IEEE TRANSACTIONS ON MAGNETICS, VOL. 42, NO.

10, OCTOBER 2006 3401

FE Analysis and Computer-Aided Design

of a Sandwiched Axial-Flux Permanent
Magnet Brushless DC Motor
Parag R. Upadhyay1;2 and K. R. Rajagopal2
Department of Electrical Engineering, Institute of Technology, Nirma University of Science and Technology,
Ahmedabad 382481, India
Electrical Engineering Department, Indian Institute of Technology Delhi, New Delhi 110016, India
In this paper, a comprehensive computer-aided design (CAD) procedure for an axial-flux permanent magnet brushless dc (PM BLDC)
motor having a stator sandwiched between two permanent magnet rotors is presented. The basic output equations are derived and used
for the design algorithm. The developed CAD program gives the design data and the calculated performances of the motor. The optimized
ratio of outer diameter to the inner diameter is used to derive the sizing equation. The design variables such as airgap flux density, slot
electric loading, winding factor, stacking factor, stator current density, slot space factor, magnet fraction, slot fraction, flux density in the
stator back iron, etc., are assumed. Three different motors or rating 70 W, 2.2 kW, and 20 kW are designed using the developed program,
and then three dimensional finite-element analyses are carried out to validate the designs.
Index Terms—Brushless motor, computer-aided design (CAD) of motor, finite-element (FE) analysis, motor, permanent magnet brush-
less dc (PM BLDC) motor, permanent magnet (PM) motor.

I. INTRODUCTION

P ERMANENT magnet brushless dc (PM BLDC) motors

are increasingly used in various domestic and industrial
applications. Among the various types of PM BLDC mo-
tors, the axial-flux PM BLDC motor with stator-sandwiched
topology as shown in Fig. 1 gives the advantages of adjustable
airgap, simpler stator winding, balanced rotor-stator attractive
forces, and better winding utilization. Performance equations
for torque, inductance, etc. of the PM BLDC motor are avail-
able in the literature [1], [2]. Development of a computer-aided Fig. 1. Three-dimensional finite-element model of an axial-flux PM BLDC
design (CAD) program for the design and performance eval- motor
uation of axial-flux surface-mounted PM BLDC motors is
attempted, and the details of the steps involved along with II. OUTPUT EQUATIONS OF AXIAL-FLUX PM BLDC MOTOR
a flowchart and recommendations are given in this paper.
Based on the expressions for the torque and back emf [1],
The design data of the motor obtained from this program, if
[2], the output equation for the axial-flux PM BLDC motor, is
needed, can be used as the input for further optimization of
derived as follows:
the designs using finite-element (FE) techniques. The design
algorithm includes a complete design procedure, data libraries
like standard wire gauge, magnetic material properties, etc.
and an interactive input and output facility. A 70-W, 350-rpm,
axial-flux PM BLDC motor is designed using the developed
program. The results are analyzed using a three-dimesional
(3-D) FE method, and the validity of the developed CAD pro-
gram is established. (1)

where is the rated power output, is the rated speed, is

motor developed torque, is the assumed efficiency of the motor,
and are the outer and inner radius of the stator respectively,
is the number of coils conducting simultaneously, is the
number of poles, is the number of slots/pole/phase, is
the winding factor, is specific magnetic loading, is number
of conductors per slot, is the ratio of outer diameter to inner
diameter of the stator, is phase current, and is specific slot
Digital Object Identifier 10.1109/TMAG.2006.879451 loading. Rather than taking the specific electric loading in PM
0018-9464/$20.00 © 2006 IEEE
3402 IEEE TRANSACTIONS ON MAGNETICS, VOL. 42, NO. 10, OCTOBER 2006

BLDC motors, a specific slot loading can be considered in the

design with advantage [1]. Equation (1) is the output equation,
and if the optimum value of [3] is taken as , then it can be
modified as given in (2) to determine the outer radius .

(2)

The outer radius depends on the torque developed by the

motor, specific magnetic loading, specific slot loading, and the
efficiency.

