Fully Parametrized Electromechanical Design Method and Toolchain for an Automotive Axial-Flux Synchronous Machine

Efficient, light-weight and compact electrical machines have been in particularly high demand since the rise of electromobility. One emerging machine concept is the permanent magnet excited axial-flux synchronous machine with a Yokeless And Segmented Armature Topology. In the context of an electric racing car of the Formula Student competition a flexible and closed toolchain was developed, allowing the design and dimensioning of the above-mentioned machine type in a power range of 10-100 kW, based on the desired power and rotational speed. The toolchain consists of an electromagnetic predesign and subsequent simulation in MATLAB/SIMULINK as well as the generation of a CAD model and manufacturing data in AUTODESK INVENTOR. An axial-flux machine designed for the Hamburg University of Technology racing car with a power of 30 kW and a rotational speed of 12 000 min(exp -1) achieves a power density of 6 kW kg(exp -1) at a diameter of 134 mm and a length of 131 mm.