Optimal rotor design of novel axial flux synchronous reluctance motor and validation

In this paper, it is aimed to design an original axial flux synchronous reluctance motor (AF-SynRM), which has not been studied in the literature, has multiple barriers in its rotor, and to produce prototype of this motor. In the preliminary study of the AF-SynRM design, analytical calculations are made on the rotor in two different topologies barrier types, multiple barrier structures, and three different insulation rates. It is modeled with the 3D finite element method (FEM). Torque, torque ripple, saliency ratio, shaft power, and efficiency parameters are analyzed. In the model that gives the best the results analytically, the model is ready for production by changing the barrier geometry with genetic algorithm (GA) based optimization analysis, reducing the torque ripple and completing the structural analysis. The model is made ready for prototype production. Compared to the radial flux model with the same power rating with the proposed design method, 2.2 kW EA-SynRM prototype with higher torque density and lower volume was produced. The prototype produced has been tested according to the criteria of IEC TS 60034-30-2 and has the IEC 60034-30-1:2014 IE4 Super Premium efficiency class. Torque, torque ripple, power factor, shaft power, torque per amper, and efficiency parameters are analyzed and compared with simulation results. It will be a good alternative in applications where high efficiency and torque are desired with its lack of copper losses due to the absence of a cage in the rotor and low maintenance costs with its magnet less structure.