2018 International Seminar on Intelligent Technology and Its Applications (ISITIA)

Design Analysis of Axial Flux Permanent Magnet

BLDC Motor 5 kW for Electric Scooter Application

Yoga Uta Nugraha Muhammad Nur Yuniarto Herviyandi Herizal

Department of Electrical Engineering
Center of Excellence for Automotive
Control & System
Institut Teknologi Sepuluh Nopember
Surabaya, Indonesia
uta.utu@gmail.com
Center of Excellence for Automotive
Control & System
Institut Teknologi Sepuluh Nopember
Surabaya, Indonesia
muhammad.nur3006@gmail.com
Department of Electrical Engineering
Institut Teknologi Sepuluh Nopember
Surabaya, Indonesia
hezlaudio@gmail.com

Dimas Anton Asfani

Dedet Candra Riawan Mochammad Wahyudi
Department of Electrical Engineering
Department of Electrical Engineering Department of Electrical Engineering
Center of Excellence for Automotive
Institut Teknologi Sepuluh Nopember Institut Teknologi Sepuluh Nopember
Control & System
Surabaya, Indonesia Surabaya, Indonesia
Institut Teknologi Sepuluh Nopember
dedet@ee.its.ac.id mochwahyudi27@gmail.com
Surabaya, Indonesia
anton@ee.its.ac.id

Abstract—The design of an optimal BLDC motor with high
efficiency is the most important thing especially for electric
scooter application since its performance is very depended on
power output of BLDC. This paper presented design of 5 kW
axial flux permanent magnet of BLDC motor based on
Solidwork and Ansys Maxwell. The motor parameters were
designed by modeling of physical parameters through
calculation, such as number of pole, stator core diameter, and
selection of material type. These physical parameters are then
designed its blueprint through Solidwork and simulated
through Ansys Maxwell with Rmxprt (Rotational Machine
Expert) feature. The analyzed electrical parameters were
speed, efficiency, flux density, and losses. The results showed
the designed axial flux permanent magnet motor BLDC with
12 slot stator and 8 pole rotor presented the torque = 9.5 Nm,
rated speed = 5050 rpm, and motor efficiency = 94.49 %.
Keywords— Ansys Maxwell, Axial Flux Permanent Magnet
BLDC Motor, Electric Scooter, and Solidwork.
I. INTRODUCTION
BLDC motor nowadays used and applied in the field of
household appliances industry, health equipment industry to
the automotive industry which focuses on the development
of electric vehicles due to the characteristics of excellent
torque speed, has a high efficiency and maintenance costs are
affordable, in line with the development of technology on
electric vehicles, researchers are driven largely to improve
performance and efficiency to improve the reliability of
electric vehicles [1], [2]. The main components that are
widely studied are the controller, battery capacity, power
electronics components and electric motors. Therefore, it is
necessary to determine the design of electric motors in order
to obtain the best performance and efficiency [3]-[4]. BLDC
motor continues to develop as the discovery of the use of
BLDC magnetic motor magnetic that has advantages as an
electric vehicle that is the small size, low cost, high torque
and high efficiency [5].
BLDC motors have two permanent magnet types namely
AFPM (Axial Flux Permanent Magnet) and RFPM (Radial
Flux Permanent Magnet). Many studies have compared the
performance of the two permanent magnet types, where
AFPM has advantages in terms of load withdrawal power, air
gap, torque, lighter weight and better heat dissipation than
RFPM [6] - [7]. The choice of 1 mm air gap can make the
magnetic field density on air gap to be higher than the wider
air gap design in the same design [8]. And the selection of
slot type in the stator slot design can improve the efficiency
of the motor [9].
In the previous research, the electrical parameters using
Artificial Intelligence method had optimization design [8], in
the other hand finite element method would simulated 3
dimension of design to known meshing, boundaries,
direction and value of flux density [9], [10]. Calculation
method obtained could be implemented and tested [1], [11].
The selection of materials when the design should be
explored the basic concepts and how to optimize the design
efficiency so as to obtain the motor with the optimal design
[10], [11].
Therefore, in this study aims to design and simulate
BLDC motor using axial flux permanent magnet with power
output of 5 kW so as to obtain electrical parameters and
expected analysis that is a permanent magnet force to be
used, the number of stator coils to be wrapped, stator and
rotor configuration, flux density, field strength, loss, speed,
torque, output power and efficiency and dimensions of the
motor so that can be used as a reference for implementation
on electric scooter application.
II. DESIGN OF MOTOR PARAMETER
A. Specification of Axial Flux Permanent Magnet Motor
BLDC
The first step in designing axial flux permanent magnet
motor BLDC is to determine the initial parameters as a
reference to be achieved. These initial parameters can be
used as a reference for the electrical and mechanical
parameter specification requirements that can support the
calculation. Parameter showed in Table I.
B. Calculation of Current Requirement
The increase in load power is proportional to the electric
current increased when the voltage was fixed. based on the

