Analysis of an Axial-Flux Slotted Limited-Angle Torque Motor with Quasi-Halbach Array for Torque Performance Improvement

Better torque performance and higher reliability have long been the focus of research for slotted limited-angle torque motors (LATMs), which are primarily used to position first-stage valves in electrohydraulic servosystems. This paper presents a high reliability axial-flux slotted LATM with quasi-Halbach array for torque performance improvement including constant torque range (CTR) and output torque. Firstly, the structure with two sets of windings and the operation principle of the proposed slotted LATM is analyzed. Secondly, a brief design procedure is presented, the structure selections of open slot and double-stator single-rotor (DSSR) interior rotor with surface mounted quasi-Halbach permanent magnet (PM) array are illustrated, and the geometric parameters are optimized to obtain the optimal design of the proposed slotted LATM. Then, 3-D finite-element method (FEM) is employed to compare the proposed slotted LATM with the conventional surface mounted PM slotted LATM in terms of cogging torque, no-load back EMF, and output torque, and the results show that the proposed LATM with quasi-Halbach array has a 10% improvement in output torque and a 25% improvement in CTR. Meanwhile, the flux linkages and torque performance of the two sets of windings under various conditions verify good magnetic isolation. Finally, prototypes of two different rotor types are manufactured and a series of experiments are performed to validate the analysis.