Optimal Design of Radial-Flux Toroidally Wound Brushless DC Machines

Toroidally wound brushless dc (BLDC) machines are compact, economical, and can operate across large air gaps. In this paper, we provide analytical design equations for a radial-flux toroidally wound BLDC machine. The validity of the design equations is checked against finite-element analyses (FEAs) and experiments. It is found that the motor constant calculated by the design equations is off only by 5% from the results by the FEAs or experiments. We also provide an optimization metric that corresponds to the maximization of machine torque while maintaining minimum power loss. Two optimal design cases are presented.