M2-2.2 - Metamodel-based Optimization of Coil Units of Axial-Flux Machines and their Validation Using a Test Bench
- Event
- 23. ITG/GMA-Fachtagung Sensoren und Messsysteme 2026
2026-06-09 - 2026-06-10
Nürnberg - Band
- Vorträge
- Chapter
- Modellbildung und Signalverarbeitung
- Author(s)
- F. Schwinning, J. Ihrens, T. A. Kern - Hamburg University of Technology, Hamburg
- Pages
- 404 - 411
- DOI
- 10.5162/sensoren2026/M2-2.2
- ISBN
- 978-3-910600-11-9
- Price
- free
Abstract
The demand for high power density in electrical machines has led to the increasing adoption of axialflux topologies. Due to the strict spatial and gravimetric constraints of these systems, optimizing the coil unit – which constitutes a primary source of thermal and magnetic losses – is a critical design objective. While metamodel-based methodologies enable rapid, multiphysical design exploration, their predictive accuracy relies heavily on empirical validation. Conventional simulation tools require significant computational effort to accurately resolve the coupled effects of manufacturing tolerances, processinduced material degradation, and complex thermal pathways. Consequently, high-quality empirical data is necessary to validate simulation models and train reliable metamodels. However, existing testing frameworks for axial-flux architectures are typically fragmented, evaluating physical domains in isolation and thereby limiting the analysis of coupled multiphysical interactions. This paper presents a novel, integrated multiphysical test bench designed for the comprehensive validation of axial-flux coil units. Operating at up to 10⁰⁰ V or 600 A, the platform enables simultaneous thermal, magnetic, and mechanical characterization of a single specimen without requiring a spinning rotor. Key innovations include active field emulation for manipulating the air gap flux density distribution, a 6-DoF hexapod with custom actuators to emulate manufacturing tolerances and measure resultant multidimensional forces, and an automated 6-DoF kinematic 3D Hall sensor system for precise air gap flux and stray flux mapping. The system architecture is coupled with a Digital Twin for asynchronous experiment planning and safe operation. By establishing this infrastructure, the proposed test bench provides the high-fidelity, cross-domain empirical data necessary to transition advanced axial-flux concepts from simulation to validated prototypes.