Design and Investigation on No-Load Performance of a Coreless Axial Flux Permanent Magnet Motor

This study introduces the design, finite element analysis (FEA), and experimental verification of a coreless axial flux permanent magnet (AFPM) motor developed using 3D printing. The proposed single stator single rotor (SSSR) AFPM motor is intended for applications such as Electric Bicycle and light weight vehicular application, where high torque and speed, reduced weight, and manufacturability are critical. The motor is designed with 9 -slot/ 10 -pole concentrated winding configuration with NdFe35 permanent magnets and PLA structural components. This significantly reduces the weight while eliminating core losses and cogging torque. The motor is simulated in ANSYS Maxwell 3D, achieving an efficiency of 89.88% with no load speed 6284.91. The fabricated prototype shows a no-load speed of 6102 rpm with a torque of 0.47 Nm, which is only 2.91% lower than the simulated result. The findings show close similarities with the simulation outcome and confirmed possibility to AFPM motor for electric vehicle applications, demonstrating both feasibility and practical performance advantages.