Study of Characteristics of Various Structures

in Axial-gap PM Motors
Yusuke Okumura, Masayuki Sanada, Shigeo Morimoto, and Yukinori Inoue
Osaka Prefecture University, 1-1 Gakuen-cho, Naka-ku, Sakai, Osaka, Japan

Abstract—High output power and small size are required In this paper, four different types of axial-gap motors
for motors intended for vehicle drive applications. are examined to find the motor with thin shape, high
Therefore, permanent magnet synchronous motors output power, and high efficiency. These axial-gap
(PMSMs) are the current standard for EV/HEV drives. motors are investigated using the same dimensions. In
There are two types of PMSMs: axial-gap motors and considering the axial-gap motor, a 2-D finite element
radial-gap motors. Axial-gap motors have their air gap in
the axial direction and the coil end in the radial direction.
(FE) model is used.
Hence, the axial-gap motor is suitable for thin motors. In Furthermore, two types of radial-gap motors with the
this paper, four types of axial-gap motors and two types of same dimensions (including its coil end) are examined
radial-gap motors of the same size (including the coil end) and compared with the axial-gap motors. Finally, the
are examined to find the motor with thin shape, high output characteristics of the axial-gap motors and radial-gap
power, and high efficiency. motors are shown, and the usefulness of the axial-gap
Based on the results, the axial-gap motor with a motor for vehicle drive applications is discussed.
concentrated winding stator and surface permanent magnet
(SPM) rotor has the highest efficiency of the four axial-gap II. ANALYSIS MODEL OF AXIAL-GAP MOTOR
models. However, in comparison with radial-gap motors,
the radial-gap motor with the concentrated winding stator A. Target Specifications and Motor Specifications
and SPM rotor has the largest maximum torque in the low-
The target specifications and motor specifications are
speed region. Also, the efficiency of the radial-gap motor is
high due to its small winding resistance.
shown in Tables I and II, respectively. In this paper, it is
assumed that the protrusion of the stator coil end is 10
Index Terms—PMSM, axial PM motor, radial PM motor, mm, regardless of whether it is a concentrated winding
minimum d-axis flux linkage stator or a distributed winding stator. Therefore, the outer
diameter of the axial-gap motor is actually 158 mm.
I. INTRODUCTION TABLE I
TARGET SPECIFICATIONS
From the standpoint of energy saving and realizing a
Item (Unit) Value
low-carbon society, low-emission vehicles such as
electric vehicles (EVs) and hybrid electric vehicles Maximum power (kW) 20
(HEVs) are now the focus of attention in the automotive Maximum torque (Nm) 34
industry. These low-pollution vehicles use electric motors Base speed (min-1) 5,600
combined with an internal combustion engine or to Maximum speed (min-1) 10,000
replace the internal combustion engine. Permanent TABLE II
magnet synchronous motors (PMSMs) are used for these MOTOR SPECIFICATIONS OF AXIAL-GAP MOTORS
vehicle drive applications. It is important that the motor is Item (Unit) Value
small in size and has high performance. Therefore, in Stator type
Concentrated Distributed
recent years, PMSMs for vehicle drive applications have winding winding
been investigated actively [1]-[3]. Stator diameter (mm) 138
There are two types of PMSMs: axial-gap motors and Motor thickness (mm) 65
radial-gap motors. Axial-gap motors have their air gap in Air gap length (mm) 1
the axial direction, and radial-gap motors have their air Thickness of PM (mm) 3
gap in the radial direction. In an axial-gap motor, it is Operation temperature (°C) 100
possible to shorten the motor thickness because its coil PM material NMX-S38EH
end does not exist in the axial direction. Moreover, there Coercive force of PM (kA/m) 850
are three types of axial-gap motors: the one-stator/one- Steel material 35H300
rotor type, the one-stator/two-rotor type, and the two- Space factor 0.4
stator/one-rotor type. Hence, the structure of the axial-gap Voltage constraint (V) 80.8
motor can be selected according to the application. Current density (A/mm2) 20
Among them, the one-rotor/two-stator type axial-gap Rated current (A) 240
motors are investigated to develop a thin shape motor for Armature winding (turns/phase) 32
vehicle drive applications [4]. Winding resistance
8.74 9.73
(at 100°C) (mΩ)
B. Method for Deriving Characteristics Average radius of each model
A 2-D FE model is used to analyze the axial-gap
motors. However, the 2-D FE model cannot be applied to
axial-gap motors directly because the magnetic path in
the axial-gap motor is three dimensional. Therefore, in (a) Inner equivalent model
this paper, equivalent models are used that divide the
axial-gap motor into three parts in the radial direction
[5],[6]. Cross-sectional views of the average radius of
each model are shown in Fig. 1.
Maximum output power control [7] is applied to derive (b) Center equivalent model (c) Outer equivalent model
Fig. 1. Three-fraction equivalent model of the axial-gap motor.
various characteristics. The iron loss and copper loss are
considered in the efficiency. The copper loss is caused by
the winding resistance, and the iron loss, which consists Teeth
of hysteresis loss and eddy current loss, is caused by the
magnetic loss in the steel core. The copper loss and iron
loss is calculated using equations (1) and (2),
Slot
Wc = 3Ra I e2 (1)
Wi = Whi + Wei (2) (a) Concentrated winding stator (b) Distributed winding stator
where Wc is the copper loss (W), Ra is the winding
resistance (Ω), Ie is the root mean square value of the Magnet
N N
phase current (A), Wi is the iron loss (W), Whi is the
hysteresis loss (W), and Wei is the eddy current loss (W). 34
Here, the iron loss is derived from flux density in each S S
element on the 2-D FE analysis considering high order
harmonics. (c) SPM rotor (d) Inset PM rotor
C. Analysis Model and Equivalent Model Fig. 2. Analysis models of axial-gap motor.

