Performance Analysis of Brushless Motors with Segmented Cores considering Manufacturing Constraints

Brushless servomotors are widely used in industry and in all domains that require precise and easy position/speed/torque control. To further improve the performance of these motors, the segmentation of the stator core is taken into account. This approach to core construction provides a high slot fill factor, compact design, and efficient use of materials. This paper aims to present that the manufacturing constraints and tolerances of this particular core construction can increase unwanted effects in brushless motors, like cogging torque, torque ripple and their influence regarding the back-EMF. Two models for a 12slots-10 pole configuration, one with segmented core and one with standard laminated core are compared and analysed using the FEA (Finite Element Analysis) method. The influence of the additional air gaps that occur in such constructions is investigated to provide an overview for the design of segmented motors. Various lengths for air gaps between the segments of the core are taken into consideration and non-uniform distribution of such gaps. The paper also provides further steps that must be taken in order to verify/validate the studied model’s impact on motor design.