Design concept of a repairable YASA axial flux machine with a hybrid cooling system

Yokeless and segmented armature (YASA) axial flux machines (AFMs) offer the potential for higher torque density at a lower axial length than radial flux machines. One challenge with this particular type of machine lies in the manufacturing of the stator. Therefore, a design concept for YASA machines is developed and investigated. The design concept considers a hybrid (re)manufacturing process, which combines additive and subtractive processing steps in one production system and therefore enables a highly integrated and functionalized stator in a polymer housing. Despite the high degree of integration, the developed design concept allows the remanufacturing of individual subcomponents in the machine's stator. In addition to reparability, a special focus lies on the cooling concept of the machine in order to not exceed the low permissible temperatures of the polymer housing. In an iterative process the overall machine design is developed and a sequence of numerical simulations in three domains (electromagnetic, thermal and mechanical) is executed to investigate the operational behaviour of the machine. The final design concept fulfils the demanded requirements and therefore is a simulative proven concept. The validation of the concept via measurements is pending.