Geometry Optimize of Printed Circuit Board Stator
Winding in Coreless Axial Field Permanent Magnet
Motor
Xiaoyuan Wang
School of Electrical Engineering and Automation dept.
Tianjin University
Tianjin, China
xywang62@tju.edu.cn
Abstract—Axial Field Permanent Magnet Motor (AFPM) can
be easily integrated into wheel-hub motor of Electrical Vehicle
(EV) as impact structure and light weight. Improved hexagonal
asymmetry coil is presented in Printed Circuit Board (PCB)
stator of coreless AFPM. Geometry parameters of coil shape is
optimized. According to the structure characteristics of coreless
AFPM, dimension formulas of PCB coil are derived. Analytical
calculation models of back-EMF and winding co-efficiency are
built up. To maximize ratio of torque to copper loss, coil
parameters such as radial length, inclined angle of active
conductors etc. are optimized. Finally comparison and
verification are performed by means of 3D finite element method
and prototype test. The ratio of torque to copper loss is increased
30%. As a result, motor rated torque is also increased at certain
motor size, heating load and dissipation condition.
Keywords—Axial Field Permanent Magnet Motor (AFPM);
PCB coil; coil shape optimization; winding coefficient; ratio of
torque to copper loss;
I. INTRODUCTION
There are many advantages of coreless Axial Field
Permanent Magnet Motor (AFPM), such as compactness
structure, higher power density, no reluctance torque, stable
low-speed operation, low vibration noise and so on. Nowadays,
it is widely used in several applications as EV, aerospace craft,
wind power generation, hand held tooling, etc. [1] Jacek F.
Gieras and some others firstly applied Halbach type permanent
magnet array in the coreless AFPM. By that means, with same
volume of permanent magnet, peak value of air-gap flux
density was raised and harmonic were reduced. Meanwhile
coreless stator which is poured by epoxy resin and coreless
rotor improved motor efficiency and power density [2].
For coreless AFPM, the most critical technology is the
manufacture of coreless disc armature. There are plenty of
researching result about it. In article [3] it’s summarized seven
steps about manufacturing process of coreless disc armature,
including coil, shaping, installing, bundling, demolding,
pouring, and cleaning. With higher cost and lower productivity,
the winding process is immature and complex. Dimension and
axial runout accuracy is hardly to be guaranteed.
978-1-5090-3528-1/16/$31.00 ©2016 IEEE
Chunpeng Li, Fei Lou
School of Electrical Engineering and Automation dept.
Tianjin University
Tianjin, China
livaroc@hotmail.com
Using PCB technology in coreless disc armature could
avoid the weakness of the traditional coil winding, stabilize the
process and increase convenience of manufacture and design
flexibility. PCB winding motor is utilized in micro disc motor
firstly, for instance, the spindle motor for hard disk, the
flywheel motor for satellite, etc., in which there are rigorous
requirements to motor efficiency, size and weight. [4-5]
Scholars from Korea analyzed advantages and disadvantages of
different layout types for PCB coil in coreless AFPM by
considering about features of PCB process [7]. Rhomboid
concentric PCB winding was designed in coreless AFPM in
article [8], by which reduces copper loss and get sinusoidal
back-EMF. In article [9] by optimization of circumferential
distribution of PCB coil in coreless AFPM, sinusoidal back-
EMF was obtained finally. In article [10] based on the
geometrical analysis about PCB coil systematically, design
process of coreless AFPM with PCB coil was raised out.
However, analytical methods of PCB coil geometry
parameters and winding coefficient design are rarely discussed
in previous researching. In this article, a 400W coreless AFPM
with PCB stator is designed, analytical calculation methods are
carried out to optimize PCB coil geometric dimensions to
obtain maximum ratio of torque to copper loss. Hexagon
concentric PCB coil is designed, dimension formulas of PCB
coil are derived, and analytical calculation models of back-
EMF and winding co-efficiency are built up. After
optimization, copper loss is obviously reduced and torque is
enhanced with sinusoidal back-EMF. Finally, verification
performed by 3D finite element method confirm optimization
result which can be engineering reference.
II. STRUCTURE OF CORELESS AFPM
The coreless AFPM analyzed in this article is designed in
line with a structure of dual-rotors and single stator. There are
single coreless PCB stator which laid on the motor axial central
plane, two axial symmetric sets of magnet steel plates, as called
dual-rotors, as well as non-magnet rotor sustaining construction
with high mechanical strength. Armature winding is made by
PCB manufacturing process, which is fixed on the motor
enclosure after parallel assembling and connecting with several
single PCB windings. Halbach permanent magnet structure is
applied for rotor magnet array. It can enhance sinusoidal flux in
air gap, reduce flux in yoke. Magnetizing direction and main
flux path for permanent magnet are showed in Fig. 1.
Φ
Fig. 1. Cross-section of Coreless AFPM with Halbach array
III. DESIGN AND ANALYSIS OF PCB COIL
