2) Reasons for Selecting Axial Flux PMSM for EV Applications

1. Higher Power Density (Compact Design)

o AF-PMSMs have a shorter magnetic path and allow for more efficient utilization of
the motor volume.

o This leads to higher torque and power output per unit volume, making the motor
compact and lightweight — a major requirement in EVs where space and weight are
limited.

2. Improved Efficiency

o Due to shorter flux paths and reduced losses, axial flux motors exhibit higher
electrical and mechanical efficiency.

o This translates to better energy utilization, increasing the driving range of EVs.

3. High Torque at Low Speed

o AF motors produce high torque at low RPM, which is especially beneficial in EVs
since it reduces or eliminates the need for complex transmission systems.

4. Better Cooling Options

o The flat, disc-like structure of axial flux motors allows for efficient surface cooling,
which is advantageous for thermal management in high-performance EVs.

5. Scalability and Modularity

o Axial flux motors can be easily scaled or stacked for higher performance without
significantly increasing the size.

o This modularity makes them adaptable to various types of EVs (from e-bikes to
electric trucks).

Conclusion (Inference)

AF-PMSMs are preferred in EV applications because they offer higher power density, better
efficiency, high starting torque, and flexible design options, all of which contribute to improved
vehicle performance, range, and packaging efficiency — critical metrics in electric mobility
solutions.

Axial Flux PMSMs are preferred in EV applications because they offer higher power and torque
density, better efficiency, and compact, lightweight design. Their flat, disc-like shape allows better
space utilization and cooling, making them ideal for electric vehicles where space, weight, and
efficiency are critical.

3)
Rotor Types and Their Significance

Surface Mount PMSM:

• Significance: These motors are simple and cost-effective. They have high magnetic strength
(flux density), but they aren't very strong mechanically. This makes them unsuitable for high-
speed applications.

Surface-Inset PMSM:

• Significance: These motors are stronger than surface-mounted ones. They are better for
medium-speed operations and offer better protection for the magnets, making them more
durable.

Interior PMSM (Radial):

• Significance: These motors are very strong and are perfect for high-speed or high-
acceleration tasks. The design helps reduce energy losses and rotor inertia, making them
efficient in demanding conditions.

Interior PMSM (Circumferential):

• Significance: These motors have a high magnetic strength due to large magnets. They are
efficient but bulky and are best used with cheaper materials like ferrites. However, they are
not ideal for compact or high-speed designs.

4) Best Control Method for PMSM in Industry:

Why FOC?

• Precise control of speed and torque

• Stops vibrations and hunting (oscillations)

• Improves efficiency and power factor

• Works well for both constant and changing speeds

• Smooth and stable operation – perfect for CNC machines and conveyor belts

In Simple Words:

FOC controls the motor like you're steering a car smoothly—it keeps everything running steady, fast,
and without shaking.

6) β (Magnet arc): Increased β improves torque but may raise losses.

Tph (Turns per phase): More turns increase torque but also resistance.

δ (Torque angle): Higher δ boosts torque but may reduce efficiency.

D (Bore diameter): Larger diameter enhances torque but affects size.

L (Bore length): Longer bore increases torque but impacts cost.

7)

There are two types of Axial Flux PMSMs shown:

2. Double-sided AFPMSM – one stator between two rotors

Unbalanced Axial Force:

• Happens in: Single-sided AFPMSM

• Why: The magnets pull the rotor toward the stator, and there’s no opposite side to balance
it.

Effects of Unbalanced Axial Force:

• Vibrations and Noise

• Extra stress on bearings

• Lower efficiency

• Possible bending or damage over time

Double-sided AFPMSM:

• Has balanced axial force

• Reduces vibration, noise, and wear

9)
10)

11)
12)

13)
14)

Parts and Materials:

1. Rotor Permanent Magnets

o Name: Rotor

o Material: Permanent magnets (usually Neodymium or Samarium-Cobalt)

2. Stator Windings

o Name: Stator

o Material: Copper windings and laminated silicon steel core

3. Hall-effect Sensors

o Name: Hall sensors

o Material: Silicon (semiconductor material)

15) Three Hall sensors are used to sense the rotor position in a BLDC Motor. These hall sensors are
either placed 120° apart from each other.

Three hall sensors can give eight combinations as shown in the following table.
Identify the logically useful combinations and mark it Yes and No for combinations which are not
useful.
Explanation:

• 000 and 111 are invalid or unused in typical 3-phase BLDC commutation because they don't
represent a unique rotor position.

• The other six combinations (001 to 110, excluding 000 and 111) are valid and used for 6-step
commutation.

16}

18)

How the BLDC Motor Works:

• The Hall sensors detect rotor position and provide signals to the controller.

• The controller activates MOSFETs (Q1–Q6) in a specific sequence to generate the rotating
magnetic field.
 • For counterclockwise rotation, the switching pattern is reversed compared to clockwise
rotation.

20)
21)

22)
The Hall element with thickness = 0.53 mm exhibits a stronger Hall effect.

24)

.Operation of the Circuit

1. Rotor Position Detection:

o The Hall element, placed on the rotor, detects the magnetic field generated by the
rotor's permanent magnets.

o As the rotor spins, the Hall element senses changes in the magnetic field and
produces an output signal indicating the rotor's position.

2. Transistor Control:

o The output signal from the Hall element is fed into the gates of the two transistors,
Tr1 and Tr2.

o Based on the rotor's position, the Hall element signal will either turn on Tr1 or Tr2.

3. Excitation of Stator Windings:

o When Tr1 is on, current flows through stator winding W1, creating a magnetic field
that interacts with the rotor's magnets.

o When Tr2 is on, current flows through stator winding W2, creating a magnetic field
that interacts with the rotor's magnets.

Direction of Rotation
 • The direction of the rotor's rotation is determined by the sequence in which the stator
windings are excited.

• If Tr1 and Tr2 are turned on and off in a specific sequence, the rotor will rotate in a particular
direction.

• For example, if the sequence is Tr1 on -> Tr2 on -> Tr1 on -> Tr2 on, the rotor will rotate
clockwise. If the sequence is reversed (Tr2 on -> Tr1 on -> Tr2 on -> Tr1 on), the rotor will
rotate counterclockwise.

In summary, the Hall element detects the rotor position and controls the excitation of the stator
windings via transistors, ensuring that the rotor continues to rotate smoothly in the desired
direction. The exact direction depends on the sequence of excitation provided by the Hall element's
output signal.

25)
23)