Fig. 2 shows the analysis models of the axial-gap

motor. The figures show one-fourth of the motor. All of
the models are eight-pole machines and two-stator/one- WU UV VW WU UV VW
rotor type axial flux designs. The center part of the
equivalent models for all of the models and their winding (a) Type AC1 (b) Type AC2
layouts are shown in Fig. 3. The models expressed in Fig.
3 are portion enclosed by the dashed line in Fig. 1.
A concentrated winding stator with 12 slots is used in U W V U W V U W V U W V
Type AC1 and AC2, and a distributed winding stator with V U W V U W V U W V U W
24 slots is used in Type AD1 and AD2. The thickness of
the back yoke is the same in both the concentrated (c) Type AD1 (d) Type AD2
winding stator and the distributed winding stator. The Fig. 3. Structures of equivalent models and winding layouts.
AC1 and AD1 models use the surface permanent magnet
(SPM) rotor structure, and the AC2 and AD2 models use 40
the inset PM rotor structure. The volume of the
permanent magnet is 33.3 cm3 in the SPM rotor and 27.7 35
cm3 in the inset PM rotor. Therefore, the amount of PM Target torque T=34Nm
in the inset PM rotor is 83.3% of that in the SPM rotor. 30
Here, the stator winding method of Type AD1 and
25
Torque T (Nm)

AD2 is distributed winding with short-pitch winding. By Concentrated

using a short-pitch winding, it is possible to reduce the 20
winding models
protrusion of the coil end in the distributed winding Distributed
winding models
model. 15 Type AC1
Type AC2
III. ANALYSIS RESULT OF AXIAL-GAP MOTOR 10
Type AD1
N=5600