PCB winding utilized for coreless AFPM is laminated by
several copper foil and isolation fiberglass and epoxy resin
material, can produce the compacted plate winding for small
space, mechanical robustness, and high reliability required
conditions [11]. The coreless structure without teeth and slots
can eliminate cogging torque, core loss or electromagnetic
force between stators and rotors. Applying PCB winding can
improve accuracy of winding shape and location, make it easier
to manufacture than traditional wire-wound winding poured by
epoxy resin, and get better process consistency. Main
characteristics of PCB winding are described as below:
1) Flexibility and convenience winding design. Whether
changing ratio of pole to slot, or the coil shape, it is easy to
change in the professional circuit design software.
2) Conductor width could be changed flexibly. Distance
between adjacent conductors is constrained according to PCB
process, however conductor width can be changed much more
flexible than traditional magnet wire.
3) Coil shape can be accurately designed. Precious coil
shape optimization can be performed to fine-tune wire-
resistance and flux linkage.
4) PCB manufacturing process is stable and reliable. High
consistency improves stator productivity and avoids defect
from traditional wound-wire manufacturing process.
5) PCB stators could achieved model design. It is easy for
serial or parallel connection, so as to extend the motor rated
characteristics, such as voltage, current, torque, power etc.
6) Better dissipation performance. The filling material are
fiberglass and epoxy resin, comparing to air, which has better
dissipation performance.
PCB coil design
To improve EV propulsion, motor torque and power
density are main design target. In this article, several geometry
parameters of PCB coil are analyzed and optimized. A non-
overlap concentric winding used on PCB armature winding is
introduced. Every ending of coil dose not coincide. The coil
and pole number should follow (1).
Nc
= 3k
GCD( N c , N m )
Where Nc is coil number, Nm is pole number, k is a integer,
GCD is the greatest common divisor between Nc and Nm.
Supposing motor pole number is 16, according to (1), when set
k to 1, it is easy to know coil number is 12. So mechanical
angle θm and electrical degree θe between adjacent coil are 30°
and 240°. Triple phases are connected with Y type connection.
Every PCB coil is consisted by four segments, in which two
are coil endings, located on both inner and outer radius; the
other two are active conductors, of which adjacent conductors
are parallel, and approximately align with axial direction.
Radial projection of active conductor generates effective
torque, but the coil ending only generates copper loss so as to
reduce motor efficiency, contribute nothing to torque. [12]
To improve PCB space utility ratio, usually, trapezoid
shape coil is applied for coreless AFPM stator. Space on board
can be utilized sufficiently by trapezoid coil design, which also
can maximum the coil area, therefore, get fully linkage to rotor
flux. But trapezoid coil ending are longer, especially on outer
radius, which will increase copper loss obviously, hence bring
negative effect on motor efficiency. By inclining active
conductors of trapezoid winding to a fixed angle on certain
point, winding shape is changed into hexagon. By this means,
although flux linkage of winding decreases a little, copper loss
is reduced obviously since winding length is reduced on coil
endings. So the motor efficiency is improved.
Geometry parameter of hexagon PCB coil as shown in Fig.
2. Where α is the angle between active conductors of coil and
circumference on mean radius, β is electricity angle on inclined
part of active conductor, b is the conductor width of PCB coil,
dmin is the distance between adjacent conductors.
β
b
dq
α
gi li
Dav
dmin
Fig. 2. Geometry parameter of hexagon PCB coil
Firstly, copper thickness w should be as much as possible,
but common value of it is from 1oz to 3oz, limited by current
manufacturing level. So 3oz is selected which is 0.106mm.
Secondly, normal distance dmin should be as little as possible,
but limited by several factors. dmin is setup to 0.2mm, due to
insurance about the electrical strength between coil and the
stability for manufacturing process based on fixed copper
thickness. Thirdly, coil circumference distance gi is restricted
by coil number, as in this article [11] group of coil is supposed.
So every coil occupy around 30° mechanical angle, even in fact
it is a little bit less for the purpose of ensuring enough
(1)
insolation distance. In addition, coil length li along radial
direction and mean diameter Dav are defined by inner and outer
diameter of permanent magnet. Finally, choosing of reasonable is coupled by hexagon winding. The fundamental amplitude of
conductor width should not only ensure sufficient turns of coil flux linkage coupled by single turn coil is equal to:
to generate back-EMF high enough, but also enlarge conductor li tan α / 2 x / tan α  2π 
section area as much as possible for reasonable current loading, ϕi = 4   Bz1 sin  x dzdx
power output and well heating dissipation.  0 0  τ  (9)
Considering about the triple phases coil number is limited  2π  
gi / 2

