The project aims to revolutionize electric propulsion systems by designing a coreless axial flux permanent magnet motor (AFPMM) as a superior alternative to traditional engines. Developing the electric propulsion system, is considered as a feasible method to reduce noise, NOx emission and fuel consumption. The engine is replaced by electric propulsion system which needs motor to provide equivalent thrust from engine. Considering the higher demand for efficiency and torque density of electric machines in aircraft electric propulsion systems, permanent-magnet (PM) machines are the go-to-go solution. The coreless AFPM machine exhibits increased efficiency and reduced torque ripples as compared to the other AFPM machines. The coreless design was chosen to reduce weight and to increase the power density. Trapezoidal shaped coils are used to increase output torque capability as compared to other winding shapes.
Objectives
To design coreless axial flux permanent magnet motor model by using Solid works.
To analyze the characteristics of an electric machine by using Finite Element Method (FEM) .
Prototyping the axial flux permanent magnet motor after getting optimized model from Ansys Maxwell.
To compare simulation and experimental results
Socio-Economic Benefit
1. High Efficiency: Coreless AFPMMs typically exhibit higher efficiency compared to conventional motors due to reduced eddy current losses and improved magnetic flux distribution. This efficiency translates to lower energy consumption and increased overall system performance.
2. Reduced Weight: By eliminating the iron core, coreless AFPMMs are inherently lighter than their conventional counterparts. This reduction in weight is especially beneficial for applications where weight is a critical factor, such as electric vehicles and aircraft, leading to improved range and payload capacity.
3. Increased Power Density: The coreless design allows for a more compact motor with a higher power-to-weight ratio. This increased power density enables the AFPMM to deliver higher levels of performance within a smaller footprint, making it suitable for applications with limited space constraints.
4. Enhanced Thermal Management: Coreless AFPMMs often feature better thermal dissipation characteristics compared to motors with iron cores. This improved thermal management helps maintain optimal operating temperatures, prolonging the motor's lifespan and ensuring reliability under demanding conditions.
5. Reduced Torque Ripple: Coreless AFPMMs typically exhibit reduced torque ripple, resulting in smoother operation and improved system performance. This benefit is particularly important for applications requiring precise control and stability, such as electric propulsion systems in aerospace and marine environments.
6. Flexibility in Design: The absence of an iron core provides greater flexibility in motor design, allowing for customized configurations to meet specific performance requirements. This versatility enables engineers to optimize the AFPMM for various applications, enhancing its adaptability across different industries.
7. Lower Maintenance Requirements: With fewer moving parts and simplified construction, coreless AFPMMs often require less maintenance compared to traditional motors. This translates to reduced downtime and lower operating costs over the motor's lifespan, contributing to overall cost-effectiveness.
8. Environmental Benefits: Electric propulsion systems powered by coreless AFPMMs contribute to environmental sustainability by reducing greenhouse gas emissions and dependence on fossil fuels. This aligns with global efforts to mitigate climate change and promote cleaner energy solutions.
Methodologies
1)Coreless Design: The AFPMM adopts a coreless configuration to minimize weight and maximize power density, crucial factors in electric propulsion applications.
2)Trapezoidal Coils: Trapezoidal shaped coils are utilized to enhance output torque capability compared to traditional winding methods, ensuring optimal performance.
3)N52 Permanent Magnets: The project utilizes N52 permanent magnets in rectangular shape due to their availability in Pakistan, providing the necessary magnetic strength for efficient motor operation.
4)CAD Modeling and FEA Analysis: SolidWorks is employed for CAD modeling to construct detailed designs, while Ansys Maxwell facilitates finite element analysis (FEA) to optimize performance and validate design choices.
5)Prototype Development: Prototypes are iteratively developed based on simulation results obtained from FEA analysis, ensuring that the final design meets performance requirements and operational needs.
Outcome
1:Design and Simulation Results: Detailed designs and simulation results showcasing the motor's performance characteristics, including torque-speed curves, efficiency maps, electromagnetic forces, and thermal behavior.
2:Prototype Development: Construction and testing of a physical prototype demonstrating the feasibility and performance of the coreless axial flux permanent magnet motor design.
3:Performance Evaluation: Experimental evaluation of the motor's performance under various operating conditions, such as load variations, speed control, and temperature changes. This include measurements of torque, speed, efficiency, power output, and other relevant parameters.
4:Comparative Analysis: Comparison of the coreless axial flux permanent magnet motor with conventional motors (such as core-based axial flux motors or radial flux motors) in terms of performance, efficiency, size, weight, cost, and other relevant factors.