Vam=80.8V
A. Torque Characteristics 5 Type AD2 Ie ≤ 240A
The torque-versus-speed curve is shown in Fig. 4, and
Table III shows a comparison of the typical properties of 0
each model. The ratio of magnet torque to reluctance 0 2000 4000 6000 8000 10000
torque at maximum torque is expressed in Fig. 5. The Speed N (min-1)
iron loss is considered in Fig. 4. From Fig. 4, all of the Fig. 4. Torque-speed characteristics.
 TABLE III
COMPARISON OF TYPICAL PROPERTIES OF ANALYSIS MODELS
Item (Unit) Type AC1 Type AC2 Type AD1 Type AD2
Stator type Concentrated winding Distributed winding
Rotor type SPM Inset PM SPM Inset PM
Maximum torque (Nm) 35.56 34.55 35.87 35.38
Current phase at maximum torque (deg.) 9 21.5 9.5 24
Torque (at 5,600min-1) (Nm) 35.22 34.19 35.50 35.00
Base speed (min-1) 5736 5617 6323 6299
Power (at 5,600min-1) (kW) 20.65 20.05 20.81 20.52
Power (at 10,000min-1) (kW) 24.25 22.16 28.03 27.19
Efficiency (at 5,600min-1) (%) 92.34 92.09 91.61 91.49
Efficiency (at 10,000min-1) (%) 93.98 94.09 93.41 93.34
PM flux linkage Ψa (Wb) 0.0210 0.0189 0.0212 0.0193
d-axis inductance Ld (at maximum torque) (mH) 0.0561 0.0585 0.0459 0.0471
q-axis inductance Lq (at maximum torque) (mH) 0.0657 0.0807 0.0552 0.0705
Minimum d-axis flux Ψdmin (mWb) -7.50 -10.35 -1.66 -3.33

models meet the target maximum torque. Type AD1

(with the distributed winding stator and SPM rotor) has 45
the largest maximum torque for the entire speed range. Reluctance torque Magnet torque
40
From Fig. 5, focusing on the ratio of the magnet torque 34.55 35.38
to reluctance torque for each model, most of the torque 35
component is magnet torque in Type AC1 and AD1. 5.22 5.99
30
From Table III, in comparing the armature flux linkage of
Torque T (Nm)

the permanent magnet Ψa, the models with a distributed 25

winding stator are larger than the models with a
20
concentrated winding stator. Thus, the magnet torque of
Type AD1 is higher than that of Type AC1. 15 35.56 29.32 35.87 29.39
On the other hand, Type AC2 and AD2 can use
reluctance torque in addition to magnet torque due to 10
their rotor saliency. Due to the use of reluctance torque in 5
the models with the inset PM rotor, the magnitude of the
total torque does not decrease significantly, even though 0
the amount of permanent magnet has decreased in the Type AC1 Type AC2 Type AD1 Type AD2
models with the inset PM rotor.
From Fig. 5, the reluctance torque of Type AC2 is less Fig. 5. Rate of torque of each model (at maximum torque).
than that of Type AD2 because the difference in d-axis
inductance and q-axis inductance in Type AD2 is larger 40
than that in Type AC2. Therefore, as radial-gap motors,
Type AC1
the reluctance torque of the axial-gap motor with the 35
Type AC2 Distributed
concentrated winding stator is reduced. winding models
30 Type AD1
B. Power Characteristics
Type AD2
Power P (kW)

Fig. 6 shows the power-versus-speed curve for each 25

model. Type AD1 has the largest output power in the
entire speed region because it produces the highest torque, 20
Target power Concentrated
as shown in Fig. 4. This model also obtains the largest P=20kW winding models
15
output power at 5,600 min-1. All of the models meet the
target output power of 20 kW from 5,600 min-1 to 10,000 10
min-1.
N=5600

From Table III, all of the models meet the target base Vam=80.8V
5
speed of 5,600 min-1. However, the base speed of the Ie ≤ 240A
concentrated winding models is less than that of the 0
distributed winding models. The concentrated winding 0 2000 4000 6000 8000 10000
models reach the voltage constraint earlier than the other Speed N (min-1)
models; this is because the inductance of the concentrated Fig. 6. Power-speed characteristics.
winding models is increased, and thus, the armature
reaction voltage is also increased.
 In general, wide constant-power operation is obtained between the models with the concentrated winding stator
when the minimum d-axis flux linkage Ψdmin is 0. From and the distributed winding stator, and the efficiency is
Table III, the model that has Ψdmin closest to zero is Type barely affected by the difference in the amount of iron
AD1. Therefore, Type AD1 has the widest constant- loss. Therefore, Type AC1 has the highest efficiency.
power characteristics of the examined models.
400
C. Motor Efficiency Type AC1 Distributed
350 winding models
The copper-loss-versus-speed and iron-loss-versus- Type AC2
speed relationships are shown in Figs. 7 and 8, 300 Type AD1
respectively. The flux density distribution of each model 250 Type AD2