by the perimeter on mean radius, conductor width b is related +  Bz1 sin  x li dx 
by p and q, as li tan α / 2  τ  

πDav Therein, gi is circumference width for one single coil turn,

b= sin α − d min (4)
 πD 
6 pq g i = 2 av − d q * (i − 1) (10)
Active conductor inclined angle α is equal to:  Nc 
Then the flux linkage coupled by every phase winding φ is
 p (1 − k d ) 
α = arc tan   (5) equal to:
 β (1 + k d )  Nt
ϕ = 4 N l ⋅ q  ϕi (α ) (11)
Where, p is pole pair number of motor, kd is the ratio of i =1
inner diameter to outer diameter, which is kd=Dout /Din.
Where, Nl is layer of PCB armature. For increasing the
Put (5) into (4), conductor width for PCB coil is: back-EMF at low speed, winding on every layers are connected
in serial. Back-EMF can be calculated according to (12).
πDav   p(1 − k d )  
b( p , q ) =
Nt
sin arctan   − d min

(6)
E = 4 2 fS c N l ⋅ q ⋅ p  ϕi (α )
 β (1 + k d )  
3 pq (12)
 i =1
The bigger p and q are, the smaller conductor width b is Therein, Sc is winding coefficient overall considered about
and the bigger winding resistance is. coil length, shape, etc. Sc can be calculated as the product of
In summary, PCB coil design parameter shows as Table I. circumference distribution coefficient Sd, radial distribution
coefficient Sr and short distance coefficient Sp. Because of the
integer distance design in this article, short distance coefficient
TABLE I. PCB WINDING COIL DESIGNING PARAMETER is approximated as 1. Due to discreteness character of PCB
winding, the winding coefficient is equal to:
designing parameter symbol value
1 N
Copper layer thickness w 0.106mm Sc =  Sd (n)Sr (n) cos γ n
N n =1
(13)
Conductor distance dmin 0.2mm
Coil circumference distance gi 30° Angle γn is between No. n coil and radial direction. Then
Coil length along radial direction li 76mm circumference distribution coefficient Sd and radial distribution
coefficient Sr are:
Mean diameter Dav 142mm
360 n(d min + b) (14)
Conductor width b 1.2mm S d ( n) = 1 − ⋅
π g i rin
Back EMF analysis
2n( d min + b) (15)
Halbach structure of permanent magnet array is applied on Sr (n) = 1 −
coreless AFPM in this article. So air-gap flux density shows rout − rin
excellent sinusoidal distribution. Actual air-gap flux density So that, single winding coefficient for each coil calculated
can be approximated by the air-gap flux density Bav(Dav,θ) on analytically as shown in Fig. 3. The coil winding coefficient Sc
mean radius position[13]. The fundamental amplitude is 0.36.
projected on axial direction Bz in coreless AFPM is equal to:
Winding co-efficiency

