Analysis of Constant Torque Profile Motor Page 1

Scope -
This is part 3 of a three part description of the axal flux, two phase, high speed,
prototype electric motor, by the Gen2 Magnetics division of Orbic Energy Conversion.
.
Part 1 is a pysical description of a general prototype motor, of a specific physical size, Based
on viewpoint control and layer control of a 3D drawing of the complete motor in Turbocad 12
Pro.
Part 2 describes a special rotor shape profile, and a special drive current profile, that result in
zero theoretical torque ripple, and therefore simplified calculation of torque, power, and losses

This part 3 is the simplified calculation, in MathCad 2000, followed by a chart comparing the
torque, specific power, and the power density to a similar industrial motor, and a similar model
motor.
Units -
The phsical prototype is designed in inches. The core slugs are 1/2 inch in diameter and 1/4
inch in length. The total gaps between slugs are 0.030 inches in magnetic length. The center
0.025 inches of the gaps are taken up by rotor blades, leaving .0025 inch clearances. There
are 39.37 inches in a meter, and that conversion factor will appear in the math below.

The presentation of magnetic analysis, in part 2, of this three part paper, is in Gaussian
magnetic units, Gauss and Oersted.

The analysis on page 3 and on in this report is in SI, or rationalized MKS units. Page 2 below
describes SI magnetic units and formulas for reference.
 UNITS AND FORMULAS FOR MAGNETIC DESIGN Page 2
UNITS: Jan 011 by NEWT
Meters are used for all linear dimensions and distances typ: lm magnetic path length

lt length of a wire turn dw diameter of magnet wire lg magnetic length of a gap

lw total wire length:
meters squared is used for: 1. Effective core cross section Ae

2 Area of Window in the Core: AW 3. Wire cross section Aw

Henrys are the units of inductance:L
Tesla is the unit of Magnetic Flux Density: B  Bmax  B
One tesla equals 10,000 Gauss
Ampere is the unit of Current I  Idc  Irms

Ampere turns per meter is the unit for Magnetizing Force H

1 ampere turn per meter = .004 x pi Oersteds

Volt is the unit of Electrical Potential: E  Edc  Erms

Second is the unit of Time: t 1

sec is the unit of frequency in cycles per second f
radian
is the unit of angular velocity or radial 
sec frequency

0 represents the permiability of space -  0  4    10  7   1.2566  10  6

0
is relative permeability. It is the listed catalog value.

Total permeability is the product of mu zero, and mu.
FORMULAS:
( 1) ( 2) N I ( 3)  0    N 2  Ae
B     0  H H  L 
lm lm

 
By solving (3) for total permiability  t [creating (4)] and substituting (2) and (4) into (1), we derive
(5)
L  lm
( 4)  t  N 2  A ( 5) B  L  I
e N  Ae
( 6) B  E  t This B is less than Bmax This B is twice Bmax in symmetrical
N  Ae in unipolar DC applications. bipolar systems.

( 6) May be solved for N yielding: Et

( 7) N 
Ae  B
 Page 3
Profile Motor Torque
Dimensions of a working gap, in meters -

Gap effective magnetic diameter, is slug diameter, plus twice the gap length, to account for fringing.
0.5
dslug  dslug  0.0127 meters
39.37
2  .0030
Effective diameter of magnetic field in the gaps - dgap  dslug  meters
39.37
Effective crossection of field in gap -
dgap  0.0129 meters
2
dgap
Ae    Ae  1.2974  10  4 meters squared
4

.030
Path length of one gap - lg 
39.37

Total path length for one of two inductors -lm  10  lg lm  7.62  10  3 meters

The reluctance of the slugs and shunts is negligible compared to the reluctance of the total gap,
so magnetic path length for the entire inductor can be taken as the total gap length.
We are defining the desired operating point as that flux density where the permiability of the #26
powdered iron has dropped from 75 to 20. Extrapolating from published data, we estimate that
flux level to be 1.8 Tesla.
At the slug.
Bsats  1.8 Tesla

