Optimized Square-Wire Windings: Unlocking Higher RMS Torque in Precision Motor Applications

Abstract:
This paper presents a novel motor design for galvanometer scanners used in high-precision laser beam deflection systems. The design features an ironless configuration with square-wire windings, which results in a significant improvement in performance, increasing the maximum RMS torque by 46% compared to conventional round-wire solutions, enabling higher throughput in laser-based precision manufacturing systems. The optimization of the winding geometry was carried out using a multiphysical simulation framework, integrating electromagnetic, thermal, and dynamic modeling to minimize coil temperature and maximize positioning dynamics. Experimental results confirm the effectiveness of the optimized design. Moreover, a close match between simulation and measurement with deviations below 10% for all key parameters validates the accuracy of the multiphysical modeling approach. A detailed comparison with traditional motor topologies demonstrates the practical benefits of the proposed design, including enhanced thermal behavior, absence of cogging torque, and therefore suitability for precision applications.