1 White-paper review Axial Flux Technology for Motors & Generators.

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Axial Flux Technology for Motors & Generators

Axial Flux Technology for Motors &

Generators

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Background:Motors & GeneratorsMotors & Generators

ClassificationClassification

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Vs. brush usingVs. brush using Vs. brush usingVs. brush using

brushbrushbrushlessbrushless

Stator windings

Rotor magnets

driver

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Vs. shapeVs. shape Vs. shapeVs. shape

CylindricalCylindricalDisk-shapedDisk-shaped

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Rotation axlesRotation axles

Vs. current-field directionsVs. current-field directions Vs. current-field directionsVs. current-field directions

CurrentsCurrents

Magnetic fieldMagnetic field

TorqueTorque

Radial-FieldRadial-FieldAxial-FieldAxial-Field

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WE DEAL WITH AND OFFER: WE DEAL WITH AND OFFER: Brushless Brushless

Disk-shaped Disk-shaped

Axial field Axial field

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Why do we offer…

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… Brushless ? No brushes – no maintenance

No brushes – long working life

No brushes – no sparking

No brushes – reduced EMI / RFI

No brushes – no maintenance

No brushes – long working life

No brushes – no sparking

No brushes – reduced EMI / RFI

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… Disk-shaped ?

ENGINE ENGINE

GENERATOR

GE

NE

RA

TO

R

Sam e Volum es

Volum e1 Volum e2 = 1.63 Volum e 1

system with CYLINDRICALSystem with DISK-SHAPED

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178 % Power

M agnetic C ircu it

Coils

Permanent M agnets

M agnetic F lux

Currents

100 % Power

AXIAL FLUXRADIAL FLUX

… Axial Flux ?

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Detailing TheAxial Flux Technology

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Version IWith Steel Core

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Electromagnetic StructureElectromagnetic Structure

coils

m agnets

C ore

structure

m agnetic flux

currents

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General DesignGeneral Design

rotor Right stator

Left housing Right housing

Left housing

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StatorStator

Core

Active coil part

Internal overhang

External overhang

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Permanent magnets

Shaft

Carrying structure

RotorRotor

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Version IICoreless

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Electromagnetic StructureElectromagnetic Structure

coils

m agnets

Yoke

structure

m agnetic flux

currents

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General DesignGeneral Design

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Coils

Carrying structure

StatorStator

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Yoke Permanent magnets

Carrying structure

RotorRotor

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Additional Featuresof Axial-Flux Machines

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Various Stators-Rotors CombinationsVarious Stators-Rotors Combinations

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End Rotors

Permanent MagnetNd FeB or Ferrite

Winding

Yoke

InterposedRotors

ModularityModularity

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Principle Features and Advantages

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Version IWith Steel Core

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FeaturesFeatures Axial direction of magnetic flux and radial direction

of electric currents Thin disk-shaped rotor Flat Nd-Fe-B magnets Reeled electric steel core Thermo conducting cooling mechanism Reduced cogging

Axial direction of magnetic flux and radial direction of electric currents

Thin disk-shaped rotor Flat Nd-Fe-B magnets Reeled electric steel core Thermo conducting cooling mechanism Reduced cogging

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Excellent torque-to-volume, torque/weight ratios (up to 2÷3 Nm/kg)

High stall torque Highest acceleration Low mechanical time constant Wide operating speed range Allowance for peak torques without forced cooling

Excellent torque-to-volume, torque/weight ratios (up to 2÷3 Nm/kg)

High stall torque Highest acceleration Low mechanical time constant Wide operating speed range Allowance for peak torques without forced cooling

AdvantagesAdvantages

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ApplicationsApplications Drives for robotic (with and without transmission) Drives for high inertia loads Direct drive rotation tables Torquers

Drives for robotic (with and without transmission) Drives for high inertia loads Direct drive rotation tables Torquers

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ImplementationsImplementations

6

5

4

13

2

BDM 002 (4.4 Nm stall 4.4 kg)

BDM 006 (14.4 Nm stall 10.0 kg)

Servo-motors for robotics Servo-motors for robotics

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Version IICoreless

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FeaturesFeatures


Light-weight disk-shaped stator Absolutely no cogging No parasitic forces between rotor and stators Self-ventilation or forced cooling Very low inductance


Light-weight disk-shaped stator Absolutely no cogging No parasitic forces between rotor and stators Self-ventilation or forced cooling Very low inductance

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AdvantagesAdvantages

No eddy-current losses Excellent power/weight, power/volume ratios Extremely high efficiency at high speeds Absolutely smooth rotation Excellent controllability Very low voltage drop under load in generators

No eddy-current losses Excellent power/weight, power/volume ratios Extremely high efficiency at high speeds Absolutely smooth rotation Excellent controllability Very low voltage drop under load in generators

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High- and medium speed alternators Direct drive for ultra-accurate position stages and

rotary tables Drives for high speed motors with or without

transmissions Spindles and flywheels

High- and medium speed alternators Direct drive for ultra-accurate position stages and

rotary tables Drives for high speed motors with or without

transmissions Spindles and flywheels

ApplicationsApplications

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Tactical automatic charger

(24V, 1kW, 8 kg)

MIL-standard EMI/RFI protected portable dual-Input diesel generator

(28 VDC, 1.5 kW, 55 kg)

Generator

Gasoline engine Controller

Dual-input Converter

Generator

Diesel engine

Charge controller

Generators and APU Generators and APU

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AT - 25 for EV

(25 kW, 10,500 rpm,

OD=260 mm) AT - 25 + gear-box 1:7.75 75 kW for EV

Motor Gear - box

Liquid-cooled motors for heavy electric vehicle Liquid-cooled motors for heavy electric vehicle

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M300

(300 W 5,000 rpm

0.9 kg, OD=127 mm)

M300 + worm gear (260 W 100 rpm)

ImplementationsImplementations Air-cooled motors for light electric vehicle Air-cooled motors for light electric vehicle

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Turntable RT -200

(accuracy +/- 1”, runout 3um)


Ultra accurate rotating optical bench

Direct drive rotating stages Direct drive rotating stages

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Hub wheel-drive for robotics 3kg (50 Nm 50 rpm)

ImplementationsImplementations Motor-reducer assembly Motor-reducer assembly

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Motor Technology Estimation (Motor Technology Estimation (1999, per VW1999, per VW))

Coreless Axial Flux

Switched Reluctance

Motor

Wir

kun

gsg

rad

Asynchronmotor

TF-Motor

PM-Synchron motor

Leistungsgewicht [kW/kg]

Design Phase

serienmäßig verfügbar

Prototypen vorhanden

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EisenloserAxialfluxmotor

Trans flux

StatusSerial production

Prototypes

Eff

icie

ncy

Specific power

1 White-paper review Axial Flux Technology for Motors & Generators.

Documents

axial flux technology

n servomotors

sparking n

maintenance n

motors generators diskshaped

motors generators version

motors generators brushless

motors generators background