Design Optimization Considering a Detailed PCB Stator Layout for Coreless AFPM Machines with Minimal Eddy and Circulating Current Losses

This paper proposes a multi-objective design optimization approach for printed circuit board (PCB) stator coreless axial flux permanent magnet (AFPM) machines based on a detailed PCB stator layout. The process begins with the machine envelope design optimization based on an evolutionary algorithm and 3D finite element analysis (FEA) models and continues with the detailed design of a PCB stator aimed at minimizing eddy and circulating current losses. This approach employs different open circuit loss mitigation techniques while taking into account PCB manufacturing limitations and standards. The process is explained through the design of an integral horsepower PCB stator coreless AFPM machine, which was prototyped and tested. The experimental results indicate negligible open circuit losses and 96% efficiency at the speed of 2,100rpm and an output torque of 19Nm, thereby validating the efficacy of the proposed approach.