Design and Preparation of a Manufacturable Flux-Switching Machine

Kurzfassung

To meet the strict targets of the Paris Agreement and Flightpath 2050, the aerospace sector is transitioning toward electric propulsion. While Permanent Magnet Synchronous Motors are widely used due to their high efficiency and power density [1], they face challenges related to cooling and magnet demagnetization, motivating the need to re-evaluate machine topologies. In this study, an outer-rotor Flux Switching Permanent Magnet (FSPM) machine is developed, which involves designing the machine with mechanical constraints derived from utilizing the Hacker Q150 motor components. In addition, electrical constraints such as a maximum DC supply voltage limit of 100 V and a phase RMS current limit of 80 A arising from the existing experimental test setup are also included. These constraints enable the performance enhancement of the machine under study through the geometric optimization of the magnetic circuit. The parametrically developed 2D base model was analyzed for electromagnetic performance characteristics through magnetostatic and transient analyses. Three optimization approaches, Parametric Sweep Optimization, Direct Optimization, and Meta-Model-Based Optimization, are implemented and compared to find optimal tradeoffs between average torque, efficiency, and torque ripple. The chosen design is validated through 3D finite element analysis to account for end-winding effects and axial flux leakage. Finally, the chosen design is translated into a manufacturable prototype, involving mechanical assembly development and technical drawing preparation. In addition, a structured failure mode analysis is conducted through a technical workshop to identify potential risks across electromagnetic, mechanical, and manufacturing domains, ensuring robustness and practical reliability of the proposed design with the help of a 3D-printed functional mock-up. The results show that a constraint-driven optimization approach enables the realization of a high-performance FSPM machine while maintaining practical feasibility and highlights the effectiveness of advanced optimization methodologies for highly coupled electromagnetic systems.