Research On Disk Permanent Magnet Synchronous Generator Based On PCB Winding

The air gap magnetic field of disk-type permanent magnet synchronous motor is distributed along the axial direction,which has the characteristics of compact axial size,small volume and high power density.Under the statorless core structure,PCB winding is adopted to replace the traditional winding,which solves the problems such as difficulty in installing the winding coil and easy to have axial buffeting.Moreover,it reduces the weight of the motor,eliminates the cogging torque and stator core loss,reduces the noise of the motor,and improves the output performance of the motor.Very suitable for micro-small-power hand generation field.Therefore,this paper takes the disk permanent magnet synchronous generator based on PCB winding as the research object,and makes a deep research on it.First of all,this paper studies the characteristics of four typical topologies of disk motor.In order to reduce the weight and axial size of the motor,a NS type single-stator dual-rotor structure is selected as the motor topology.In this topology,PCB winding is made of statorless core structure to further optimize the motor performance.The basic electromagnetic relations such as permanent magnet operating point,no-load back potential and electromagnetic power are deduced,and the steady-state operation characteristics of the generator are analyzed and calculated.Secondly,the design method of fixed rotor dependent parameters of core-free permanent magnet synchronous generator is studied.The characteristics of the fractional slot winding and the constraints of the polar slot combination of the motor are analyzed.Aiming at the rotor parameter design,the magnetic properties of different permanent magnet materials were compared to determine the rotor permanent magnet material.The magnetic density distribution of rotor and air gap under the permanent magnet of different shapes was compared and analyzed.The size of permanent magnet was designed based on the size equation,and the influence of permanent magnet thickness and air gap length on magnetic induction intensity was explored.Aiming at the design of PCB winding,the characteristics of waveform winding and concentric winding are studied,and the back-to-back concentric winding I is adopted as PCB motor winding arrangement.The advantages and disadvantages of several different shapes of winding coils are compared and analyzed.Combined with the performance advantages of circular coil and trapezoidal coil,the structure of a sector winding coil is designed.The parameters of copper coating thickness,conductor spacing,conductor wire width,hole size,coil turns and plate series layers are analyzed and designed.In addition,a PCB disk-type permanent magnet synchronous generator model was established in ANSYS Maxwell finite element software,and the air-gap magnetic field,noload characteristics and load characteristics of the motor were simulated and analyzed,which verified the rationality of the designed parameters.At the same time,in order to reduce the eddy current effect of magnetic leakage on the generator housing,a lightweight shaped magnetic yoke structure was proposed and the parameters of permanent magnet were optimized.The eddy current distribution of the housing before and after optimization and the output performance of the generator were compared and analyzed.Finally,an experimental prototype was made and an experimental test platform was built.The no-load and loading tests were carried out by driving the prototype with the prime mover.The feasibility of the designed disk-type permanent magnet synchronous generator was verified by comparing the test values with the simulation results,which provided a certain reference for the subsequent research.