Eddy Current Loss Reduction in 3D-Printed Axial Flux Motor Using 3D-Printed SMC Core

Axial-flux permanent magnet synchronous motors (AFPMSMs) have higher torque densities than the conventional radial-flux permanent magnet synchronous motors (RFPMSMs). However, RFPMSMs have the advantage of lower eddy current losses in the core, owing to the use of electrical steel plates that can be stacked. Therefore, most studies on reducing the eddy current losses of the extant AFPMSMs cores have been focused on reducing the eddy current loss by using a soft magnetic composite (SMC) material or rolling an amorphous electrical steel plate. The method, which is proposed for reducing the eddy current loss of AFPMSMs in this paper, utilizes 3D printing technology to insert a 3D-printed SMC core into the stator shape of a motor that generates a large amount of eddy current; it also inserts air insulation to produce the same effect as that produced by the extant RFPMSM stacking method. The eddy current loss of a stator insulation structure using the 3D-printed SMC core is compared to that of an AFPMSM using the extant SMC core, and the validity of the proposed shape is verified through finite element analysis.