Axial flux motor

Last updated
A miniature DC brushless axial motor showing the integration with PCB construction techniques. The rotor shown to the right is magnetized axially with alternating polarity. HP StorageWorks DAT 72 USB - Tape Drive Capstans, brushless DC electric motor-92900.jpg
A miniature DC brushless axial motor showing the integration with PCB construction techniques. The rotor shown to the right is magnetized axially with alternating polarity.

An axial flux motor (axial gap motor, or pancake motor) is a geometry of electric motor construction where the gap between the rotor and stator, and therefore the direction of magnetic flux between the two, is aligned parallel with the axis of rotation, rather than radially as with the concentric cylindrical geometry of the more common radial flux motor. [1] [2] With axial flux geometry torque increases with the cube of the rotor diameter, whereas in a radial flux the increase is only quadratic. Axial flux motors have a larger magnetic surface and overall surface area (for cooling) than radial flux motors for a given volume. [3]

Contents

Characteristics

Design

AFMs can use single or dual rotors or single or dual stators. The dual stator/single rotor design is more common in high power applications, although it requires a yoke (housing) with accompanying iron losses. Single stator/dual rotor designs can dispense with the yoke, saving its weight and increasing efficiency. In the latter, the rotors and their iron plates that close the flux move in the same direction/speed as the magnetic field. [5]

In one example, grain-oriented (30Q120) steel was used to make the stator tooth for an induction motor. It used 18 teeth between the two rotors. Each stator tooth was wound with coils connected in series, 6 for each phase. The magnetic potential adds the air gap magnetic potential, stator tooth magnetic potential and rotor yoke and tooth magnetic potential. [6] [3]

AFMs can be stacked to provide higher power output in modular fashion. [3] YASA's 37kg stackable 750 R motor delivers >5kw/kg with an axial length of 98 mm (3.9 in). [7]

Uses

Although this geometry has been used since the first electromagnetic motors were developed, its usage was rare until the widespread availability of strong permanent magnets and the development of brushless DC motors, which could better exploit this geometry's advantages.

Axial geometry can be applied to almost any operating principle (e.g. brushed DC, induction, stepper, reluctance) that can be used in a radial motor. Even within the same electrical operating principle, different application and design considerations can make one geometry more suitable than the other. Axial geometries allow some magnetic topologies that would not be practical in a radial geometry. Axial motors are typically shorter and wider than an equivalent radial motor.

Axial motors have been commonly used for low-power applications, especially in tightly integrated electronics since the motor can be built directly upon a printed circuit board (PCB), and can use PCB traces as the stator windings. High-power, brushless axial motors are more recent, but are beginning to see usage in some electric vehicles. [8] One of the longest produced axial motors is the brushed DC Lynch motor, where the rotor is almost entirely composed of flat copper strips with small iron cores inserted, allowing power-dense operation.

Automotive

Mercedes-Benz subsidiary YASA (Yokeless and Segmented Armature) makes AFMs that have powered various concept (Jaguar C-X75), prototype, and racing vehicles. It was also used in the Koenigsegg Regera, the Ferrari SF90 Stradale and S96GTB, Lamborghini Revuelto hybrid and the Lola-Drayson. [9] The company is investigating the potential for placing motors inside wheels, given that AFM's low mass does not excessively increase a vehicle's unsprung mass. [10] YASA is targeting motors that deliver 220 kw in a 7 kg package (31 kW/kg. By contrast, the state of the art EV motor from Lucid Motors offers a 500 kW, 31.4-kg motor, or 16 kW/ kg. [11]

Aircraft

The Rolls-Royce ACCEL, holder of the current world speed record for an electric aircraft, uses three axial flux motors. [12]

Emrax makes a line of axial flux motors: the Emrax 228 (power density 4.58 kw/kg), Emrax 268 (5.02 kw/kg), and Emrax 348 (4.87 kw/kg). [13]

Siemens offers a 5kw/kg motor. [14]

Evolito makes AFMs for the 3-motor Rolls Royce Spirit of Aviation. Their target is aircraft motors that deliver 50 watts/kg, to allow for the substantial weight reductions needed to enable electric-powered flight. [11]

Related Research Articles

<span class="mw-page-title-main">Electromagnetic coil</span> Electrical component

An electromagnetic coil is an electrical conductor such as a wire in the shape of a coil. Electromagnetic coils are used in electrical engineering, in applications where electric currents interact with magnetic fields, in devices such as electric motors, generators, inductors, electromagnets, transformers, sensor coils such as in medical FMRi imaging devices with coils going upto 3-7 and even higher Tesla. Either an electric current is passed through the wire of the coil to generate a magnetic field, or conversely, an external time-varying magnetic field through the interior of the coil generates an EMF (voltage) in the conductor.

