Abstract:

The article presents the process of designing the BLDC "Direct Drive" drive with the support of virtual prototyping tools using FEA techniques. Virtual prototyping techniques allow you to test various product concepts and optimise them in a much shorter time and at lower costs. Only the best constructions are next selected for physical prototyping, which significantly affects the products' quality. The article proposes a method for selecting the best BLDC drive design based on the simulation of its operation using the finite element method. FEM environments that also consider electromagnetic phenomena allow for simulation testing of the impact of various motor parameters, e.g., the number of magnets and windings and the air gap and magnet thickness on the density of the electromagnetic field and the cogging and electromagnetic torque. Three-dimensional FEM (3d-FEM) simulations, especially taking into account the Multiphysics approach, are a very resource-intensive and time-consuming process. On the other hand, analysis performed only in two dimensions with  FEM (2d-FEM) allows for a significant simplification of calculations and, thus, their considerable acceleration. Unfortunately, this is burdened with the deterioration of the accuracy of the obtained results.