Axial flux synchronous reluctance motor design, prototype manufactoring and tests

In this thesis, an Axial Flux Synchronous Reluctance Motor (AF-SRM) with multiple barriers on its rotor, which is an original study that has not been studied in the literature, was designed, then prototype production was made and finally performance tests were completed. In the preliminary study of the AF-SRM design, two different topology barrier types, multiple barrier structures and three different insulation ratios were analytically calculated on the rotor and modeled with the 3D Finite Element Method (FEM). In the model that gave the best analytical result, the torque ripple value was reduced by changing the barrier geometry with a Genetic Algorithm (GA) based optimization analysis, structural analysis and thermal analysis were completed and a prototype motor was produced. Produced prototype has been tested according to IEC TS 60034-30-2 criteria and has IEC 60034-30-1:2014 IE4 Super Premium efficiency class. Torque, torque ripple, power factor, shaft power, torque per current and efficiency parameters were analyzed and compared with simulation results. As a result, this completed thesis study has been a good alternative in applications where high efficiency and torque are required, with no copper losses due to the absence of a cage in the rotor and low maintenance costs with its structure without magnet. With its axial structure, it has become a candidate to replace radial flux motors in the cases with dimension problems.