<span class="mw-page-title-main">Electric motor</span> Machine that converts electrical energy into mechanical energy

An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft. An electric generator is mechanically identical to an electric motor, but operates in reverse, converting mechanical energy into electrical energy.

<span class="mw-page-title-main">Stator</span> Stationary part of a system

The stator is the stationary part of a rotary system, found in electric generators, electric motors, sirens, mud motors, or biological rotors. Energy flows through a stator to or from the rotating component of the system, the rotor. In an electric motor, the stator provides a magnetic field that drives the rotating armature; in a generator, the stator converts the rotating magnetic field to electric current. In fluid powered devices, the stator guides the flow of fluid to or from the rotating part of the system.

<span class="mw-page-title-main">Rotating magnetic field</span> Resultant magnetic field

A rotating magnetic field is the resultant magnetic field produced by a system of coils symmetrically placed and supplied with polyphase currents. A rotating magnetic field can be produced by a poly-phase current or by a single phase current provided that, in the latter case, two field windings are supplied and are so designed that the two resulting magnetic fields generated thereby are out of phase.

<span class="mw-page-title-main">Synchronous motor</span> Type of AC motor

A synchronous electric motor is an AC electric motor in which, at steady state, the rotation of the shaft is synchronized with the frequency of the supply current; the rotation period is exactly equal to an integer number of AC cycles. Synchronous motors use electromagnets as the stator of the motor which create a magnetic field that rotates in time with the oscillations of the current. The rotor with permanent magnets or electromagnets turns in step with the stator field at the same rate and as a result, provides the second synchronized rotating magnet field. A synchronous motor is termed doubly fed if it is supplied with independently excited multiphase AC electromagnets on both the rotor and stator.

<span class="mw-page-title-main">Brushless DC electric motor</span> Synchronous electric motor powered by an inverter

A brushless DC electric motor (BLDC), also known as an electronically commutated motor, is a synchronous motor using a direct current (DC) electric power supply. It uses an electronic controller to switch DC currents to the motor windings producing magnetic fields that effectively rotate in space and which the permanent magnet rotor follows. The controller adjusts the phase and amplitude of the current pulses that control the speed and torque of the motor. It is an improvement on the mechanical commutator (brushes) used in many conventional electric motors.

<span class="mw-page-title-main">DC motor</span> Motor which works on direct current

A DC motor is an electrical motor that uses direct current (DC) to produce mechanical force. The most common types rely on magnetic forces produced by currents in the coils. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current in part of the motor.

<span class="mw-page-title-main">Armature (electrical)</span> Power-producing component of an electric machine

In electrical engineering, the armature is the winding of an electric machine which carries alternating current. The armature windings conduct AC even on DC machines, due to the commutator action or due to electronic commutation, as in brushless DC motors. The armature can be on either the rotor or the stator, depending on the type of electric machine.

<span class="mw-page-title-main">Field coil</span> Electromagnet used to generate a magnetic field in an electro-magnetic machine

A field coil is an electromagnet used to generate a magnetic field in an electro-magnetic machine, typically a rotating electrical machine such as a motor or generator. It consists of a coil of wire through which a current flows.

<span class="mw-page-title-main">AC motor</span> Electric motor driven by an AC electrical input

An AC motor is an electric motor driven by an alternating current (AC). The AC motor commonly consists of two basic parts, an outside stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft producing a second rotating magnetic field. The rotor magnetic field may be produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.

<span class="mw-page-title-main">Rotor (electric)</span> Non-stationary part of a rotary electric motor

The rotor is a moving component of an electromagnetic system in the electric motor, electric generator, or alternator. Its rotation is due to the interaction between the windings and magnetic fields which produces a torque around the rotor's axis.

A brushed DC electric motor is an internally commutated electric motor designed to be run from a direct current power source and utilizing an electric brush for contact.

<span class="mw-page-title-main">Dynamo</span> Electrical generator that produces direct current with the use of a commutator

A dynamo is an electrical generator that creates direct current using a commutator. Dynamos were the first electrical generators capable of delivering power for industry, and the foundation upon which many other later electric-power conversion devices were based, including the electric motor, the alternating-current alternator, and the rotary converter.

