Seung-Hoon Ko

The Axial Flux Permanent Magnet Synchronous Motor (AFPMSM) has gained significant attention as a core power source for next-generation industrial sectors, including electric vehicles, wind turbines, robot joints, and drone propulsion motors, due to its high power density from a short axial length and large radial dimensions. Despite these structural advantages, cogging torque caused by magnetic interaction between the stator teeth and permanent magnets remains a critical drawback, inducing noise and vibration. While conventional Soft Magnetic Composite (SMC) core methods facilitate 3D flux paths, they suffer from low magnetic permeability, insufficient mechanical strength, and manufacturing complexity. To address these issues, this study proposes a stepped structure model utilizing electrical steel sheets to effectively reduce cogging torque. This structure features radial stacking of identical electrical steel sheets with varying widths, where each layer’s center is incrementally shifted in the rotational direction. This configuration achieves an effect analogous to continuous skewing without specialized 3D machining. To validate the proposed design, 3D Finite Element Analysis (FEA) was conducted. Results demonstrate that the peak-to-peak cogging torque was reduced to approximately 86% of the conventional model’s value, while maintaining the back-EMF reduction rate within 5%. By presenting a novel skewing technique, this research provides a practical alternative for high-precision and high-power AFPMSM.

As the electrification of the automotive industry accelerates, the importance of small-scale motors used in applications such as HVAC systems and water pumps is growing. To design small motors that exhibit high efficiency and high output within limited spaces, applying axial flux motors (AFMs) instead of conventional radial flux motors (RFMs) can maximize the power density within the same volume, offering advantages in both weight reduction and miniaturization. This study proposes an optimized end-turn layout design to mitigate back-EMF imbalance in AFMs utilizing PCB stators. Optimization results demonstrated that the structure employing a non-adjacent end-turn layout with equalized average end-turn heights (BCAACB type) exhibited the best performance in terms of average resistance and phase resistance variance, effectively mitigating back-EMF imbalance. The validity of the optimized end-turn structure was verified through finite element analysis (FEA). The analysis confirmed that the motor’s back-EMF balance was improved, and the magnitude of phase resistance was reduced. This reduction led to lower copper loss, thereby increasing overall efficiency. Furthermore, the variance in resistance for each phase was minimized, resulting in enhanced electrical balance. The results of this study are expected to contribute to enhancing the applicability of PCB stators in small motor design.

Axial Flux Permanent Magnet Synchronous Motor (AFPMSM) offers high power density in structures with short axial lengths and large radial dimensions, making it attractive for applications that require thin structures, such as in-wheel motors. This study proposes an AFPMSM design process applicable under fixed inner/outer diameter and axial length constraints. The proposed process is presented as step-by-step procedures: selection of pole/slot combinations, adjustment of slot depth, determination of stator/rotor dimensional ratios, and slot structure design. It is universally applicable to both bobbin-type rectangular wire windings and shoe-type round wire windings. The validity of the proposed process was verified through finite element method (FEM) analysis, and the differences between the two winding structures were examined through post-processing of the results. By presenting an AFPMSM design methodology that can be consistently applied under constrained spatial conditions, this study provides practical design guidelines for the development of in-wheel motors for next-generation mobility applications.

Duct fan motors must provide high torque within limited space to maintain airflow while requiring low vibration characteristics to minimize fluid resistance caused by fan oscillation. Axial Flux Permanent Magnet Motor (AFPM) offers higher torque performance than Radial Flux Permanent Magnet Motor (RFPM) due to their large radial and short axial dimensions. In particular, the coreless AFPM structure enables superior low-vibration performance. Conventional AFPM typically employs a core-type stator, which presents manufacturing difficulties. In core-type AFPM, applying a multi-stator configuration linearly increases winding takt time in proportion to the number of stators. Conversely, a Printed Circuit Board (PCB) stator AFPM significantly reduces stator production time, making it favorable for implementing multi-stator topologies. The use of multi-stator structures enables various topological configurations depending on (1) stator placement, (2) magnetization pattern of permanent magnets, and (3) rotor arrangement—each offering specific advantages. This study evaluates and analyzes the performance of different topologies based on efficient arrangements of magnets and stators, aiming to identify the optimal structure for duct fan applications. The validity of the proposed approach and design was verified through three-dimensional finite element analysis (FEA).