Geometry Optimize of Printed Circuit Board Stator Winding in Coreless Axial Field Permanent Magnet Motor

Axial Field Permanent Magnet Motor (AFPM) can be easily integrated into wheel-hub motor of Electrical Vehicle (EV) as impact structure and light weight. Improved hexagonal asymmetry coil is presented in Printed Circuit Board (PCB) stator of coreless AFPM. Geometry parameters of coil shape is optimized. According to the structure characteristics of coreless AFPM, dimension formulas of PCB coil are derived. Analytical calculation models of back-EMF and winding co-efficiency are built up. To maximize ratio of torque to copper loss, coil parameters such as radial length, inclined angle of active conductors etc. are optimized. Finally comparison and verification are performed by means of 3D finite element method and prototype test. The ratio of torque to copper loss is increased 30%. As a result, motor rated torque is also increased at certain motor size, heating load and dissipation condition.