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slot and pole combination table [4]. Estimated the value of TABLE I. INITIAL PARAMETERS IN MOTOR DESIGN
power factor (Cos θ) with slot number 12 and pole number 8 Parameters Value
that is 0.866. The pole number approach was obtained from Power Output 5000 Watt
the following equation, sequentially Ns, f, Pole are speed Operational Voltage 100 Volt
frequency, and number of pole : Power factor (estimation) 0.866
Efficiency (estimation) 0.95
120 f Phase 3
 Ns    Inverter Output Frequency 330 Hz
Pole Speed 5000 rpm
(120)330 
Pole   D. Calculation of Core Diameter
5000
To obtain an effective motor design based on a
Current requirement calculation sequentially I, Pout, predetermined pole value. So it can be determined the ratio
Vrated,  estimation, and Cos θ are current, power output, rated between the inner diameter (Ds) with the outer diameter (Dse)
of the core was an optimum Kd value of 0.48 [5]. Besides, to
voltage, efficiency estimation, and power factor, as follows: determine Dse and Ds, one of them must be made constraint.
Pout In this case, the inner diameter constraint is chosen with the
I   inner diameter of 80 mm. From (5) Kd from obtained
(Vrated )( estim ation )(Cos ) parameter value.

5000  Ds  
I  Kd 
100 0.95 0.866  Dse

I  60.8 A  Dse  0.4880   

Based on 4-pole stator winding, for a current of 60.8 A
can be estimated the size of the wire to be used. The stator 4-
pole winding was arranged in parallel then each winding will
feel the current of 15.2 A. The copper wire used refers to the
standard American Wire Gauge (AWG). Selected AWG 8
with conductor diameter of 3.26 mm which included the
addition of safety factor more than 15 %.
Determined the number of windings obtained from the
ratio of the cross-sectional area of the stator slot. So as to
obtain the number of strands as much as 8 and the maximum
number of windings of 48 turns.
C. Calculation of Flux Density
Density value starts with finding the value of loading
value (qi). The equation (3) loading value sequentially qi,
Nph, Irms, and Di are Loading value, number of winding,
current, and inner diameter, as follows :
3( N ph )( I rms )
 qi   
Di
3(48)(15.2)
qi  
(3.14)(0.00115 )
qi  606.31KAturn / m 
The value of loading value is 606.31 KA turn/m. Then,
found the value of flux density sequentially T, Bg, Ro, and Kr
are torque, flux density, radius, and constanta, through the
equation below:
2 2
 T  ( B g )(q i )( Ro 3 )( K r )(1  K r 2 ) 
3 Modeling on the stator is determined based on the design
9.55
Bg 
2 2
(3.14)(606.31)(10 3 )(0.083) 3 (0.48)(1  0.48 2 )
3 component of the stator which is used to conduct current and
Bg  0.0145Tesla 
Dse  166 mm  
E. Calculation of Torque Value
The determination of the torque value can be calculated
by estimating the speed of 5000 rpm. In the 5 kW motor will
flow the resulting frequency at a speed of 5000 rpm is around
83.33 Hz. So we can know the angular velocity of 523.33
rad/s. So it can be calculated torque value. The equation (6)
torque obtained from the calculation with 5 kW motor power
and 5000 rpm speed is 9.55 Nm.
P
 T   

