Losses and Thermal Analysis of an Integrated PCB Coreless Axial Flux PMSM with the Drive System

In this article, an integrated coreless axial-flux permanent-magnet synchronous machine (AFPMSM) system is integrated with winding and drive/control circuits on a same printed circuit board (PCB) stator. The losses and thermal problems of winding and drive/control circuits are very important for the safe operation of the integrated PCB coreless AFPMSM system. First, the losses of each part of the integrated AFPMSM system are analyzed, including stator and rotor losses, drive controller losses and mechanical losses. Then, the thermal simulation model is established to evaluate the thermal characteristics. Furtherly, the losses and thermal performances are improved by redesigning the permanent-magnet pole-arc coefficient, the shape of winding and the circuit arrangement. Finally, two integrated PCB coreless AFPMSM system prototypes before and after improvement are manufactured and tested to validate the analysis results.