Axial Flux Permanent Magnet Machine Research Articles

Performance and Design Comparison of Coreless Axial Flux Permanent Magnet Machines With Different Typical Rotor Optimizations

Performance and Design Comparison of Coreless Axial Flux Permanent Magnet Machines With Different Typical Rotor Optimizations

Design and Optimization of High-Efficiency Coreless PCB Stator Axial Flux PM Machines With Minimal Eddy and Circulating Current Losses

Design and Optimization of High-Efficiency Coreless PCB Stator Axial Flux PM Machines With Minimal Eddy and Circulating Current Losses

Analysis and Optimization of Winding Losses of Axial Flux Permanent Magnet Machine With Concentrated Winding Flat Wires

Analysis and Optimization of Winding Losses of Axial Flux Permanent Magnet Machine With Concentrated Winding Flat Wires

Superior Efficiency Under PWM Harmonic Current in an Axial-Flux PM Machine for HEV/EV Traction: Comparison With a Radial-Flux PM Machine

Superior Efficiency Under PWM Harmonic Current in an Axial-Flux PM Machine for HEV/EV Traction: Comparison With a Radial-Flux PM Machine

Performance Analysis of Slotless Axial Flux Permanent Magnet Machines with Skewed Magnets under Loading Condition

Performance Analysis of Slotless Axial Flux Permanent Magnet Machines with Skewed Magnets under Loading Condition

Vibration Performance Analysis of a Yokeless Stator Axial Flux PM Motor with Distributed Winding for Electric Vehicle Application

This article presents a detailed analysis of the electromagnetic force and vibration behavior of a new axial flux permanent magnet (AFPM) machine with a yokeless stator and interior PM rotor. Firstly, the configuration of an AFPM machine with a dual rotor and a sandwiched stator is introduced, including the structural design, fixation of the yokeless stator and segmented skew rotor structure. Then, the influence of anisotropic material and a fixed structure on stator modes is analyzed, including elastic modulus, shear model, the skew angle of slot and the thickness of stator yoke. Furthermore, a new non-equally segmented skew rotor structure is proposed and calculated for the reduction in vibration based on the multiphysics model. Three different segmented skew rotor schemes are compared to illustrate the influence of reducing vibration and noise. The predicted results show that the effect of the non-equally segmented skew rotor on reducing vibration is better than the other two schemes. Finally, a 120 kW AFPM motor is experimented with and the result matches well with the predicted data. The vibration performance of the AFPM motor with a dual rotor and sandwiched yokeless stator is revealed comprehensively.

A study of rare-earth magnet profiles for torque ripple improvement of axial flux permanent magnet machine

Purpose The purpose of this study is to reduce the cogging torque in axial flux permanent magnet (AFPM) machine using optimal magnet shape. Design/methodology/approach This study analyzes different magnet shapes for AFPM machine performance enhancement. Three-dimensional (3D) finite element analysis is performed to see the effects of pole shaping on the cogging torque of the AFPM machine. Findings The magnetic pole shape has a significant effect on cogging torque and overall efficiency. The conventional model has the highest torque whereas the conventional skewing affected cogging torque positively and significantly reduced the cogging torque. The combination of skewing the pole along with face curving is more effective and decreases the cogging torque from 3.88 Nm to 1.5 Nm. Originality/value Rare-earth magnets are the most expensive and important part of AFPM machines. Shape and volume optimization of rare-earth magnets is crucial for the performance of AFPM machines. The research aims to analyze the different permanent magnet designs for performance improvement of the AFPM machine. Conventional flat top trapezoidal, curved-top and skewed-magnet shapes are analyzed and the performance of the AFPM machine is compared with different magnet shapes. Curved-top shape and skewed magnet significantly reduce the cogging torque. Furthermore, a combination of curved-top shape and skew magnet shape is proposed to reduce the cogging torque further and improve the AFPM machine’s overall performance. Newly proposed magnet profile gives skewed curve magnet shapes which reduce the cogging torque further. 3D finite element analysis has been used to analyze the single-sided AFPM with all four different magnet shapes. The research focuses on single-sided AFPM machines, but the results are also valid for double-sided AFPM machines and can be extended to other topologies of AFPM machines.

Design of a Printed Circuit Board Axial Flux Permanent Magnet Machine for High Speed Applications

Design of a Printed Circuit Board Axial Flux Permanent Magnet Machine for High Speed Applications

Design Optimization of a Spoke-Type Axial-Flux PM Machine for In-Wheel Drive Operation

Design Optimization of a Spoke-Type Axial-Flux PM Machine for In-Wheel Drive Operation

Hybrid Optimization and Comparative Analysis of a Novel Double-Side Asynchronous Rotor Axial-Flux Permanent Magnet Machine

Hybrid Optimization and Comparative Analysis of a Novel Double-Side Asynchronous Rotor Axial-Flux Permanent Magnet Machine

Ultra‐fast finite element analysis of coreless axial flux permanent magnet synchronous machines

AbstractLarge‐scale design optimisation techniques enable the design of high‐performance electric machines. Electromagnetic 3D finite element analysis (FEA) is typically employed in optimisation studies for accurate analysis of axial flux permanent magnet (AFPM) machines, which require extensive computational resources. To reduce the computational burden, a FEA‐based mathematical method relying on the geometric and magnetic symmetry of coreless AFPM machines is proposed to estimate the machine performance indicators using the least number of FEA solutions, thereby significantly lowering the running time. This method is generally applicable to AFPM machines with low saturation effects and cogging torque as exemplified for a printed circuit board (PCB) stator coreless AFPM machine. To further reduce the computation time, a systematically simplified equivalent 3D FEA model for planar PCB coils integrated with this machine is also proposed. The practical implementation of the introduced method is elaborated based on an example optimisation study, and an analytical method for fast design scaling is also discussed. The results of the proposed approach are compared with detailed transient FEA results, and a prototype 26‐pole PCB stator coreless AFPM machine was also used to validate the results experimentally.

