A coreless motor Saurabh Kumar,12304EN004 M.Tech(MD) Sem-2,IIT BHU.

Iron loss due to ferromagnetic core. Torque pulsations due to non uniform magnetic field.

Moderate efficiency ( 70-80 %).

Low power density ( 131W/kg in IM and 222W/kg in SM)

 PM motors has core accompanying the armature which

encounter a very high frequency flux cutting (frequency proportional to speed of motor), causing high eddy current loss . (as in PMDC). P= kf2 ( f=NP/120).

The maximum flux density encountered is around 0.6 T

which is not sufficient to create a high power density machine.

YES, we can do this with the help of Halbach array

 A Halbach array is a special arrangement of permanent magnets

that augments the magnetic field on one side of the array while cancelling the field to near zero on the other side.

Fig1: Basic Process of Halbach Array generation.

Fig2: Flux density plot of NdFeB- (52MGOe) magnet

 For rotary disc machine applications, this array can be

made in a circular form as shown below:

F ig3: Linear array

Fig4: Circular disc array

The field decreases somewhat where the ends of the magnet

array join on itself, but this decrease is not more than 5%.

 The peak value of the magnetic flux density at the active

surface of Halbach array is given by :

For example: taking a medium grade NdFeB magnet ( Br= 1.25T, =262, nM=4, hM=0.006m, we get Bmo = 0.9T which is sufficient for a high power density machine.

Fig5: Exploded view of disc type PMBM

Fig6: Multidisc configuration

 The tangential torque developed can be given by the

following equation:

There is a flexibility in controlling maximum possible torque

by controlling Dout and Din. However there is a mechanical limit up to which Dout can be increased. In this case we can go for multidisc arrangement.

Fig7: Speed torque characteristics similar to sync. motor

 Operation wise it is similar to sync. Motor, so speed

below base speed is achieved by frequency control. Speed above the base speed can be achieved by flux weakening. Halbach discs give a static field. However discs can be nested, and by rotating one disc relative to the other, cancellation of the field and adjustment of the direction can be achieved. As the outside field of a disc is quite low, the relative rotation does not require big forces.

Fig8: Efficiency and PF as function of current

%=92.5,p.f.=0.94 (at rated current)

 Power density is 82% higher (444.25 W/kg versus 243.55

W/kg)

 High efficiency coreless disc-type PMBMs are excellent

machines for application where efficiency is the primary demand and high power density is required.

Some applications are:

Airborne apparatus (lightweight construction), solar powered vehicles, solar powered boats or even solar powered aircrafts. Single disk motors are used for servo drive systems.

 Some torque pulsations due to quasi sinusoidal flux very

near to the array.

Fig9: Magnet Arc Shaping

Magnet Arc Shaping Technique (MAST) can be applied to solve the above-mentioned problem. In this technique, the Laplaces equation is used to determine the magnet shapes for producing the required flux distributions.

 The experimental results, analysis and the FEM simulation

show the advantages of coreless disk type PMBMs in terms of performance and mass of active materials. A 10 kW coreless motor is about 45% lighter and has 82% higher power density than its laminated counterpart. Owing to lack of ferromagnetic cores, the hysteresis and eddy current losses do not exist. High cost of manufacturing limits commercial applications of coreless PMBMs to small size machines, special servo drives, airborne apparatus (lightweight construction) and drives where ripple free torque application is required.

The high cost of manufacturing is temporarily against the mass production of coreless motors.

[1.] J. C. Mallinson, One-sided Fluxes - A Magnetic Curiosity?, IEEE TRANSACTIONS ON MAGNETICS, VOL. MAG-9, NO. 4, DECEMBER 1973, PP. 678-682. [2.] Richard F Post, Hallback Array DC Motor/ Generator, Patent U. S. 5705902, Jan 6, 1998. [3.] Jacek F. Gieras Advancements in Electrical Machinery, 1st ed., Springer, Illinois, 2008. [4.]Jacek F. Gieras, Performance Analysis of a Coreless Permanent Magnet Brushless Motor Industry Applications Conference ,VOL 4., OCTOBER 2002, PP. 2477-2482. [5.] Jae-Seok Choi and Jeonghoon Yoo, Design of a Halbach Magnet Array Based on Optimization Techniques, IEEE TRANSACTIONS ON MAGNETICS, VOL.44, NO. 10, OCTOBER 2008, PP. 2361-2366. [6.]Min-Fu Hsieh and Yu-Sheng Hsu, An Investigation on Influence of Magnet Arc Shaping Upon Back Electromotive Force Waveforms for Design of PermanentMagnet Brushless Motors, IEEE TRANSACTIONS ON MAGNETICS, VOL.41, NO. 10, OCTOBER 2005, PP. 3949-3951. [7.] Video, Helios aircraft( NASA), http://www.youtube.com/watch?v=TlFlRURUW3k