1500W BLDC Outer Rotor Machine Electro-Magnetic Design

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Simulation of a Brushless DC Motor in ANSYS – Maxwell 3D

5. 1500W BLDC Outer Rotor Machine Electro-Magnetic Design


The above analytical (4) model will now be designed in accordance with the calculated rated
input/output parameters the RMxprt module of ANSYS – Maxwell. For this purpose four variants
of the 1500W, BLDC motor are designed and simulated in the software interface.
1. 24 Slots, 16 Pole BLDC machine
2. 36 Slots, 16 Pole BLDC machine
3. 48 Slots, 22 Pole BLDC machine
4. 72 Slots, 32 Pole BLDC machine

5.1. 24 Slot, 16 Pole BLDC Machine in ANSYS – Maxwell - RMxprt:


A 24 Slot, 16 Pole machine configuration is selected based on the optimum phase/pole/slot
configurations mentioned in [15]. Its dimensioning will be discussed in the following sections.
5.1.1. Machine & Circuit:
The general machine and circuit parameters are as follows,
Parameter Value Unit
Number of Poles 16
Frictional Loss 10 W
Windage Loss 20 W
Reference Speed 380 Rpm
Lead angle of trigger 0 ˚
Trigger Pulse Width 120 ˚
Transistor/Diode Drop 2 V
Table 4: General Machine & Circuit data
The friction and windage losses account to approximately 2% of the total out power capacity.
The transistor and diode drop are usually neglected for power converter dimensioning but here
their value impacts the efficiency significantly.
It is calculated as, 𝑉𝐷𝑅𝑂𝑃 = 0.6𝑉 + [ 𝐼𝐴𝑉𝐺 × (𝑅𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 + 𝑅𝑑𝑖𝑜𝑑𝑒 )]

5.1.2. Stator Dimensions:


Parameter Value Unit
Outer Diameter 180 mm
Inner Diameter 90 mm
Stacking Factor 0.95
Length 50 mm
Steel Type M100-23P
Number of Slots 24
Table 5: Stator Data Slot Type 4
Skew Width 1 Slots

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Simulation of a Brushless DC Motor in ANSYS – Maxwell 3D

5.1.2.1. Slot Design:


The selected slot type 4 in RMxprt is based on the research done by [14]. Its design are dimensions
are depicted and tabulated below.

Figure 25: Slot Design (Type 4)


Parameter Value Unit Parameter Value Unit
Hs0 3 mm End Extension 4 mm
Hs1 3 mm Base Inner Radius 0.5 mm
Hs2 30 mm Tip Inner Diameter 1 mm
Bs0 3 mm End Clearance 1 mm
Bs1 16 mm Slot Liner 0.5 mm
Bs2 8 mm Wedge Thickness 0.3 mm
Rs 0.6 mm Layer Insulation 0.1 mm
Table 6: Slot Dimensions Limited Fill Factor 0.75
Table 7: End/Insulation Data
5.1.2.2. Winding Design:
The stator winding data & geometry is depicted and tabulated below, while the end/insulation data
is depicted above the aim of the design is to minimize the armature copper losses while keeping
the stator slot fill factor in practical limits.

Parameter Value Unit


Winding Layers 2
Winding Type Whole Coiled
Parallel Branches 1
Conductors per slots 18
Coil Pitch 1
Number of Strands 5
Wire Wrap 0.2 mm
Wire Size
1.369 mm
(Diameter)
Table 8: Winding Data
Figure 26: Stator Winding

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Simulation of a Brushless DC Motor in ANSYS – Maxwell 3D

5.1.3. Rotor Dimensions:


The general data for the machine rotor is tabulated below,

Parameter Value Unit


Outer Diameter 200 mm
Inner Diameter 182 mm
Stacking Factor 0.95
Length 50 mm
Steel Type M100-23P
Pole Type 1
Table 9: General Rotor Data
Due to the outer rotor geometry of the BLDC machine only pole type 1 is allowed for analysis
depicted below in Figure 27.

Pole Type 1
Figure 27: Pole Shape 1 in ANSYS – Maxwell RMxprt.

5.1.3.1. Pole Data:


The pole data is tabulated below,
Parameter Value Unit
Embrace 0.9
Offset 4 mm
Magnet Type NdFeB
Magnet Thickness 4 mm
Table 10: Pole Data
5.1.4. Analysis Setup:
The machine’s rated operating state input/output parameters are tabulated below,
Parameter Value Unit
Load Type Constant Power
Rated Output Power 1500 W
Rated Voltage 48 V
Rated Speed 380 Rpm
Operating Temperature 75 ˚C

Table 11: Analysis Setup

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