In electrical engineering, electric machine is a general term for machines using electromagnetic forces, such as electric motors, electric generators, and others. They are electromechanical energy converters: an electric motor converts electricity to mechanical power while an electric generator converts mechanical power to electricity. The moving parts in a machine can be rotating or linear. While transformers are occasionally called "static electric machines", since they do not have moving parts, generally they are not considered "machines", but as electrical devices "closely related" to the electrical machines.

<span class="mw-page-title-main">Bipolar electric motor</span> Electric motor with only two poles to its stationary field

A bipolar electric motor is an electric motor with only two poles to its stationary field. They are an example of the simple brushed DC motor, with a commutator. This field may be generated by either a permanent magnet or a field coil.

<span class="mw-page-title-main">Magneto</span> Electricity-producing machine

A magneto is an electrical generator that uses permanent magnets to produce periodic pulses of alternating current. Unlike a dynamo, a magneto does not contain a commutator to produce direct current. It is categorized as a form of alternator, although it is usually considered distinct from most other alternators, which use field coils rather than permanent magnets.

<span class="mw-page-title-main">Flux switching alternator</span>

A flux switching alternator is a form of high-speed alternator, an AC electrical generator, intended for direct drive by a turbine. They are simple in design with the rotor containing no coils or magnets, making them rugged and capable of high rotation speeds. This makes them suitable for their only widespread use, in guided missiles.

Electromagnetically induced acoustic noise, electromagnetically excited acoustic noise, or more commonly known as coil whine, is audible sound directly produced by materials vibrating under the excitation of electromagnetic forces. Some examples of this noise include the mains hum, hum of transformers, the whine of some rotating electric machines, or the buzz of fluorescent lamps. The hissing of high voltage transmission lines is due to corona discharge, not magnetism.

In engineering, a solenoid is a device that converts electrical energy to mechanical energy, using an electromagnet formed from a coil of wire. The device creates a magnetic field from electric current, and uses the magnetic field to create linear motion.

A radial flux motor generates flux perpendicular to the axis of rotation. By contrast, an axial flux motor generates flux parallel to the axis.

References

  1. Parviainen, Asko (April 2005). "Design of axial-flux permanent-magnet low-speed machines and performance comparison between radial-flux and axial-flux machines" (PDF). MIT.
  2. EP2773023A1,Woolmer, Timothy; King, Charles& East, Market al.,"Axial flux motor",issued 2014-09-03
  3. 1 2 3 "Axial Flux technology". AXYAL Propulsion. Retrieved 2024-04-03.
  4. "Axial and Radial flux permanent magnet machines – What is the difference?". EMWorks Blog. 2020-10-12. Retrieved 2022-04-08.
  5. "Double-rotor or Double-stator: a Matter of Efficiency". traxial.com. 2021-08-28. Retrieved 2024-03-31.
  6. Huang, Pinglin; Li, Hang; Yang, Chen (February 2021). "A Yokeless Axial Flux Induction Motor for Electric Vehicles Based on Grain-oriented Silicon Steel". Journal of Physics: Conference Series. 1815 (1): 012042. Bibcode:2021JPhCS1815a2042H. doi: 10.1088/1742-6596/1815/1/012042 . ISSN   1742-6596.
  7. "750 R Electric Motors Product Sheet" (PDF).
  8. Moreels, Daan; Leijnen, Peter (30 Sep 2019). "This Inside-Out Motor for EVs Is Power Dense and (Finally) Practical". IEEE. Retrieved 2 August 2020.
  9. "About YASA | The History Of YASA Axial Flux Motors | YASA Ltd". YASA Limited. Retrieved 2024-04-04.
  10. "YASA & Mercedes Benz | A message from our Chairman | YASA Ltd". YASA Limited. Retrieved 2024-04-04.
  11. 1 2 Oliver, Ben. "An Innovative EV Motor Used by Lamborghini, McLaren, and Ferrari Is Being Mass-Produced by Mercedes". Wired. ISSN   1059-1028 . Retrieved 2024-05-13.
  12. "Electric Planes Are FINALLY Here and They're Breaking Records!". YouTube .
  13. "348 (400kW | 1000Nm)". EMRAX. Retrieved 2024-03-31.
  14. "Siemens and Emrax claim best power to weight ratio for electric motors in the 5 to 10 kilowatt per kg range | NextBigFuture.com". 2015-04-20. Retrieved 2024-03-31.