There is a need for higher torque density electric actuators in novel (quasi-)direct-drive robotic applications. Since the torque density is inherently limited by material properties, designers have to look at novel materials to push the torque density limit further. In this work, anodised aluminium foil is considered as an alternative to enamelled copper wire in a yokeless and segmented armature axial flux machine. This machine topology has a high torque density and is particularly suited for an anodised aluminium foil winding. The DC resistance, thermal properties and eventually the torque density of a prototype test case machine are compared for both winding materials. A 3D thermal finite element model is used to analyse the influence of the thermal interface between winding body and housing, and the influence of the cooling performance on the torque density. This has shown that the use of anodised aluminium foil can increase the torque density up to 37\%. To conclude, anodised aluminium foil winding offers a higher torque density in direct-drive yokeless and segmented armature axial flux actuators where the winding body thermal resistance is dominant in the thermal path from heat source to heat sink. It is experimentally shown that for the prototype machine, the torque per kg active stator mass increases 13\% through the use of anodised aluminium foil.
Anodised aluminium foil winding axial flux machine for high torque density robot actuators
2022-01-01
Faculty of Engineering and Architecture Research Symposium 2022 (FEARS 2022), Abstracts
Conference paper
Electronic Resource
English
Anodized aluminium foil winding axial flux machine for direct-drive robotic applications
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