2
For the gap -  dslug 
Bsatg  Bsats    Bsatg  1.758
 d gap  Tesla

From the Units sheet -  0  1.257  10  6

The magnetizing force that will cause Bsat in the gaps is, from (1) -
Bsatg
Hsat  Hsat  1.398  10 6 ampere turns per meter
0

Inductor A has 12 coils of 12 turns each - NA  144

Solving formula (2) for current - Hsat  lm

Isat  Isat  73.9894 Amps
NA
 Page 4
From formula (3), the inductance of motor inductor A is
-
2
 0  NA  Ae
LA  LA  4.4378  10  4 Henrys
lm
At the end of rotor sector 4 rotation, 1 2
the energy stored in inductor A is - WA   LA  Isat W  1.2147 Joules or Watt-Seconds
2 A

At the end of sector 1 rotation, the inductance has increased. The inductance is still determined by
the gaps, but the total gap is now the sum of the 20 clearances. Magnetic total gap length -
.0025
lmcl  20  lmcl  1.27  10  3 meters
39.37

Crossection area -
2
dslug
Acl    Acl  1.2668  10  4 meters squared representing negligible fringing
4

2
 0  NA  Acl
Inductance of inductor A -
LAcl  LAcl  2.5999  10  3 Henries
lmcl
The ratio of the inductance, at the start of sector 1 rotation, to inductance at the
end -
LAcl
RatioL  RatioL  5.8586
LA
This ratio would be 6.0 except for the effects of fringing.

The magnetizing force, in the clearances, that will cause Bsats in the slugs is -
Bsats
Hsatcl  Hsatcl  1.432  10 6 Amp turns per meter
0

Hsatcl  lmcl
The current that will produce B.sat in the slugs -
Isatcl  Isatcl  12.6293 Amps
NA

The energy stored at the end of sector 1 - 1 2

WAcl   LAcl  Isatcl WAcl  0.2073 Joules
2
This energy is returned to the source during rotor sector 2

Energy available per torque sector 1 -

Wtq  WA  WAcl Wtq  1.0074 Joules
 Page 5

Assuming constant torque over the sector, and assuming torque from Inductor B immediately following
etc, the continuous torque of the motor, is this energy divided by the angle of sector 1
Wtq
Tm  Tm  0.6413 Newton-meters or watt-seconds per radian

2

If we assume a desired rotational speed of 50,000 rpm, then angular velocity is-
50000  2  
 25   25  5.236  10 3 radians per second
60

The shaft power in watts is -

Pm  Tm   25
Pm  3.3579  10 3 Watts

Pm
In horsepower this is -
HPm  HPm  4.5012 horsepower
746

As a crosscheck, the energies at the ends of Sector 1 can be expressed in terms of energy density
times gap volume. At the start of sector 1 -
Bsatg is somewhat reduced from the saturation flux density of powdered iron by fringing -

Bsatg 2 Bsatg  1.7576 Tesla

Energy density - 1
dW  
2 0 dW  1.2287  10 6 Joules per cubic meter

The crossection of the gap is somewhat

greater than the crossection of a slug - Ae  1.2974  10  4 meters squared

Total gap length - lm  7.62  10  3 meters

Total gap volume - Vm  Ae  lm

Vm  9.8859  10  7 cubic meters

Energy as energy density times volume - WgA  dW  Vm

WgA  1.2147 Joules

Which agrees with the energy computed from current and inductance - WA  1.2147 Joules
 Similarly, at the end of sector 1, fringing is Page 6
Bsats  1.8 Tesla
negligible, the flux density in the clearances is
-
2
Energy density - 1 Bsats
dWcl   dWcl  1.2888  10 6 Joules per cubic meter
2 0
.0025
The total volume of the clearances is - Vcl  20  Acl 
39.37
Vcl  1.6088  10  7 cubic meters

Energy as density times volume -

WclA  dWcl  Vcl WclA  0.2073 Joules

Which agrees with energy from inductance and

WAcl  0.2073 Joules
current-

Losses
Copper loss -

The windings are AWG 14 flattened to .03 thick. An average turn length is figured as follows -

