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Design and optimization of radial flux Brushless DC motors with flexible PCB windings

De Gréef, Christophe
(2017)

Files

DeGreef_47841200_2017.pdf
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  • Adobe PDF
  • 7.62 MB

Details

Supervisors
Dehez, Bruno ; Baudart, François
Faculty
Ecole polytechnique de Louvain
Degree label
Master [120] : ingénieur civil électromécanicien
Abstract
Slotless BLDC motors are commonly accepted to be well suited for fractional horsepower applications. Nevertheless, their performances can be increased by printing the windings on flexible PCB. This master’s thesis proposes to fully profit from the potential of this technology not only by optimizing the shape of the windings, but also by optimizing the dimensions of the motors. A complete multiphysics modeling of radial flux motors is described. This includes a 3D FEM magnetic model, which takes into consideration the saturation of the materials and the border effects, a lumped element parameters thermal model, and a 2D analytical mechanical model. These models are validated by the construction of a prototype. The results show a 60% power density gain by replacing the windings with flexible PCB windings. Also, the gain reaches 98% by optimizing the dimensions of the motor. Moreover, five hundred motors have been optimized based on their motor constant. This database allowed to give an analytical correlation of the optimized dimensions of the motor. Finally, a comparison to axial flux motors shows that radial flux motors have better performances when the length to diameter ratio exceeds 80%.