 sin(π nM ) 1 
Bz = Br [1 − e − βhM ] cosh(βz ) sin(βx)
 π nM cosh(βg / 2) 
(8)
Where, Br is residual flux density, hM is magnet thickness
on single side, nM is magnet number for each pair of poles, and
nM =8. β=2π/τ, in which τ=πDav/p is pole arc length on mean
radius position. g is equivalent air-gap length, which is sum of
air-gap length of both sides and the stator plate thickness. Coil turn Number
Back-EMF calculation needs calculating flux linkage which Fig. 3. Coil winding coefficient for each turn
Ratio of torque to copper loss analysis So phase resistance is equal to,
Nt
For winding shape optimizing, optimized target [17] is 1
proposed below: R ph = 4 N l qρ
btc
l
i =1
i (25)
kT I d k
kp = = T (16)
I d R ph R ph IV. FINITE ELEMENT SIMULATION
This optimized target involves both torque constant kT and Air-gap magnet field on PCB stator AFPM is a kind of 3D
phase resistance Rph. When numerator and denominator magnet field. It requires applying finite element method to
simultaneously multiply by the current effective value in (16), build 3D model in order to high accuracy 3D analysis. Main
kp will be changed into the ratio between motor torque and parameters are showed in Table II. Due to symmetry structure
square root to single phase copper loss. In coreless AFPM, the of magnet path, 1/4 model is sufficient to simulation. For
heating of motor is almost all contributed by stator copper loss. simplifying the simulation model for coils, the PCB coil
kp presents the generated torque per unit copper loss. For structure of multi-layer can be considered as single layer, with
certain size, heating loading and heating dissipation condition, thickness lumping of all parallel circuit branches, and without
the bigger kp is, the higher the desired motor rated torque is. considering the distance between layers, as showed in Fig. 4.
Torque of AFPM motor is calculated as [15]:
TABLE II. MAIN PARAMETER FOR PROTOTYPE
m
Td = pNk tφm I (17)
Design parameter Symbol Value
2
Power(W) Pout 400
Where, kt is synthesis coefficient for motor winding ， Rotation speed(r/min) n 375
which decided by actual distribution of air-gap flux density and Pole pair number p 8
winding geometry shape [16].
Magnet inner diameter (mm) Din 104
kt = k w1 ⋅ k3 D ⋅ ki (18)
Magnet outer diameter (mm) Dout 180
In the formula, k3D is air-gap flux density coefficient, with PCB layer number NB 4
considering about flux leakage and edge effect for permanent Stator coil number Q 12
magnet edging, ki is coil inclined coefficient. PCB coil number per layer Nt 10
sin β Coil number per phase Np 640
ki = (19)
β Stator thickness (mm) Hst 6.3
Air gap length (mm) g 8
Summarize (11), (17), (18) and (19), motor torque is: Single border permanent magnet
Nt hM 6
m thickness(mm)
Td = pk w1k3 D ki N l q  φi I = kT I (20)
2 i =1
3D distribution for air-gap flux density under a pair of poles
Therein, torque coefficient is, is as Fig. 5 showed. The distribution along axial direction is flat
n
m wave and related to radius, which amplitude is the biggest and
kT = pk w1k3 D ki N l q  φi (21) flat near average radius. But it decreases near inner and outer
2 i =1 diameter due to edge effect. Air gap flux density shows sine
Phase resistance calculation formula of AFPM is as below: distribution through circumference direction.
Nt
R ph = 4 N l q  Ri (22)
i =1

Where, Ri is the No. i coil resistance:

li
Ri = ρ (23)
bt c
Therein, ρ is copper resistivity, tc is thickness for copper
conductor, li is length of No. i coil. The length of conductor is
related with inclined angle of active conductor. Fig. 4. 3D finite simulation model on coreless AFPM motor
D (1 − k d ) / 2 + 2(i − 1)(b + d min )
li = out
sin α (24)
( 4π / 3 − 2 β ) 720(i − 1)(b + d min )
+ Dav −
p π