( .51  .03)  
lmin 
39.37 lmax 
( .51  6  .033)    lmin  lmax
39.37 lt 
2

lt  0.0498 meters

Total winding length -

lw  lt  144 lw  7.17 meter-
s
Resistance of AWG 14 copper wire is given in ohms /meter as R14  8.282  10  3

Total winding resistance of inductor A - Rw  R14  lw Rw  0.0594 Ohms

Summing the square of currents times their duty cycles by segments, duty cycles are -
1 1
D1  D2  D3  D2 D4  D2
2 6
During sector 3 the current is zero I3  0

During sector 4, the current rises linearly from zero to 2

Isat
Isat. The average square is - Asq4 
3
 During sector 1, the current decays linearly from Isat to Page 7
Isatcl. The average square is -
 Isat  Isatcl 2
Asq1 
3
During sector 2, the current decays linearly from Isatcl to
zero. The average square is - Isatcl 2
Asq2 
3
Weighting the non-zero sectors by their duty cycles, we arrive at an overall average of the current
squared
Asqa  Asq4  D4  Asq1  D1  Asq2  D2 Asqa  1.5635  10 3 Amps squared
rms current in Inductor A-
Irms   Asqa  Irms  39.5406 Amps

Copper loss, accounting for Inductor A, and Inductor B -

LossCop  2  Asqa  Rw LossCop  185.6882 Watts

As a fraction of rated power - LossCop

perunitloss  perunitloss  0.0553
Pm
or 5.6%

Core loss -
Core loss, slugs -
Rated operating frequency - The frequency of the variation of flux in the slugs is one cycle per shaft
rotation -
50000
Fslug  Fslug  833.3333 Hertz
60
Reading the Micrometals chart at 833 Hz, and extrapolating to 18,000 peak gauss, the
specific loss is -
Lossslugsp  3.7  10 6 watts per cubic meter

The total loss in the slugs is given by mutiplying specific loss by total slug volume -
2
 .5 
Lossslug  Lossslugsp  24   
 39.36   .25
4 39.36 Lossslug  71.4854 Watts

As a fraction of rated power - Lossslug

perunitslug  perunitslug  0.0213 or 2.1%
Pm
 Page 8
Total loss in powdered iron end shunts -

The flux flows in both directions around the toroidal

shunt, so the effective area is twice that listed for the
part Aeshunt  2  1.88  10  4

Aeshunt  3.76  10  4 square meters

2
dslug
The crossection of a slug - Aslug    Aslug  1.2668  10  4 square
4 meters
Flux density is decreased from slug flux density by the ratio of the areas -

Aslug
Bshunt  Bsats  Bshunt  0.6064 Tesla
Aeshunt

From Micrometals chart at 833 Hz and

Loss26sp  0.6  10 6 watts per cubic meter
0.607 Tesla, the specific loss is -

There are two shunts with volume listed at 21 cubic centimeters -

Vshunts  2  21  10  6 cubic meters

Total shunt core loss - Lossshunt  Loss26sp Vshunts Lossshunt  25.2 Watt-
s
Total core loss - Losscoret  Lossslug  Lossshunt
Losscoret  96.6854 Watts
Losscoret
As a fraction of rated power -
perunitcore  perunitcore  0.0288
Pm
or
2.9%
Size and weight -
3.61
Length - lOr  meters
39.37

Diameter 2.78
dOr  meters
39.37
2
Volume - dOr
vOr     lOr vOr  3.5908  10  4 cubic meters
4
 Page 9
Mass of two powdered iron end shunts -
Volume of one piece from Micrometals catalog - Vshunt  21  10  6 cubic meters

Density of #26 material -

d26  7.0  10 3 kilogram per cubic meter
Mass of two - M2shunt  2  Vshunt  d26
M2shunt  0.294 kilograms

Weight of slugs is figured from weight of toroids of same diameter, multiplied by a volume correction -

