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PCB axial flux PMSM/BLDC motor (WIP)
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AF-PMSM (axial flux permanent magnet synchronous machine) PCB stator, inspired by the sabanekko3/pcb_stator_v2 and CarlBugeja/PCB-Motor-v4.
In the design of a PMSM, selecting the slot/pole topology is the first step [5].
The Star of Slot (SOS) method is commonly used for this purpose.
The slot-to-pole relationship can be classified into:
For a three-phase motor, the relationship can be analyzed as follows:
$$ Q=\frac{N_{s}}{3\cdot 2p} $$
where:
Based on [1], the winding layout can be categorized into the following types:
The design in [1] features a 144-slot , 16-pole configuration with 3 slots per pole per phase on a double-layer PCB. The PCB has a thickness of 1mm, an air gap of 1mm, and a copper thickness of 70μm.
According to the findings, radial and concentric windings exhibit the highest torque and induced phase voltage. However, among these, the concentric winding has the highest losses and THD (Total Harmonic Distortion). The radial winding has the lowest THD, making it suitable for high-precision applications. The parallel winding has the lowest resistance, whereas the unequal width parallel winding reduces phase resistance by 17% compared to the standard parallel winding while maintaining the same induced phase voltage and output torque.
The study in [3], based on the results of [1], selected the radial winding layout for PCB motor design. However, an axial unequal-width winding design was adopted. The primary advantage of using unequal width traces is that the larger copper cross-sectional area results in lower phase resistance compared to equal-width traces. Additionally, increasing the total copper area helps reduce thermal stress by providing lower thermal resistance.
The motor specifications are as follows:
For permanent magnet rotors, the Halbach array can be considered.