Iron loss Wi (W)

is shown in Fig. 9.
From Fig. 7, the copper loss in the models with the 200 Vam=80.8V
concentrated winding stator is less than that of the models Ie ≤ 240A
150
with the distributed winding stator due to their low Concentrated
winding resistance. Some models have decreased copper 100 winding models

N=5600
loss in the high-speed region due to reducing the current
value by applying maximum torque/flux control. 50
As shown in Fig. 8, Type AD1 and AD2 (with the 0
distributed winding stator) have high iron loss. Here, the 0 2000 4000 6000 8000 10000
flux density in the back yoke of the models with the Speed N (min-1)
concentrated winding stator is almost the same as that of Fig. 8. Iron loss of each model.
the models with the distributed winding stator, as shown
2.0 1.5 1.0 0.5 0 (T)
in Fig. 9. However, the flux density in the teeth of the
models with the distributed winding stator is higher than
that of the models with the concentrated winding stator.
Therefore, lower iron loss is produced in models AC1
and AC2. On the other hand, in comparing the models
with the same stator, the iron loss is almost the same
among them, except in the high-speed region; this is
because the flux density in magnetic steel is decreased by
applying flux-weakening control. Especially in the high-
speed region, iron loss is different in each model because (a) Type AC1 (b) Type AC2
the operation point is different due to the application of
maximum torque/flux control.
Fig. 10 shows the efficiency-versus-speed curve of
each model. The efficiency was calculated using the
following equation:
ωT
η= × 100 (3)
ωT + Wc + Wi
where ω is the mechanical angular velocity (rad/s), T is (c) Type AD1 (d) Type AD2
the torque (Nm), and η is the efficiency (%). Fig. 9. Flux density distribution of each model (at maximum torque).
The copper loss dominates in the total loss due to the
high current density. Hence, even the iron loss is different 96
Vam=80.8V
1800 94
Ie ≤ 240A
1600 92
1400 Concentrated Distributed
90
Copper loss Wc (W)

winding models winding models

Efficiency η (%)

1200 Distributed
winding models 88
1000 Concentrated
winding models
800 Type AC1 86 Type AC1
600 Type AC2 84 Type AC2
N=5600

N=5600

400 Type AD1 Vam=80.8V Type AD1

82
200 Type AD2 Ie ≤ 240A Type AD2
80
0
0 2000 4000 6000 8000 10000
0 2000 4000 6000 8000 10000 Speed N (min-1)
Speed N (min-1) Fig. 10. Efficiency-speed characteristics.
Fig. 7. Copper loss of each model.
 IV. COMPARISON WITH RADIAL-GAP MOTOR N N
Among the axial-gap motors in the previous discussion, Magnet
WU
Type AC1 shows superior efficiency. Here, two radial- U
gap motors are also examined and compared with Type V
S S
AC1 to find a motor structure suitable for thin motors. V
W
A. Analysis Model of Radial-gap Motor
(a) Stator (b) Rotor (Type RC1) (c) Rotor (Type RC2)
Fig. 11 shows the analysis models of the radial-gap
motor. Both models are eight-pole machines and use a Fig. 11. Analysis models of radial-gap motor.
concentrated winding stator with 12 slots. The amount of
magnet in each rotor is identical with the amount in the TABLE IV
DIMENSIONS AND WINDING SPECIFICATIONS
axial-gap motor. Here, the motor dimensions (including
Axial-gap Radial-gap
its coil end) of the radial-gap motor were set to be the Item (Unit)
motor (AC1) motor
same as those of the axial-gap motors discussed before by Motor core diameter (mm) 138 158
assuming that the protrusion of the coil end is 10 mm. Motor core thickness (mm) 65 45
Table IV shows the dimensions and winding Coil-end length (mm) 10
specifications of the axial-gap motor and the radial-gap Winding diameter (mm) 3.91
motor. Number of turns per slot 32 24
B. Comparison Results Winding resistance (mΩ) 8.74 7.26
The power-versus-speed curve is shown in Fig. 12.
Table V shows a comparison of the typical properties of
40
Type AC1, RC1, and RC2. Type RC1 has the largest
output power in the low-speed region because it produces 35
Type AC1
the highest torque, as shown in Table V. However, Type Type RC1
AC1 has the largest torque and output power in the high- 30
Axial gap type
speed region. At 10,000 min-1, the output of Type AC1 is Type RC2
more than 2.7% higher than that of Type RC1. Here, the 25
Power P (kW)

model with the Ψdmin closest to zero is Type AC1.

