Abstract
This paper proposes the design of a three-phase axial flux permanent magnet alternator (AFPMA) that is characterized with an air-cored stator and two-rotor (ACSTR) configuration. The AFPMA is harnessed with fully controlled AC/DC converter using six bridge Insulated Gate Bipolar Transistor (IGBTs) capable to deliver a constant DC output power as an attempt to replace the Lundell alternator for automotive applications. First, the design methodology and analysis of the AFPMA is introduced. The most effective parameters, such as rotor diameter, magnet thickness, number of turns, and winding thickness are determined. A smart digital control which facilitates the comparison between the magnitudes of the three-phase input signals instead of finding the zero crossing points is developed. Moreover, custom design comparators are specially designed and developed to generate adaptive signals that are fed into an Arduino Uno microcontroller. Accordingly, the Arduino generates the timely precise pulses that are necessary to maintain the appropriate triggering of the IGBTs. This technique allows the IGBTs to conduct in an adaptive manner to overcome the problem of asymmetrical voltage outputs from the AFPM alternator. The system is also capable of handling the variation in the speed of the AFPMA via the rigor code in Arduino that detects the change in the supply frequency and voltages in a real time process. The system is first analyzed via simulations using MATLAB/Simulink and then experimentally validated at certain speed and loading conditions. The preliminary tests results indicate that such system is capable to provide an efficient solution to satisfy automotive electric power demands.
Highlights
When implementing electrical technology or components into vehicles, the size, weight, cost, performance, and efficiency are the major factors that need to be considered for successful integration.Steadily but surely, automobile manufacturers are looking to improve vehicle component performance and increasing their power density
Conclusions and Analytical results showed that the axial flux permanent magnet alternator (AFPMA) having four turns per coil per phase is suitable were developed, and optimization of the machine was performed based on parametric analysis
Analytical results showed that the AFPMA having four turns per coil per phase is suitable to run at nearly 4800 rpm to achieve an power output of 1.2 kW at rated line voltage of 17 and rated current of 40 A at an expected efficiency of 94%
Summary
When implementing electrical technology or components into vehicles, the size, weight, cost, performance, and efficiency are the major factors that need to be considered for successful integration. Automobile manufacturers are looking to improve vehicle component performance and increasing their power density. Among these components is the on-board electrical power charging system which normally consists of the alternator, power converter, and battery. Lundell alternators suffer from major drawbacks such as reduced efficiency, limited output power, and the need for continuous maintenance. This in turn has limited the utilization of such machines in Energies 2018, 11, 274; doi:10.3390/en11020274 www.mdpi.com/journal/energies
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