ANALYTICAL MODELLING AND MULTI-OBJECTIVE OPTIMIZATION OF AXIAL-FLUX PERMANENT MAGNET MACHINE WITH VARIOUS PCB STATORS AND DEVELOPMENT OF A GAN SWITCHED INTEGRATED MOTOR DRIVE PCB MOTOR

2022-5-27
Tokgöz, Furkan
The axial-flux machines have been gaining popularity thanks to their higher torque density and short axial length compared to radial-flux machines. However, they are not easy to mass manufacture because of their thin form factor. Printed circuit board (PCB) technology offers a solution to the problem by utilizing the highly developed, precise, and consistent PCB manufacturing process. However, having a low copper fill factor and low inductance are the main disadvantages of the PCB motors. This thesis focuses on the design and development of double rotor single stator axial-flux permanent magnet synchronous machines with PCB stators. Multi-objective optimization algorithms are used and compared in order to improve the torque density with the developed analytical cost function of the PCB motors. The comparison of several stator winding topologies is investigated to find out which winding shape is suitable in different applications. The analytical calculation methodology of induced phase voltage and output torque of wave windings are developed and compared with test results. An integrated motor drive PCB motor with gallium nitride (GaN) switches at a 1 MHz switching frequency is developed to overcome the problem of low inductance. The motor is optimized using the constructed model, and the non-dominated sorting genetic algorithm (NSGA-II) and two stator types are designed to compare the effect of unequal trace width. A mechanical and thermal solution is offered by utilizing the copper traces of the stator board and the housings. The system is tested in both generator and motoring modes under various load conditions up to 7000 RPM. The overall system efficiency is found as 82% at rated torque with feed-forward compensated field-oriented control (FOC).

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Citation Formats
F. Tokgöz, “ANALYTICAL MODELLING AND MULTI-OBJECTIVE OPTIMIZATION OF AXIAL-FLUX PERMANENT MAGNET MACHINE WITH VARIOUS PCB STATORS AND DEVELOPMENT OF A GAN SWITCHED INTEGRATED MOTOR DRIVE PCB MOTOR,” M.S. - Master of Science, Middle East Technical University, 2022.