vents are selected as the main rotor cooling features for the design. Several design iterations are then made to fine-tune the rotor geometry targeting low operating temperature of the permanent magnets at a low cost of windage losses. The thermal performance of the different designs is assessed and compared to each other using conjugate heat transfer (CHT) computational fluid dynamics (CFD) analyses. Safe operating temperature of the magnets is achieved at an acceptable windage losses value with the final design, and it is selected for prototyping.