Reliability Analysis of Coils in a Coreless Axial Flux Motor Considering Axial Forces

With the continuous development of new energy vehicle technology, coreless axial flux motors have garnered increasing attention due to their advantages in overload capacity and power density. However, as overload capacity and power density improve, the evaluation and enhancement of the reliability of epoxy resin‐encapsulated stators have become critically important. This paper evaluates the risk of epoxy resin fracture during full‐load motor operation under high‐temperature conditions. Additionally, the risk of coil breakage under axial forces is assessed, considering potential epoxy resin failures. By replacing the rotor auxiliary permanent magnet materials and optimising the coil fixation areas, the reliability of the coils is improved. A prototype with adjusted parameters is fabricated and tested under various operating conditions, demonstrating the structural robustness of the motor. This study contributes positively to preventing coil fractures in coreless axial flux motors.