Progettazione e analisi di un motore BLDC PMS per l'applicazione di ventole di ventilazione utilizzando Altair Flux Motor e il software Flux

This thesis presents the design, optimization, and analysis of a Brushless DC (BLDC) Permanent Magnet Synchronous Motor (PMSM) specifically developed for oven ventilation fan applications. The study aims to achieve an energy-efficient, compact, and thermally stable motor that meets application-specific requirements, including efficiency targets, operating speed range, power output, and converter compatibility. A systematic approach is adopted, encompassing the entire motor development process, from initial feasibility studies to advanced simulation-based validation. The design process begins with defining the electromagnetic and mechanical requirements, followed by an analytical pre-design evaluation to determine key motor parameters such as stator and rotor dimensions, winding configurations, and material selection. The motor features an interior permanent magnet (IPM) rotor topology, chosen for its mechanical robustness, flux concentration capability, and reduced sensitivity to airgap harmonics. The stator is constructed using M800-50A laminated steel, while Neodymium-Iron-Boron (NdFeB) permanent magnets of Grade N48H are selected due to their high energy density and temperature resistance. To ensure optimal performance, the motor design is evaluated through finite element method (FEM) simulations using Altair Flux Motor and Flux 2D software. The study focuses on analysing electromagnetic characteristics, including back EMF, torque production, core losses, and cogging torque minimization. Additionally, thermal analysis is conducted to assess the impact of winding and magnet temperature variations on performance and efficiency, ensuring reliable operation in a 70°C ambient environment. The simulation results confirm that the proposed design meets the specified performance targets, demonstrating a strong correlation between analytical predictions and FEM-based assessments. Although the motor design has been rigorously validated through computational analysis, due to time and material constraints, an experimental prototype and real-world testing were not conducted in this study. Future work will focus on prototype fabrication, laboratory testing, and experimental validation to further verify the predicted electromagnetic, thermal, and mechanical performance. Additional optimizations, including alternative rotor topologies, advanced control strategies, and AI-driven design methodologies, will also be explored to enhance the efficiency and reliability of PMSMs for ventilation fan applications. This research provides a comprehensive foundation for the development of high-performance, application-specific BLDC PMS motors, contributing to advancements in motor design methodologies, computational modelling, and optimization techniques in small-scale industrial applications.