Disciplines
Electro-Mechanical Systems | Other Engineering | Power and Energy | Robotics
Abstract (300 words maximum)
This study presents a novel approach to the design, manufacture, and optimization of segmented stators for composite construction axial flux permanent magnet DC motors. Traditional axial flux stator manufacturing is both challenging and expensive, creating a bottleneck in rapid prototyping and innovation. To overcome these limitations, the stator is divided into individually fabricated segments using advanced composite polymer materials and low-cost additive manufacturing techniques. This segmentation not only drastically reduces production complexity and cost but also allows for customized coil geometries that maximize the surface area for improved heat dissipation.
A key innovation of our design is the integration of a dielectric ferrofluid cooling system that addresses the thermal management challenges inherent in non-iron core stators. This system efficiently transfers heat from the electromagnets to the rotor, preventing thermal buildup and maintaining optimal operating conditions under load. Preliminary experimental results indicate significant enhancements in thermal efficiency and power output, demonstrating that the segmented design not only sustains higher performance under continuous operation but also improves overall motor stability and reliability.
These early findings highlight the great application and implementation capabilities of this novel approach, marking a scalable pathway for the development of high-performance axial flux motors. The flexibility offered by segmented construction paves the way for rapid design iterations and bespoke modifications, making this method particularly attractive for both academic research and industrial applications. Future work will focus on further optimizing the cooling system and segment geometries to fully exploit the benefits of additive manufacturing in motor design.
Academic department under which the project should be listed
SPCEET - Robotics and Mechatronics Engineering
Primary Investigator (PI) Name
Dr. Razvan Voicu
Included in
Electro-Mechanical Systems Commons, Other Engineering Commons, Power and Energy Commons, Robotics Commons
Low Cost Additive Manufacturing of Segmented Stator Composite Polymer Permanent Magnet DC Motors
This study presents a novel approach to the design, manufacture, and optimization of segmented stators for composite construction axial flux permanent magnet DC motors. Traditional axial flux stator manufacturing is both challenging and expensive, creating a bottleneck in rapid prototyping and innovation. To overcome these limitations, the stator is divided into individually fabricated segments using advanced composite polymer materials and low-cost additive manufacturing techniques. This segmentation not only drastically reduces production complexity and cost but also allows for customized coil geometries that maximize the surface area for improved heat dissipation.
A key innovation of our design is the integration of a dielectric ferrofluid cooling system that addresses the thermal management challenges inherent in non-iron core stators. This system efficiently transfers heat from the electromagnets to the rotor, preventing thermal buildup and maintaining optimal operating conditions under load. Preliminary experimental results indicate significant enhancements in thermal efficiency and power output, demonstrating that the segmented design not only sustains higher performance under continuous operation but also improves overall motor stability and reliability.
These early findings highlight the great application and implementation capabilities of this novel approach, marking a scalable pathway for the development of high-performance axial flux motors. The flexibility offered by segmented construction paves the way for rapid design iterations and bespoke modifications, making this method particularly attractive for both academic research and industrial applications. Future work will focus on further optimizing the cooling system and segment geometries to fully exploit the benefits of additive manufacturing in motor design.