Circumference position/° Radial length/mm
Fig. 5. 3D surface picture on motor air gap magnet density
Back EMF of AFPM with PCB stator winding is analyzed
by both analytical calculation and finite element simulation.
Results are almost same between both ways. Voltage amplitude
for finite simulation is 60V, while for analytical method it is
59.5V. The peak tolerance is around 0.5V, which is sufficient
for design requirement. The reason why amplitude of finite
simulation is bigger than of analytical method, is ignorance
about edge effect and magnet loss, etc.
V. PCB WINDING OPTIMIZATION
Edge effect
For improving motor torque per unit copper loss, the coil
must be designed to couple rotor flux linkage as much as
possible. As the increasing of active conductor length through
radial direction, coil can couple rotor flux even at the edge of
permanent magnet so as to increase flux linkage, but in the
meanwhile, it will lead to increase of end-turn length.
Fig. 6 shows magnet flux density distribution on the edge
of permanent magnet. The minimum coil size Romin and Rimin is
defined when radial length is as same as which of permanent
magnet. And maximum coil radial length is defined as Romin
and Rimin with considering about edge effect. By setting
equivalent to the length of permanent magnet as reference, coil
radial length is changed symmetry. Increase of radial length
can increase the coil radial distribution coefficient, and partly
eliminate the negative effect of coil overall length increasing.
Then finite simulation result on copper loss as shown in Fig. 7.
From which it can be derived that, when the coil radial length
increases 50%, ratio of torque to copper loss kp is improved
21%, and the analytical coil coefficient calculated is raised to
0.44, while flux leakage decrease 22%.
Fig. 6. Flux density distribution
Δkp/%
Coil radial length/mm
Fig. 7. Affect of Coil Radial Length to kp
Incline of Active Conductor
Coreless PCB coil is unconstrained by slots, and flexible on
shape design. Trapezoid coil can increase flux linkage while
enlarge the ending length. Diamond coil can considerably
reduce the ending length, but reduce flux linkage also, so as to
sacrifice torque. Incline active conductor of hexagon PCB coil
reasonably to a certain electricity angle which change from 0°
to 60° can find balance between. When β=0°, winding shape is
trapezoid, when β=60°, it will change into diamond coil.
Referring to trapezoid coil, both analytical method and
finite element method are proposed to analysis the relationship
between conductor inclined angle β and kp, as shown in Fig. 8.
110 FE method
Analytical
100
90
Δkp/%
80
70
60
0 10 20 30 40 50 60
Incline Angle β/〫
Fig. 8. Relationship of β to kp by both analytical and FE method
The peak value of kp appears at around 20° as incline angle
changing from 0° to 60°. That is because copper loss decrease
quicker than electromagnet torque in 0°<β<20°. Comparing
with trapezoid winding, the coil resistance reduces 16%, and
the ratio of torque to copper loss increases 10% when β is
around 20°.
VI. PROTOTYPE MOTOR TEST
To verify analysis result, a prototype motor is manufactured
with design parameters in table II. Prototype and test system
are showed in Fig. 9 and Fig. 10. Actual back-EMF is
measured. It is clear to find that is sinusoidal, as shown in Fig.
11. Prototype can meet design requirements.

Fig. 9. PCB stator and Prototype Motor
Fig. 10. Experiment Setup
Fig. 11. Back EMF wareform
VII. CONCLUSION
In this article, a structure with dual-rotors and single stator
on PCB stator AFPM is proposed. 45° Halbach permanent
magnet array is applied on rotor to obtain sinusoidal air-gap
flux density wave. PCB winding is used instead of traditional
coil winding poured by epoxy to get better manufacturability.
An improved hexagonal asymmetry coil and corresponding
optimizing analytical method are carried out. According to the
structure characteristics of coreless AFPM, dimension formulas
of PCB coil are derived, meanwhile analytical calculation
models of back-EMF and winding co-efficiency are built up.
By reasonably setting coil radial length and inclined angle of
active conductors, to maximize ratio of torque to copper loss,
winding coefficient, coil ending length and copper loss are
optimized. Winding coefficient is improved 22% and ratio of
torque to copper loss kp is improved 21% when the coil radial
length increases 50%. Furthermore, coil resistance reduces
16% and ratio of torque to copper loss increases 10% by
inclining active conductor angle β to 20°. Analytical result is
verified by finite element method and lab test. Motor torque
characteristics is obviously improved. Higher torque and power
density would bring more benefits for EV application.
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