A Proposal of an Axial-Flux Permanent-Magnet Machine Employing SMC Core With Tooth-Tips Constructed by One-Pressing Process: Improving Torque and Manufacturability

This study aims to improve the torque performance and manufacturability of axial-flux permanent magnet (AFPM) machines. Hence, we propose a novel AFPM machine that employs a soft magnetic composite (SMC) core with tooth-tips constructed by a one-pressing process and die. In this paper, the proposed...

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Bibliographic Details
Published in:IEEE access 2023-01, Vol.11, p.109435-109447
Main Authors: Tsunata, Ren, Takemoto, Masatsugu, Imai, Jun, Saito, Tatsuya, Ueno, Tomoyuki
Format: Article
Language:English
Subjects:
Atmospheric modeling
axial gap motor
Axial stress
Axial-flux permanent magnet machine
Magnetic cores
Manufacturability
Manufacturing
Mass production
Permanent magnets
PMSM
press process
Presses
Pressing
semi-closed slot structure
shoe
soft magnetic composite (SMC)
Stator cores
Teeth
Tips
tooth-tips
Torque
YASA motor
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Summary:This study aims to improve the torque performance and manufacturability of axial-flux permanent magnet (AFPM) machines. Hence, we propose a novel AFPM machine that employs a soft magnetic composite (SMC) core with tooth-tips constructed by a one-pressing process and die. In this paper, the proposed AFPM machine is compared to two conventional AFPM machines using an SMC core. One of them has open-slot structure without tooth-tips. Another model employs an SMC core with tooth-tips pressed by a conventional pressing process that requires multiple operations and dies. As a result of the comparison, the proposed AFPM machine realizes a much higher torque than the two conventional machines. Additionally, the manufacturability of an SMC core with tooth-tips pressed by the proposed method is superior to the conventional one because the proposed structure can be realized by the one-pressing process and die. Furthermore, two prototypes of the proposed AFPM machine and the conventional one with an open-slot structure are fabricated, and then, they are compared by experiments. Consequently, the proposed AFPM machine achieves a 15.7% higher torque than that of the conventional machine using an open-slot structure. Finally, this paper presents an improved design of an AFPM machine with SMC cores using the proposed pressing process. As a result, the proposed AFPM realizes a 20% larger torque than that of a conventional model employing an open-slot structure.
ISSN:2169-3536
2169-3536
DOI:10.1109/ACCESS.2023.3321829