Design for Loss Reduction in a Compact AFPM Electric Water Pump with a PCB Motor

Do-Hyeon Choi, Hyung-Sub Han, Min-Ki Hong, Dong-Hoon Jung and Won-Ho Kim ()
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Do-Hyeon Choi: Next Generation Energy System Convergence, Gachon University, Seongnam 13120, Republic of Korea
Hyung-Sub Han: Next Generation Energy System Convergence, Gachon University, Seongnam 13120, Republic of Korea
Min-Ki Hong: Electrical Engineering, Hanyang University, Seoul 04763, Republic of Korea
Dong-Hoon Jung: Advanced Materials & Electrical Engineering, Geongguk National University, Andong 36729, Republic of Korea
Won-Ho Kim: Electrical Engineering, Gachon University, Seongnam 13120, Republic of Korea

Energies, 2025, vol. 18, issue 10, 1-20

Abstract: A PCB stator axial flux permanent magnet (AFPM) motor is presented that overcomes the manufacturing challenges associated with the complex geometry of conventional stators by employing a PCB substrate. Traditionally, AFPM motors are produced by winding coils around the stator teeth, a process that requires specialized winding machinery and is both labor intensive and time consuming, ultimately incurring considerable manufacturing costs and delays. In contrast, PCB substrates offer significant advantages in manufacturability and mass production, effectively resolving these issues. Furthermore, the primary material used in PCB substrates, FR-4, exhibits a permeability similar to that of air, resulting in negligible electromagnetic cogging torque. Cogging torque arises from the attraction between permanent magnets and stator teeth, creating forces that interfere with motor rotation and generate unwanted vibration, noise, and potential mechanical collisions between the rotor and stator. In the PCB stator design, the conventional PCB circuit pattern is replaced by the motor’s coil configuration, and the absence of stator teeth eliminates these interference issues. Consequently, a slotless motor configuration with minimal vibration and noise is achieved. The PCB AFPM motor has been applied to a vehicle-mounted electric water pump (EWP), where mass production and space efficiency are critical. In an EWP, which integrates the impeller with the motor, it is essential that vibrations are minimized since excessive vibration could compromise impeller operation and, due to fluid resistance, require high power input. Moreover, the AFPM configuration facilitates higher torque generation compared to a conventional radial flux permanent magnet synchronous motor (RFPM). In a slotless AFPM motor, the absence of stator teeth prevents core flux saturation, thereby further enhancing torque performance. AC losses occur in the conductors as a result of the magnetic flux produced by the permanent magnets, and similar losses arise within the PCB circuits. Therefore, an optimized PCB circuit design is essential to reduce these losses. The Constant Trace Conductor (CTC) PCB circuit design process is proposed as a viable solution to mitigate AC losses. A 3D finite element analysis (3D FEA) model was developed, analyzed, fabricated, and validated to verify the proposed solution.

Keywords: axial flux permanent magnet motor (AFPM); AC loss; electric water pump (EWP); PCB stator; PCB motor; slotless motor (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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