Thermal Analysis of Small-Scale Axial Flux Permanent Magnet Synchronous Motors

In this study, the advantages of small-scale AFPMSMs over traditional radial flux machines are highlighted, with a focus on their superior torque and power densities and thermal capabilities. This study explores the complex interplay of electrical, magnetic, and thermal processes in AFPMSMs, with a specific emphasis on thermal analysis. A novel contribution of this research lies in the analytical thermal model developed to address the challenges posed by natural convection cooling in AFPMSMs with no air inlet. This model considers intricate fluid flow regimes and temperature-dependent material properties, offering insights into heat convection, joule losses, and material behavior. Experimental validation of the analytical model through prototyping and testing, including thermal and efficiency measurements, strengthens the reliability of the proposed design. Comparisons between analytical predictions and experimental results demonstrate the accuracy of the proposed model in predicting crucial performance metrics. This research delves into the thermal behavior of the AFPMSM under diverse operating conditions, elucidating temperature variations in stator windings and outer cases. Experiments were conducted with a current density of 30 A/mm
²
for AFPMSM. This study also highlights the significantly high thermal capacity of small-scale AFPMSMs.