Design and Implementation of an Optimized Printed Circuit Board Axial-Flux Permanent Magnet Machine

Although axial-flux machines are used in a different variety of applications, production challenge of the stator winding is a limiting factor for more widely use of these machines. Printed circuit board winding (PCB) can mitigate the production challenges of the axial-flux machines by introducing cheap and precise mass production capabilities. In this paper, the design and implementation of an 16 pole, 2000 RPM, 40 W axial-flux permanent magnet machine with PCB winding for gimbal camera stabilization system used in aviation industry is presented. The machine’s flux density, induced voltage, number of turns and some other parameters are analytically calculated. Parameters are optimized using a genetic optimization algorithm. The design with highest torque density value is validated by an finite element analysis tool, ANSYS Maxwell. Finally, the prototype is tested at 2000 RPM. In order to check the machine can take the thermal stress, it was put under the full load and the temperature level is recorded. The temperature of the windings did not exceed $45 \mathrm{C}^{\circ}$ under full-load. The efficiency of the motor is found as 72%. Expectations are met by analytical, FEA and test results.