Simulation and Fabrication of an Axial Flux Permanent Magnet Synchronous Motor

Axial flux motors have many advantages according to conventional motors. Compared to radial flux motors axial flux motors have high power density and less space occupancy. Axial flux motors can be designed with single air gap or multiple air gaps with slotted, slot less or even fully coreless armature. In this project, an Axial Flux Permanent Magnet Synchronous Motor (AFPMSM) was designed, simulated and fabricated. A single airgap AFPMSM was designed by calculating the machine dimensions, as per the specifications. Using those dimensions, a full simulation is run by the Ansys software and gain the remaining values needed. Using the values, the stator and the rotor is machined with the specific tools and has been assembled. The stator has been machined with the laser cutter method. The aluminium core rotor is machined in lathe and then the permanent magnets (Neodymium) are pasted alternatively on the rotor surface. The axial flux motors are finding applications in direct drive wind energy conversion systems and electric vehicles with all wheel drive system, with higher efficiency and lower cost.