On the design and analysis of a printed circuit board in a high speed surface permanent magnet axial flux machine

This dissertation involves aspects of the electromagnetic, thermofluid and structural attributes of the design of a high speed surface permanent magnet machine. The machine novelty includes the use of a PCB as the stator of the machine. The intent of the work detailed within this document was to design build and test a high power density electrical machine for an aerospace application.;The analytical and numerical work noted includes electromagnetic, thermal and structural analysis. The electromagnetic modeling includes the rotor magnet flux, armature reaction flux distributions as well as stator eddy current losses. The thermofluid modeling utilized Computational Fluid Dynamics to model the Stator - Rotor interfaces. The estimated heat transfer coefficients were then utilized in a finite difference model to estimate the stator temperature. The mechanical modeling involved the PCB and rotors accounting for the physical properties of the materials and geometries under a variety of conditions.;The testing of the machine as designed was completed with electromagnetic and thermal attributes of the machine recorded and compared to the design. The resultant thermal characteristics of the electrical machine of this type are novel. The electrical loading of the machine may be increased as the speed of rotation of the rotor is increased. Therefore, more than proportional increases in power density are achievable with increasing rotational speed of the rotor.;Suggestions regarding further improvement and enhancements of the machine topology are noted. The principle drawback of a machine of this type is the low inductance, which limits the use of voltage source inverters to drive the machine.