Design and Analysis of Integrated Motor Drive for Cordless Vacuum Cleaners

This paper presents the design, development, and experimental evaluation of a high-speed integrated motor drive for cordless vacuum cleaners. The drive employs an axial integration structure, where the inverter PCB is soldered directly to the motor terminals, reducing wiring losses and improving electromagnetic compatibility. A novel PMSM with a star-shaped stator and toroidal winding provides high power density, reduced weight, and enhanced cooling. The motor operates at 120,000rpm, generating airflow enabling forced-air cooling of both the motor and the inverter. The inverter design is constrained by strict geometric and thermal requirements. Its layout is based on the symmetric positioning of six MOSFETs around the motor axis, achieving uniform airflow distribution and reducing local overheating. Experimental tests under variable suction and airflow conditions, simulating realistic VC operation, demonstrated improved thermal management compared with existing commercial solutions, confirming the effectiveness of the proposed integrated drive.