Dual Rotor Axial Flux Permanent Magnet Motor using PCB Stator

This paper presents a framework for the design and analysis of a light and low-cost axial flux permanent magnet motor which consists of dual permanent magnet rotors and a coreless Printed Circuit Board stator. Removal of the conventional laminated stator core significantly reduces core losses, decreases cogging and torque ripple and increases efficiency. The proposed design drastically eliminates magnetic forces between the rotor and the stator as well as the torque ripple, hence reduces the acoustic noise. A fully integrated variable frequency drive is proposed which uses high efficiency silicon carbide MOSFET inverter design. Using Printed Circuit Board stator enables simpler and faster manufacturing. An in-house analytical simulation has been used to model the motor design and evaluate the performance. The proposed design has been manufactured and was tested successfully. Finally, the test results are compared with the simulation results as well as finite element analysis.