1 Axial Flux Coreless Technology Technology Description Axial Flux Coreless Technology

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Axial Flux Coreless TechnologyT

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Axial Flux Coreless Technology

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Background:Electric MachinesElectric Machines

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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Des

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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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Driven(Driving)System

Driven(Driving)System

ElectricMachine

Ele

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Same Volumes

Volume1 Volume2 = 1.63 Volume 1

… Disk-shaped ?

system with CYLINDRICALSystem with DISK-SHAPED

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tion 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 Coreless Technology

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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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Permanent MagnetNd FeB or Ferrite

Winding

Yoke

Modularity - Modularity - Example of 3-Module StructureExample of 3-Module Structure

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Principle Features and Advantages

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FeaturesFeatures

Axial direction of magnetic flux and radial direction of electric currents

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

Axial direction of magnetic flux and radial direction of electric currents

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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Des

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tion 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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ImplementationsImplementations

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

Documents

1 Axial Flux Coreless Technology Technology Description Axial Flux Coreless Technology