高频供电条件下的PCB定子盘式永磁电机绕组优化设计

PCB定子盘式永磁无铁心电机的定子采用印制电路板(printed circuit board,PCB)结构,其电机的损耗主要来源于绕组上的交流附加铜耗和直流铜耗,因此定子绕组的设计直接影响电机整体性能。针对应用在较高频率且工况稳定的PCB电机,该文提出一种新型分布式绕组。首先建立反电势、直流铜耗、交流附加铜耗和电阻的解析表达式,分析PCB电机的空载特性。其次,以提高电机的效率为目的,提出在绕组有效导体部分加入绝缘材料。对新型绕组进行优化找到最合适的导体线宽,然后根据有限元理论对比分析新型分布式绕组和已有绕组负载特性。结果表明新型绕组不仅可以降低总铜耗,提高电机效率,有效降低定子稳定温升,并且新型结构也不会影响电机输出性能。最后制作一台16极600W样机进行验证,对PCB定子盘式永磁电机设计具有一定的参考价值。

Optimal Design of Winding of Permanent Magnet Motor Based on High Frequency PCB Stator

The stator structure of axial flux motor is a printed circuit board(PCB), and the main sources of the loss of the PCB motor are AC additional loss and copper loss on the winding. Thus the design of stator winding has a direct influence on the effective utilization rate of the stator and the motor performance. This paper proposed a new type of distributed winding for PCB motors applied at high frequencies and stable operating conditions. This paper first established analytical formulas for back EMF, power, AC additional loss, and resistance. The no-load characteristics of PCB motors were analyzed. Secondly, for the purpose of improving the efficiency of the motor, it was proposed to add insulation line width to the effective conductor part of the winding to optimize the new winding to find the most suitable line width. Then according to the finite element theory, the load characteristics of the new distributed winding and the existing winding were analyzed and compared. The results showed that although the new winding improves the copper loss, it could effectively reduce the size of the eddy current loss. Moreover, not only the total loss was reduced, but also the stable temperature rise of the stator could be effectively reduced, and the new structure would not affect the output performance of the motor. Finally, an 8-pole 600 W prototype was produced for verification, which had certain reference value for the design of PCB stator disc permanent magnet motor.