Design and engineering of high efficiency ironless axial flux BLDC motors.
Abstract (300 words maximum)
Axial flux motors are well-known for their superior power density and efficiency but remain difficult and costly to manufacture, limiting their widespread adoption in cost-sensitive applications. Traditional radial flux stator manufacturing techniques are incompatible with the unique constraints of axial flux motors, presenting a significant challenge. This research seeks to address this limitation by designing, manufacturing, and optimizing a low-cost axial flux permanent magnet direct current (DC) motor that simplifies production while maintaining high performance. The motor utilizes two innovative stator designs: an air-core stator made from high-temperature engineering polymers and a composite iron 3D-printed filament functioning as an iron core. To mitigate the heat dissipation issues typically associated with non-iron core stators, a dielectric ferrofluid cooling system is introduced. This system efficiently transfers heat from the electromagnets to the rotor, allowing for sustained operation under load and enhancing the motor's maximum power output. A key novelty of this research lies in the integration of composite metallic polymer filaments into the stator construction, which, together with the advanced cooling system, enables high efficiency without the need for costly materials. The findings offer valuable insights into how innovative materials and cooling strategies can overcome traditional manufacturing and performance barriers, thereby advancing the practical use of axial flux motor technology in both research and industrial applications.
Academic department under which the project should be listed
SPCEET - Robotics and Mechatronics Engineering
Primary Investigator (PI) Name
Dr. Razvan Voicu
Design and engineering of high efficiency ironless axial flux BLDC motors.
Axial flux motors are well-known for their superior power density and efficiency but remain difficult and costly to manufacture, limiting their widespread adoption in cost-sensitive applications. Traditional radial flux stator manufacturing techniques are incompatible with the unique constraints of axial flux motors, presenting a significant challenge. This research seeks to address this limitation by designing, manufacturing, and optimizing a low-cost axial flux permanent magnet direct current (DC) motor that simplifies production while maintaining high performance. The motor utilizes two innovative stator designs: an air-core stator made from high-temperature engineering polymers and a composite iron 3D-printed filament functioning as an iron core. To mitigate the heat dissipation issues typically associated with non-iron core stators, a dielectric ferrofluid cooling system is introduced. This system efficiently transfers heat from the electromagnets to the rotor, allowing for sustained operation under load and enhancing the motor's maximum power output. A key novelty of this research lies in the integration of composite metallic polymer filaments into the stator construction, which, together with the advanced cooling system, enables high efficiency without the need for costly materials. The findings offer valuable insights into how innovative materials and cooling strategies can overcome traditional manufacturing and performance barriers, thereby advancing the practical use of axial flux motor technology in both research and industrial applications.