Design of a Novel High Power Density Single Sided Axial Flux Motor Using SMC Materials

In this paper a novel construction of a single sided axial flux permanent magnet motor with a hybrid stator using Soft Magnetic Composite and laminated soft magnetic iron for hand-held power tool applications is presented. The required motor characteristic, the design process of the motor as well as the construction of the prototype are shown. The required motor characteristic is derived based on dynamic measurements of screwing sequences with different screw sizes. Based on the requirements and the geometry constraints, a high power density single sided axial flux motor is designed and optimized using 3D-FEA simulations. Challenges in the construction of single sided axial flux motors are identified and handled. Measurements of the motor characteristic validate the design process and show the advantages of the axial flux motor concept.