High speed coreless axial flux permanent magnet motor with printed circuit board winding

High speed gearless and compact motors rotating at speeds above 10000 rpm are finding many applications nowadays. Design of the high speed motor is indeed a technological challenge. This paper presents novel design and analysis of a coreless axial flux permanent magnet motor for high speed, low power application. The proposed motor is designed to rotate at a speed of 30000 rpm. To achieve high reliability of the motor at this speed, the torque ripple and axial pull in the axial flux machine should be minimized. For this purpose, coreless stator design is preferred. Furthermore, a novel multilayer Printed Circuit Board (PCB) stator is proposed to obtain uniform distribution in phase winding which minimizes harmonics in the back emf of the motor. In order to improve the air gap flux density in the coreless design, halbach array based rotor is used. The proposed axial flux motor has light, yet strong, well-balanced halbach rotor. The novel multilayer PCB stator has made the motor highly efficient and reliable. MagNet 3-D is used for the Finite Element Analysis (FEA) and optimization of the motor and the results are presented.