III. IMPORTANT DESIGN CONSIDERATIONS

The design of PM BLDC motors necessitates the selection of
a few general parameters such as: 1) number of phases; 2) slots/
pole/phase; 3) number of magnet poles; 4) PM material; 5) soft
magnetic material; 6) winding factors such as pitch factor, distri-
bution factor, and skew factor; 7) stacking factor; 8) slot space
factor; 9) current density; 10) specific magnetic loading; and
11) specific slot electric loading, which can be arrived at using
the results and interpretations given the literature [1], [2].
Nd–Fe–B and samarium cobalt permanent magnets are pre-
ferred because of their high energy-product BH and reten-
tivity B . The selection depends on the cost and the operating
temperature. The choice of soft magnetic material for stator and
rotor core depends on the frequency and operating flux den-
sity. The current density between 4–10 A/mm is generally rec-
ommended for PM motor windings [2], based on the cooling
method employed. The lower range is advisable for small and
totally enclosed motors. For high efficiency, still smaller current
densities can be used, but with higher size and cost for the motor. Fig. 2. Flowchart for CAD of PM BLDC motor
For the fixed main dimensions, with the increase in the number
of poles , either the width of magnet spacer or the magnet
program of the PM BLDC motor is a two-loop MATLAB pro-
fraction will decrease, which will result in decrease in specific
gram with different function calls. Motor specifications, type of
magnetic loading and thereby the developed torque also. The
configuration, material types, and other assumed data for the
end turn becomes shorter for higher , which reduces the
design are the input. The outer loop is to set and correct the
phase resistance, thereby increasing the efficiency. The leakage
assumed efficiency. Initially, the efficiency of the motor is as-
inductance for higher is less, but with increase in the drive
sumed as . The CAD program designs the motor and calcu-
frequency. Larger airgaps will result in reduced phase-induc-
lates the actual efficiency. The correction loop is active till the
tance, armature reaction effects, and also the cogging torque, but
error between the assumed efficiency and the actual efficiency
will necessitate bigger magnets, thereby increased cost. Gener-
is within the given limit, . The inner loop is for reducing the
ally for very small motors, an airgap of 0.125–0.25 mm is used.
difference between the assumed and actual airgap flux densi-
For medium-size motors, 0.375–0.5 mm and for higher rating
ties by changing the length of the magnet in a similar way.
motors, a 0.625– to 0.875-mm airgap is preferred [2]. Specific
The magnet length is increased till the error between the two is
magnetic loading depends on the type of configuration and per-
less than a given limit, . As given in the flowchart of the de-
manent magnet properties. The use of rare earth magnets may
veloped CAD program in Fig. 2, the calculation of the main di-
allow the value of to be as high as 0.9 T. Higher values of
mensions, stator design, permanent magnet rotor design, and the
specific slot electric loading leads to increase in copper loss,
performance calculations are the main four stages of the design.
but because of the reduction in the permanent magnet require-
The airgap flux density, slot electric loading, winding factor,
ment, reduces the overall cost. On the other hand, a low value
stacking factor, stator current density, slot space factor, magnet
of gives high efficiency, but necessitates a huge quantity of
fraction, slot fraction, flux density in the stator back iron, etc.,
permanent magnet material resulting in increased cost.
are assumed as fixed input parameters in the design. The phase
current is decided by the power requirement, and induced emf
IV. CAD OF SANDWICHED AXIAL-FLUX PM BLDC MOTORS decides the number conductors per slot.
The flowchart of the developed CAD program for the sand- Three motors with the following ratings were designed using
wiched axial-flux PM BLDC motor is given in Fig. 2. The CAD the developed CAD program: 24 V, 70 W, 350 rpm; 230 V,
UPADHYAY AND RAJAGOPAL: FE ANALYSIS AND CAD OF A SANDWICHED AXIAL-FLUX PM BLDC MOTOR
TABLE I
DESIGN OUTPUTS OF THE PM BLDC MOTORS OBTAINED
USING THE DEVELOPED CAD PROGRAM
Fig. 3. Three-dimensional flux density plot of an axial-flux PM BLDC motor
Fig. 4. Two-dimensional flux density plot of an axial-flux PM BLDC motor at
mean airgap
2.2 kW, 1450 rpm; 230 V, 20 kW, 1500 rpm. Important param-
eters and performance of the motors are given in Table I. It is
observed that: 1) the efficiency increases with the rating: 2) the
phase-inductance is more when the voltage is more; and 3) for
the same voltage, the phase-inductance decreases with increase
in the power rating. Figs. 3 and 4 respectively give the 3-D 2-D
flux density plots of the designed 70-W motor.
V. VALIDATION OF THE CAD RESULTS BY FE ANALYSIS
The accuracy of the developed CAD program is established
by conducting 3-D FE analyses of the designed motors with two
3403
TABLE II
COMPARISON OF CAD AND FE RESULTS FOR AN AXIAL-FIELD
PM BLDC MOTOR
Fig. 5. Torque-angle characteristics of designed 70-W PM BLDC motor
of the three phases excited at a time with rated current fed to the
phase windings.
A comparison of CAD and FE results is given in Table II. It
is observed that the results are within the acceptance tolerance;
however, the minor difference between the two can be attributed
to the empirical design coefficients and formulae used in the
CAD program. The torque-versus-angle characteristics of the
designed motor, obtained using FE analysis by giving constant
currents in two phases of the motor in appropriate switching
cycle, is given in Fig. 5.
VI. CONCLUSION
A comprehensive CAD procedure involving the derivation of
the output equation and two self-corrective loops—one for the
efficiency and the other for the airgap flux density—for the sand-
wiched axial-flux PM BLDC motor is discussed. Three designs,
one each in fractional, low, and medium hp categories, arrived at
using the developed CAD program are giving the targeted torque
within an acceptable tolerance band, but with high efficiencies.
The CAD-based designs are validated using the FE analyses.
REFERENCES
[1] D. C. Hanselman, Brushless Permanent Magnet-Motor Design. New
York: McGraw-Hill, 1994.
[2] J. R. Handershot and T. J. E. Miller, Design of Brushless Permanent
Magnet Motors. Oxford, U.K.: Oxford Univ. Press, 1994.
[3] D. Patterson and R. Spee, IEEE Trans. Indust. Appl., vol. 31, no. 5, pp.
1054–1061, Sept./Oct. 1995.
[4] C. C. Chan, IEEE Trans. Energy Conv., vol. EC-2, no. 2, pp. 294–300,
Jun. 1987.
Manuscript received March 13, 2006 (e-mail: parag_311@yahoo.com).