A Study on a Slotless Brushless DC Motor with Toroidal Winding

Abstract

In this study we developed a brushless DC (BLDC) slotless motor with toroidal winding. The proposed toroidal winding is a method of winding a coil around a ring-type stator yoke in the circumferential direction. As there is no need for a slot or tooth structure, it can be designed with a slotless motor structure that is advantageous for vibration and noise. The basic principle of operation and motor characteristics of a slotless motor with toroidal winding were explained using an analytical method and finite element analysis (FEA). Further, the air gap flux density, winding factor, and back electromotive force (EMF) for changes in the winding angle and number of coil turns were calculated using the analytical method and compared with the FEA results. Finally, the resistance, back EMF, cogging torque, and performance of the prototype were measured and compared with the FEA results. The results show that the air gap flux density and winding factor were approximately the same with an error of <2%, while the back EMF had an error of ~10% from the analysis result. Thus, the proposed slotless motor provides a basic design for conveniently manufacturing brushless DC (BLDC) slotless motors with toroidal windings.