Potential of Flex-PCB Winding in Coreless Tubular Permanent Magnet Synchronous Machines

Many applications are limited by the performance of the motors that power them. In the small power range, slotless BLDC motors are commonly used due to their intrinsic high power density and smooth torque characteristic. However, recent work has shown that the power density of radial flux rotating motors could be significantly increased by replacing their windings, made of copper wire by windings printed on flexible PCB, taking most advantage of the possibilities offered this technology. The aim of this work is to evaluate the performance gain that could be obtained by using this technology in linear tubular motors. To that end, an analytical model is implemented and used for comparing different winding shapes regarding to two criteria, one related to the power density, the other to the force smoothness. A track shape which annihilates the higher harmonics is developed and compared to different 3-segment PCB windings and to a conventional wire winding.