5000
T 
523.33
T  9.55 Nm 
F. Selection of Air Gap
In determining the air gap need to pay attention to the
size of the winding. So get the optimal air gap results. Based
on research [1], [6], that 1 mm of air gap can make the field
density value on the air gap higher when compared to the
wider air gap under the same design conditions.
III. MODELING OF AXIAL FLUX PERMANENT MAGNET BLDC
MOTOR USING ANSYS MAXWELL
Modeling through Ansys Maxwell uses modules in the
Rmxprt (Rotational Machine Expert) feature. This feature
can be used to design simultaneously simulate electrical
engine design so as to make it easier for users to analyze it.
 1) Stator
results on the stator cores, slot type, and stator winding.
Where there are 12 slots that have slot type 3. Type slot is a
constraint factor. The stator winding is an important
voltage on the motor with a total of 48 loops. Modeling

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stator and other specification showed on Table II-IV and TABLE V. SPECIFICATION OF ROTOR
design stator using Ansys Maxwell showed on Fig.1. Parameters Value
Number of Pole 8
2) Rotor Outer Diameter 166 mm
Modeling on the rotor was divided into two, rotor core Inner Diameter 25 mm
design and permanent magnet. Obtained rotor specification Length 10 mm
with 8 poles and 28 mm magnetic length. Modeling Rotor, Stacking Factor 0.95
magnet and other specification showed on Table V-VI and Material Type Steel_1010
design Rotor using Ansys Maxwell showed on Fig. 2. Skew Width 0.2 deg

3) Assembly Design TABLE VI. SPECIFICATION OF MAGNET

Ansys Maxwell assembly design used to simulate
Parameters Value
electrical parameters on the motor. So we get graph of motor Magnet Type NdFe35
characteristics with time variable as reference. Assembly Magnet Length 28
showed on Fig. 3. Magnet Thick 5

IV. MODELING OF AXIAL FLUX PERMANENT MAGNET BLDC

MOTOR USING SOLID WORK
In the mechanical modeling of calculated parameters can
be modeled axial flux permanent magnet motor BLDC
through Solidwork. Motors modeling aims to get blueprint
results so that printing can be done through the printing
press. The following is the result of stator design, rotor, and
assembly of axial flux permanent magnet BLDC motor using
Solidwork. On Fig. 4 showed the design of stator for the
electric motor. On Fig. 5 showed the design of rotor. And on
Fig. 6 showed assembly design of axial flux permanent Fig. 1. Designed stator using Ansys Maxwell
magnet BLDC motor.

TABLE II. STATOR SPECIFICATION

Parameters Value
Number of Pole 8
Number of Slot 12
Circuit Type Y3
Outer Diameter 166 mm
Inner Diameter 80 mm
Length 45 mm
Stacking Factor 0.95
Slot Type 3
Fig. 2. Design rotor using Ansys Maxwell
TABLE III. SPECIFICATION OF SLOT TYPE STATOR
Parameters Value
Hs0 4 mm
Hs1 0 mm
Hs2 30 mm
Bs0 4 mm
Bs1 14 mm
Bs2 14 mm
Rs 0 mm

TABLE IV. SPECIFICATION OF WINDING STATOR

Parameters Value Fig. 3. Assembly design on Ansys Maxwell
Winding Type Whole-Coiled
Pararel Branches 4
Number of Coil 48
Number of Strands 8
Wire Wrap 0.2
Wire Size 1.151 mm2
Conductor Type Copper

Fig. 4. Design stator using Solidwork

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 V. RESULT AND ANALYSIS this simulation is still considered tolerable. Torque curve
This section discusses the results of the design, 2D showed on Fig. 10.
analysis and 3D analysis of the simulation results obtained
from the axial flux permanent magnet parameters of the
BLDC motor. The design performed on Ansys Maxwell
software aims to get the characteristic curve and electrical
parameters.
A. 2D-based Simulation Results of Motor Performance
Through Ansys Maxwell simulation on 2D design. There
are several characteristics of the curve to variable speed. In
this research will be conducted focus analysis on
performance that produce performance on motor. At this
stage, results are obtained with parameters, velocity,
currents, and power on loading. On the characteristic curve,
velocity, current, and power to loading indicate the most
appropriate speed in the design obtained. Fig. 5. Designed rotor using Solidwork

