Performance Assessment of Axial-Flux Permanent Magnet Motors from a Manual Manufacturing Process

Adrian Mlot,Juan González

doi:10.3390/en13082122

Adrian Mlot, Juan González

Open Access

https://doi.org/10.3390/en13082122

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Journal: Energies	Publication Date: Apr 24, 2020
Citations: 4	License type: CC BY 4.0

Affiliation: Opole University of Technology

Abstract

Implementation of a new design for the process of assembling an axial-flux permanent magnet synchronous motor (AF PMSM) may lead to unstable motor parameters during operation at low and high speeds. In this paper, experimental data related to the AFPMSM used in an electric traction motor was monitored. The paper presents tracing of machine performance in order to find quality-related issues and to evaluate the assembly process. To assess the manual manufacturing process (low-volume production) and electrical machine performance, several motors, characterized by the same size and topology, were extensively tested. Useful AF PMSM parameters such as continuous torque and continuous current were measured. The winding temperature of the stators was also monitored and carefully examined. An attempt to assess motor performance, based on measurements and aimed at the identification of the weakest parts of the electric motor design is presented. In this paper it can be seen how the subcomponents of the machine and its detailed assembly process and tolerances play key roles in achievement of the designed continuous performance with symmetrical temperature distribution in the stator winding. Selected conclusions drawn from the obtained measurements were explained by a rotor/stator misalignment study using 3-D finite element analysis.

Highlights

The concept of electric vehicles is expanding into the areas of passenger cars, trucks, buses, and special purpose vehicles
The main aim of the present paper is to analyze the monitored performance of an axial-flux permanent magnet synchronous motor (AF PMSM) for several identical electric motors from a low-volume production line
From the results of measurements and numerical calculations, it can be concluded that the development of new electric motors requires analysis of the impact of assembly tolerances on motor performance

Summary

Introduction

The concept of electric vehicles is expanding into the areas of passenger cars, trucks, buses, and special purpose vehicles This requires engineers to consider the design of electric motors with suitable thermal- management systems, inverters, and motor controls [1,2,3]. The manufacture of these vehicles requires the development and launch of electrical machines with low noise levels, improved motor performance, high efficiency, a high level of reliability, intensive active cooling of the stator (as well as, in many cases, of the rotor), and a long lifespan [4,5,6]. Tolerance sensitivity analysis of a new group of electrical machines is important in order to assess their weaknesses [8,9,10]

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