A review of electromagnetic simulation and modelling approaches for the research on axial flux synchronous machines

Abstract

Extensive electromagnetic (EMAG) studies are necessary to fully realize the potential of axial flux machines (AFMs). However, the disc-shaped air gap and the complex three-dimensional path of magnetic flux pose challenges in modelling AFMs compared to conventional radial flux machines. This study reviews current research on EMAG modelling and simulation of AFMs, highlighting the need for tools that address AFM-specific effects. Existing approaches are analysed based on the requirements composed by fundamental objectives of EMAG simulations and AFM-specific effects, revealing limitations in flexibility and the ability to capture emerging trends in the field of AFMs. While computationally expensive 3D finite element analysis (FEA) offers comprehensive flexibility in EMAG modelling, it lacks efficiency to carry out extensive studies on such trends. Therefore, there is a need to either further accelerate 3D FEA or to increase the flexibility of existing alternatives to facilitate and thereby promote research in the field of AFM and other 3D flux machines. While the integration of some production-specific effects, such as manufacturing tolerances, already is investigated for EMAG simulations of AFMs the future research on the early estimation of manufacturability based on EMAG simulations is crucial for evaluating designs and anticipating manufacturing influences.