Anodised Aluminium Foil Winding Axial Flux Machine for (Quasi-)Direct-Drive Robotic Applications: Preliminary Design and Manufacturing

Motivated by the need for higher torque density actuators in novel (quasi-)direct-drive robotics applications, a Yokeless and Segmented Armature Axial Flux Permanent Magnet Synchronous machine with anodised aluminium foil conductors instead of enamelled copper wire is considered in this work. Based on a requirements analysis of (quasi-)direct-drive actuators, a prototype axial flux machine is designed. Several design aspects are discussed keeping the application requirements in mind. It could be concluded that the combination of the machine topology and conductor material results in a high fill factor and excellent thermal properties, making it particularly promising for high torque density, low speed applications. A prototype was manufactured to demonstrate the feasibility of the design. The interconnection of aluminium foil to copper wire appeared to be challenging, two interconnection methods were tested and compared qualitatively.