20
The copper loss and iron loss of each model are Target power
indicated in Figs. 13 and 14, respectively. The flux P=20kW Radial gap type
15
density distribution is shown in Fig. 15, and the
efficiency-versus-speed curve is shown in Fig. 16. 10
N=5600

From Fig. 13, the copper loss of the radial-gap models Vam=80.8V
is less than in Type AC1 because the winding resistance 5 Ie ≤ 240A
of radial-gap motors is low. From Fig. 14, Type RC2 has
0
the highest iron loss in the low-speed region. However, in
the high-speed region, Type AC1 has the highest iron loss. 0 2000 4000 6000 8000 10000
Speed N (min-1)
Fig. 12. Power-speed characteristics.

TABLE V
COMPARISON OF TYPICAL PROPERTIES OF ANALYSIS MODELS
Item (Unit) Type AC1 Type RC1 Type RC2
Motor structure Axial gap type Radial gap type
Stator type Concentrated winding
Rotor type SPM Inset PM
Maximum torque (Nm) 35.56 37.72 37.32
Current phase of maximum torque (deg.) 9 6 27
Torque (at 5,600min-1) (Nm) 35.22 36.82 35.37
Base speed (min-1) 5736 5210 5020
Power (at 5,600min-1) (kW) 20.65 21.59 20.74
Power (at 10,000min-1) (kW) 24.25 23.60 20.35
Efficiency (at 5,600min-1) (%) 92.34 93.85 93.54
Efficiency (at 10,000min-1) (%) 93.98 95.12 95.29
PM flux linkage Ψa (Wb) 0.0210 0.0225 0.0190
d-axis inductance Ld (at maximum torque) (mH) 0.0561 0.0647 0.0656
q-axis inductance Lq (at maximum torque) (mH) 0.0657 0.0718 0.0982
Minimum d-axis flux Ψdmin (mWb) -7.50 -8.79 -13.70
From Fig. 15, the magnetic flux density of Type AC1 is 1600
less than that of Type RC2 at maximum torque. However, 1400
Axial gap type
the magnetic density is high mainly in the stator, and the
1200
volume of the stator iron core in Type AC1 is larger than
1000

Copper loss Wc (W)

in radial-gap motors. Hence, from the relationship
between the magnetic flux density and the iron core 800
volume, the iron loss of the axial-gap motor is larger than Radial gap type
600 Type AC1
that of the radial-gap motors in the high-speed region.
400 Type RC1

N=5600
As shown in Fig. 16, radial-gap motors are high Vam=80.8V
efficiency in the entire speed range. The efficiency of 200 Type RC2 Ie ≤ 240A
Type RC1 is slightly higher than that of Type RC2 in 0
most of the speed range. This is the reason why the iron 0 2000 4000 6000 8000 10000
loss of Type RC1 is lower than that of Type RC2. Speed N (min-1)
Fig. 13. Copper loss of each model.
V. CONCLUSIONS
250
Four kinds of axial-gap motors were examined, and Type AC1 Axial gap type
their torque, power, and efficiency performance were 200 Type RC1
discussed. As a result, Type AC1, which combines the Type RC2
concentrated winding stator and the SPM rotor, has the

Iron loss Wi (W)

150
highest efficiency while satisfying the target
specifications. Radial gap type
100
In comparing radial-gap motors and axial-gap motors,

N=5600
Type RC1 has a higher efficiency than the axial-gap 50 Vam=80.8V
motors. However, in actuality, thick windings are Ie ≤ 240A
required under the high current density, so it is difficult to 0
keep the protrusion of the coil end within 10 mm, even in 0 2000 4000 6000 8000 10000
the concentrated winding stator. Therefore, it is Speed N (min-1)
considered that the axial-gap motor has an advantage in Fig. 14. Iron loss of each model.
cases where the motor thickness is shorter than
approximately 65 mm.
(T)
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