Weight of 24 powdered iron small toroids - 3.7 ounces

Volume of toroid -  .5 2 .25 2 

Vtoroid         .25
 4 4  cubic inches

Volume of slug - .5 2
Vslug     .25 cubic inches
4

Weight of 24 powdered iron slugs - Vslug

W24slug  3.7  W24slug  4.9333 ounces
Vtoroid
In SI units -
M24slug  W24slug  .028 M24slug  0.1381 kilograms

Weight of disks is figured as the measured weight of a

7"X14.5" fiberglass piece, multiplied by an area ratio -

Area of one disk - 2.80 2

Adisk    Adisk  6.1575 square inches
4
Area of eight disks -
A8  8  Adisk A8  49.2602 square inches

Area of fiberglass piece -

Apiece  7.0  14.5 Apiece  101.5 square inches

Weight of fiberglass piece - Wtpc  3.2 ounces

A8
Weight of 8 disks - Wt8  Wtpc 
Apiece Wt8  1.553 ounces

In SI units - Mt8  Wt8  .028

Mt8  0.0435 kilograms
 Page 10
Weight of windings -

Length of all windings - lwtot  2  lw lwtot  14.3404 meters

Mass of 1 meter of AWG 14 - M14  .0185 kilogram

Mass of all windings - Mtotc  lwtot  M14 Mtotc  0.2653 kilograms

Weight of a fiberglass case with 0.10" thickness, 2.8" diameter, and length of sum of motor parts
-
Linmot  6  0.5  5  .03  2  0.71 Linmot  4.57 inches
Volume of case is thickness x circumference x length

Vincase  Linmot    2.8  0.1 Vincase  4.02 cubic inches

1
Vmcase  Vincase 
39.36 3
Vmcase  6.5926  10  5 cubic meters

Density of fiberglass - dfr4  1850 killogram per cubic meter

Mass of case - Mcase  Vmcase  dfr4 Mcase  0.122 kilograms

Total mass of two end shunts+24 slugs+ 8 disks+ 1 case + all windings -

Mtotmotor  Mcase  Mtotc  Mt8  M24slug

Mtotmotor  0.5689 kilograms
Conclusion
This concludes the nmathematical analysis of the profile motor. Page 11, following, is a chart
comparing the Orbic Profile Motor predicted performance, with an industrial motor, and a model motor,
of similar size. Page 12 is an appendix showing how some of the chart data was figured from published
specifications of the motors.
 Motor Comparison Page 11
Between the Orbic Prototype Motor and high performance permanent magnet motors of similar size
There is a sharp distinction between motors for industial use and those built for hobby models.
The Faulhaber motor below is the highest performing industrial motor that we have come across.
As can be seen in the data, it is outclassed by the NeuMotor model motor, and by the Profile motor.

Specific Power
Model Number Manufacturer Torque Speed Shaft Pwr Length Diameter Mass Volume Power Density
| | Newton-mtr rpm Watts mm mm Kg m^3 Watt/Kg W/m^3
4490024B Faulhaber 0.12 16000 201 92 44 0.75 1.39E-04 268 1.45E+06

2215/1.5Y NeuMotor 1.01 19112 1944 84 45 0.71 1.33E-04 2738 1.46E+07

Profile1 Orbic/Gen2 0.641 50000 3358 92 70.6 0.57 3.59E-04 5891 9.35E+06

The NeuMotor shown has a four pole rotor. The torque per pole is lower than the Profile Motor.
 Appendix
Page 12

Conversions for Comparison

NeuM power PNeu  2023 watts

rpmNeu  2  
NeuM rpm rpmNeu  19112  Neu   Neu  2.0014  10 3
60
NeuM Torque PNeu radians per second
TNeu  TNeu  1.0108 Newton meters
 Neu

Faul power PFau  201 watts

Faul rpm rpmFau  16000 rpmFau  2  

 Fau   Fau  1.6755  10 3
PFau 60
Faul Torque TFau  TFau  0.12
 Fau