In Fig. 7 the characteristic curve obtained characteristics

that have been close to the expected calculation. When the
speed reaches 5050 rpm the characteristic curve shows the
power of 5100 Watt with an efficiency of 94.49% and a
current of 54.3 A when loading of 9.5 Nm.
The simulation result of efficiency, speed, current, and
power to loading is done by using chopping current control
(CCC) feature that limits the current with maximum current
of 240 A and a minimum current of 5 A. Simulation is done
in full load condition. Power on the curve decreases after
passing the rating speed this is because the load torque
slowly begins to disappear frequently with increasing speed.
While the characteristic efficiency curve of loading shows an
Fig. 6. Assembly design on Solidwork
increasing efficiency along with the increase of loading on
the motor.
B. 3D –based Simulation Results
Modeling design through Ansys Maxwell can be
simulated to 3D design, so that the characteristics of motor
design have been designed in the form of current, voltage,
torque, flux density, field direction, and loss. In this analysis
will be discussed related to a 3D simulation that produces the
following characteristics.
1) Characteristics of Current and Voltage Input
In this simulation, a three-phase voltage and current
value was applied where maximum current value was 160 A
Fig. 7. Characteristic of curve power, efficiency, current, speed vs load
and 75 Volts. In addition, the characteristic phase wave has
torque
an angular difference of 1200 which has the difference of
phase. It also can be obtained by the value of Irms 113 A and
Vrms of 50.9 Volt. The simulated characteristic is a motor
input characteristic. The current and motor voltages are
affected by the source of the controller where the DC source
is set at 100 Volts DC. The current coming out of the
controller depends on the number of turns on the useful
stator producing an electric field. Voltage and Current curve
showed on Fig. 8-9.
2) Characteristics Curve Torque vs Time
On the torque curve with respect to time on the graph
obtained simulation results with an average torque value of
10.95 Nm (taken at 1-10 ms seconds when steady state).
While the value of torque analytically when the design was
9.55 Nm. This error occurs due to an error analysis on
software that used 3D based on methods of finite element
methods [5]. Error simulation equal to 9.95%. The error in
Fig. 8. Curve of voltage vs time for 10 ms

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Fig. 9. Curve of current vs time for 10 ms
Fig. 10. Curve of torque vs time for 10 ms
Fig. 11. Characteristic of flux density
Fig. 12. Characteristic of direction field
3) Characteristics of Flux Density
In an animated simulation of flux density, the magnetic
field generated is caused by flux changes to the coil on the
stratum. Flux density value obtained maximum results of 2.7
Tesla. In the animation obtained magnitude flux density
where the value of safety is given a blue indicator until the
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worst marked by a red indicator. The motor has a distribution
of flux distribution with the dominant blue color on the
surface of the stator cross-section which indicates the motor
can operate optimally. In addition, the distribution of the flux
distribution tends to be stronger in the inner part of the stator
with the dominant color of green and yellow, and slightly
indicates the red color found at the stator core points of
angle. Characteristics of flux density represented on Fig. 11.
4) Characteristics of Direction Field
The following simulation shows the direction of the field
current from the motor. Can be seen in the animation
obtained direction of running current on the stator and rotor
are shown with green lines. On the stator the direction of the
field will move towards the Z axis and back again to the
starting point, while the rotor direction of the outward
direction toward the outer direction of the magnet.
Characteristics of direction field represented on Fig. 12.
VI. CONCLUSION
The axial flux permanent magnet BLDC motor that was
designed using Solidwork and simulated using Ansys
exhibited a high performance and an optimal analysis design
for electric vehicle application. The designed axial flux
motor permanent magnet BLDC motor had 5 kW rated
power with 12 stator slot numbers and 8 rotor poles. In
addition, the motor's mechanical torque reached a value of
9.5 Nm at a speed of 5050 rpm with input current of 113 A
and input voltage of 50.9 V. Furthermore, the obtained motor
efficiency was 94.49 %. The design that has been designed
can be a reference for implementation and subsequent
research. the design results that have been obtained can be
validated by testing through implementation.
ACKNOWLEDGMENT
The authors would like to thank Center of Excellence for
Automotive Control & System (PUIPT SKO ITS) for the
funding of research and publication
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