Mechanical construction and analysis of an axial flux segmented armature torus machine

This paper deals with the mechanical construction and static strength analysis of an axial flux permanent magnet machine with segmented armature torus topology, which consists of two external rotors and an inner stator. In order to conduct the three dimensional magnetic flux, the soft magnetic composites is used to manufacture the stator segments and the rotor yoke. On the basis of the detailed electromagnetic analysis, the main geometric dimensions of the machine are determined, which is also the precondition of the mechanical construction. Through the application of epoxy with high thermal conductivity and high mechanical strength, the independent segments of the stator are bounded together with the liquid-cooling system, which makes a high electrical load possible. Due to the unavoidable errors in the manufacturing and montage, there might be large force between the rotors and the stator. Thus, the rotor is held with a rotor carrier made from aluminum alloy with high elastic modulus and the form of the rotor carrier is optimized, in order to reduce the axial deformation. In addition, the shell and the shaft are designed and the choice of bearings is discussed. Finally, the strain and deformation of different parts are analyzed with the help of finite element method to validate the mechanical construction.