Design and Manufacturing Rotor Disc for DSSR AFPM Motor using Hybrid Fiber Composite to Minimize Solid Loss whilst Maintaining Acceptable Rigidity

This paper presents the design and manufacturing of a rotor disc for a Double-Stator Single-Rotor (DSSR) Axial Flux Permanent Magnet (AFPM) motor. Mathematical analysis has been conducted to select the appropriate rotor size and the number of poles to obtain the intended motor specification. Material selection to manufacture the rotor has been conducted. Traditional metallic rotor discs structure material such as steel or aluminum exhibit significant eddy current losses due to their high conductivity, which is verified using finite element analysis (FEA). To address this, we propose a fiber composite with tailored resin matrices to achieve low electrical conductivity. This research proposes a hybrid fiber-reinforced composite to minimize solid losses (eddy current and hysteresis losses) while maintaining sufficient rigidity. This work provides a practical framework for composite rotor design in AFPM motors, enabling higher efficiency in electric vehicle application where weight and losses are critical.