Asako Watanabe

Development and evaluation of an axial gap motor with neodymium bonded magnet

In general, radial gap motors employing neodymium sintered permanent magnet (Nd sintered PM) are used to achieve high torque density in many applications. However, the motors are not suited to a flat, disk-like shape because the dead space, such as the coil ends, occupies most of the motor volume. Therefore, axial gap motors are frequently used for flat shape instead of radial gap motors. Nd sintered PM is a well-known high-performance magnet that has high residual magnetic flux density, but eddy current loss easily occurs in the magnet because of its high conductivity. In axial gap motors for industrial applications, it is difficult to make measure against eddy current loss of Nd sintered PM in terms of cost. Therefore, general axial gap motors employing Nd sintered PM often have the unsatisfactory characteristics such as low efficiency, even though the motor produces high torque. Accordingly, this paper discusses an axial gap motor employing neodymium bonded permanent magnet (Nd bonded PM) for flat shape. Compared with Nd sintered PM, Nd bonded PM has lower residual magnetic flux density, but also lower cost. In addition, Nd bonded PM has extremely low eddy current loss due to its low conductivity. It is found from 3D-FEA and experimental results that the axial gap motor employing Nd bonded PM can achieve higher torque and higher efficiency compared with the radial gap motor employing Nd sintered PM with the same PM weight and a flat shape.

Development and Evaluation of an Axial Gap Motor Using Neodymium Bonded Magnet

In general, radial gap motors employing neodymium sintered permanent magnet (Nd sintered PM) are used to achieve high torque density in many applications. However, the motors are not suited to a flat, disk-like shape because the dead space, such as the coil ends, occupies most of the motor volume. Therefore, axial gap motors are frequently used for flat shape instead of radial gap motors. Nd sintered PM is a well-known high-performance magnet that has high residual magnetic flux density, but eddy current loss easily occurs in the magnet because of its high conductivity. In axial gap motors for industrial applications, it is difficult to take measures against eddy current loss of Nd sintered PM in terms of cost. Therefore, general axial gap motors employing Nd sintered PM often have unsatisfactory characteristics, such as low efficiency, even though the motor produces high torque. On the other hand, radial gap motors can take measures to suppress eddy current in PMs easily if radial gap motors employ interior permanent magnet structure. Accordingly, this paper discusses an axial gap motor employing neodymium bonded permanent magnet (Nd bonded PM) for flat shape. Compared with Nd sintered PM, Nd bonded PM has lower residual magnetic flux density, but also lower cost. In addition, Nd bonded PM has extremely low eddy current loss due to its low conductivity. It is found from three-dimensional finite element analysis and experimental results that the axial gap motor employing Nd bonded PM can achieve higher torque and higher efficiency compared with the radial gap motor employing Nd sintered PM with the same PM weight and a flat shape.

Pure-iron/iron-based-alloy hybrid soft magnetic powder cores compacted at ultra-high pressure

We developed Fe/FeSiAl soft magnetic powder cores (SMCs) for realizing the miniaturization and high efficiency of an electromagnetic conversion coil in the high-frequency range (∼20 kHz). We found that Fe/FeSiAl SMCs can be formed with a higher density under higher compaction pressure than pure-iron SMCs. These SMCs delivered a saturation magnetic flux density of 1.7 T and iron loss (W1/20k) of 158 kW/m3. The proposed SMCs exhibited similar excellent characteristics even in block shapes, which are closer to the product shapes.

Investigation of enhancing efficiency and acceleration in a flat shape axial gap motor having high torque characteristic

In recent years, flat shape motors are desired for many industrial applications such as robot arm, automobiles and so on. Thus, this paper discusses axial gap motors which have advantage for flat shape. In general, axial gap motors have high torque density with flat shape because of its wide air-gap area. Axial gap motors are therefore used for limited space like disk shape instead of radial gap motors which are the most general motor. However, compared with radial gap motors, the acceleration of axial gap motors is relatively lower because of the larger moment of inertia. In this paper, rotor structure to enhance the acceleration of axial gap motors is proposed and analyzed by 3D-FEA. In addition, material for permanent magnet of axial gap motors is properly selected in order to enhance efficiency at high speed and high torque area. Finally, prototypes of both axial and radial gap motor with flat shape are evaluated by some experiments. It is found that proposed axial gap motor can achieve the higher torque and efficiency compared with the radial gap motor with flat shape. Proposed axial gap motor additionally achieved the slightly larger acceleration compared with the radial gap motor.