Development of a Novel Yokeless and Segmented Armature Axial Flux Machine Based On Soft Magnetic Powder Composites (WP1603296108)

The magnetic and mechanical properties of soft magnetic powder composites (SMC) have been recently significantly improved. Within the project “Design and analysis of an electric motor based on new material components (SMC)” Daimler AG, the Institute of Electrical Engineering (ETI) at the Karlsruhe Institute of Technology (KIT) and PMG Füssen GmbH examined and evaluated the use of soft magnetic composites in the electrical machine with segmented armature torus structure, especially as a main drive in hybrid electric or pure electric vehicles. Because of the existing threedimensional magnetic flux in this machine topology, the complex soft magnetic components can only be manufactured with SMC rather than with conventional electrical steels. Based on 3D FEM electromagnetic analysis, the mechanical construction and analysis have been carried out and a prototype has been built at KIT. The measurements of the manufactured prototype on the test bench in ETI proved its simplicity, stability and functionality.