Axial Flux Motor Design using Ansys MotorCAD
In this video, we demonstrate how to design an axial flux motor using the template-based software, MotorCAD. MotorCAD offers three different topologies for axial flux motors and allows four different views:
- Radial view
- Axial view
- 3D view
- Linear view
Currently, we are displaying the dual rotor, single stator configuration. MotorCAD also offers:
- Single stator, single rotor
- Double stator, single rotor
Each configuration serves a specific function. At Junior Essential Motors, we have three different display options for these configurations. Let's return to our original design for a single stator, dual rotor setup.
Design Specifications
Define the slot type as yokeless. There are many parameters the user can change, such as the rotor type. We can also display the radial view only for the rotor, showing how the magnets are arranged with their spacing, radial locations, and other dimensions and settings that can be modified.
Winding Section
This section is similar to the one used for the original BPM motor design in MotorCAD. It allows you to:
- Examine winding factors and harmonics
- Define parallel paths
- Configure windings with single or double layers
- Choose between round and rectangular wires
Material Section
There are a few new materials available, but the basic types remain the same, including laminations, iron cores, and magnets. The settings have minor updates but are largely consistent with previous versions of MotorCAD.
Calculations
We will perform a vacuum EMF test and a solution. This involves an open circuit vacuum EMF at 500 RPM, which will be our first FEA solution. After that, we will solve for software torque.
E-Magnetics Tab
Here, we can view our flux density plots. The linear model for the machine is used, involving only one slice.
Output Data
Similar to previous MotorCAD versions, we can display all necessary data and more. In the graphics section, we will examine the vacuum EMF, which is largely sinusoidal, and the air gap flux density. A couple of options are available here:
- Plot the Y-axis flux density
- Plot the flux linkage
Torque Calculation
We will disable the vacuum EMF and enable only the torque calculation. Once the solution is ready, we can view the FEA plot in the E-magnetics tab. In the output data, we can see:
- Shaft torque: 6 Nm, 6.2 Nm
- System efficiency
- Motor power: approximately 300 watts
- Loss calculations, including magnet losses
- Torque as a function of rotor position
Conclusion
This is the basic workflow for designing an axial flux permanent magnet motor using MotorCAD. We will be uploading more videos on this topic and comparing these outputs against 3D Maxwell models. Thank you for watching.
Title: Axial Flux Motor Design using Ansys MotorCAD In this video, we are going to demonstrate how to design an axial flux motor using template-based software MotorCAD. MotorCAD has three different topologies for axial flux motors and it allows four different views: radial, axial, 3D, and linear.
Currently, we are displaying the dual rotor or single stator. We can also see here that MotorCAD offers a single stator, single rotor, and double stator, single rotor. These will serve different functions.
At Junior Essential Motors, we have three different ways of displaying this one in its different views. Let's go back to our original design for a single stator dual rotor. Define the slot type as yokeless. There are many things the user can change, for example, the rotor type.
We can also display the radial view only for the rotor. We can see how the magnets are arranged here with their spacing, radial locations, and many other dimensions and settings that the user can modify. Let's go to the winding section.
This winding section is very similar to the one for the original BPM motor design in BuildMotorCAD. It allows you to look at the winding factors, the winding harmonics, to define parallel paths, to define windings with a single or double layers, and it also includes round and rectangular wires.
For the material section, there are a few new materials, but the basic material types are the same: laminations, iron cores, and magnets. The same with the settings; there are a few new things, but it's pretty much the same as what we had in previous MotorCAD. Now let's go to the calculations tab.
We will perform a vacuum F test and a solution. So this will be open-circuit vacuum F at 500 rpm. That will be our first FEA solution, and after that, we will solve all software torque. We can go to the E-magnetics tab and take a look at our flux density plots.
We can see the linear model for the machine is being used, with only one slice involved. Now let's go to the output data tab. Similar to previous MotorCAD versions, we can display everything we need here and more.
Let's go to the graphics and take a look at the vacuum F because it's pretty much sinusoidal. The air gap flux density, a couple of options here. So we'll take a look at the E-magnetics tab. We will plot the Y-axis flux density and also the flux linkage.
Now we will go on to the calculations tab and solve for torque. So we'll disable the vacuum F and enable only the torque calculation. Okay, the solution is ready. Let's go to the E-magnetics tab. We can look at our FEA plot.
Now if we go to the output data, we can see the shaft torque, 6 Nm, 6.2 Nm, system efficiency. This is a very low power motor, around 300 watts. We can look at the losses. It will calculate magnet losses as well.
And then we will also be able to, of course, look at the torque function of the rotor position. That's the basic workflow for Axial Flux permanent magnet motor design using MotorCAD. We will be uploading more videos about this topic and also comparing these outputs against 3D Maxwell models.
Thanks for watching.
