Development of an electrically excited axial flux machine with stabilized disk rotor

Because of the constant progress regarding calculation methods, materials and production technologies, new opportunities for alternative machine concepts are offered. The concept of axial flux machines is one of these alternative machine concepts and currently under investigation in many research projects. Axial flux machines are well suited for applications, in which high torque densities are required in combination with a short axial motor length. To reduce costs of powerful axial flux machines, mostly used rare earth magnets could be replaced with alternative solutions, e. g. excitation coils. There are several arrangements of rotor and stator in axial flux machines. This paper deals with the design process of a prototype machine in double stator, single rotor arrangement with aerostatic stabilization. The aerostatic stabilization primarily serves to center and stabilize the rotor disk between the two stators. One conceivable application for this machine would be mobile applications where high torque requirements have to be handled. In addition to the design of the axial flux machine, the evaluation of a centrifugal test and the assembly of the machine as well as the installation on a test bench are carried out. Furthermore, first measurement results are available, which are compared with a 3D-FEM simulation. The central objective of the research work is the development of a design and manufacturing methodology with regard to series production.