Nonlinear Analytical Solution in Axial Flux Permanent Magnet Machines Using Scalar Potential

Analytical model (AM) has significant value on early design stage for electric machines, in terms of both time and accuracy. AM can be developed based on vector or scalar potential, but all AMs for armature reaction are using the vector potential, and it is a difficult matter to model armature reaction by scalar potential. This is the gap that the work here proposed aims to fill. We, for the first time, report the load magnetic field prediction by using magnetic scalar potential. Also, the proposed nonlinear AM is developed for the surface mounted permanent magnet machine. The proposed model is development based on the two-dimensional harmonic subdomain approach by solving the Maxwell's equations. The magnetic sources, viz., the armature reaction is regarded as line current and solved at the connection boundaries. The comprehensive derivations and calculation algorithm are explained in detail. Moreover, the analytical model is developed for an axial flux PM machine, both finite element model and experiment are verified the correctness of proposed model, and good agreement is achieved. Moreover, a slightly modification can also be applied to the radial flux PM machines.

Multi-Objective Optimization of Yokeless and Segmented Armature Machine for In-Wheel Traction Applications Based on the Taguchi Method

For electrical machines with complex structures, the design space of parameters can be large with high dimensions during optimization. Considering the calculation cost and time consumption, it is hard to optimize all the design parameters at the same time. Therefore, in that situation, sensitivity analysis of these design parameters is usually used to sort out crucial parameters. In this paper, the sensitivity analysis-based Taguchi method is applied to optimize the axial-flux permanent magnet (AFPM) machine with yokeless and segmented armature (YASA) topology for an in-wheel traction system. According to the key parameters and their sensitivity analysis, the optimal machine scheme to meet the performance requirements can be formed. In this case study, the machine performance is improved significantly after optimization. Lastly, the experimental results verify the accuracy of the model used in this study.

Analytical model of an ironless axial flux permanent magnet machine for electromagnetic force calculation and vibration analysis

Analytical model of an ironless axial flux permanent magnet machine for electromagnetic force calculation and vibration analysis

Prototype development of a fully coreless multi-stage axial-flux permanent-magnet machine (AFPM) through the performance comparison between single-stator double-rotor (SSDR) and double-stator single-rotor (DSSR) configurations

Cascading rotor and stator in axial flux permanent magnet (AFPM) machine is a beneficial concept to increase the power density without increasing the diameter of the machine. Multi-stage AFPM can provide higher torque capability in applications requiring high power density. In this regard single-stator double- rotor (SSDR) and double-stator single-rotor (DSSR) are efficient machines compared to single -stage AFPM. Since SSDR and DSSR are also considered modular units to make multi-stage AFPM, like single-stage AFPM, this paper makes a comparison with analysis between SSDR and DSSR AFPM machines. Based on 3-D finite element analysis (FEA), the air-gap magnetic flux, voltage, current, torque, torque ripple, power and power density, efficiency are comparatively investigated to evaluate their performance. Results show that fully coreless topology only be achieved in SSDR AFPM machine with a higher power density. Finally, a prototype multi-stage coreless generator has been developed using a single stator double rotor (SSDR) configuration to justify the fully coreless concept. This prototype coreless generator eliminates eddy current losses and reduces weight, making it a suitable option for certain portable applications.

Equivalent Analytical Model of Magnetic Field in Parallel Magnetic Circuit Axial Flux Permanent Magnet Machines

The axial flux permanent magnet (AFPM) machines with the parallel magnetic circuit (PMC) rotor can effectively improve its torque density. The PMC rotor consists of two sub‐rotors, radial Halbach array permanent magnet (PM) and tangential PM. The magnetic fields generated by two sub‐rotors are not in the same 2‐D analytical planes. In this paper, an equivalent analytical model of PMC‐AFPM machines is proposed to solve this problem. The radial Halbach array PM rotor is equated to the axial Halbach array PM rotor based on the equivalent transformation principle. The exact subdomain models of equivalent axial Halbach array PM rotor and tangential PM rotor are built respectively and then superimposed to obtain the magnetic field distribution. The electromagnetic characteristics of the PMC‐AFPM machine under no‐load and load conditions are calculated by the proposed analytical model and compared with calculations of the finite element model (FEM). The results verify the accuracy of the equivalent analytical model. The comparative analysis of the AFPM machines with PMC rotor and tangential PM rotor verifies the advantage of PMC rotor configuration to improve the torque density. © 2024 Institute of Electrical Engineer of Japan and Wiley Periodicals LLC.

Study on the Influence of a Combined-Halbach Array for the Axial Flux Permanent Magnet Electrical Machine With Yokeless and Segmented Armature

To increase torque density, a combined-Halbach array for the axial flux permanent magnet machine (AFPMM) with yokeless and segmented armature (YASA) is presented in this paper. Firstly, the YASA machine models with conventional axial magnets and combined-Halbach array magnets are established by using 3-D finite-element method (FEM). Then, the torque, torque per magnet-volume and no-load back electromotive force (back-EMF) are calculated, and the performance of two machines are analyzed and compared. It is demonstrated that the combined-Halbach array can improve the torque density of the machine and the utilization rate of the magnets. Finally, the combined-Halbach array rotor is optimized, where the rotor with unequal-thickness magnets is established, and its torque density is calculated under different thickness. The results show that the combined-Halbach array with unequal-thickness magnets can decrease the amount of permanent magnet materials, thus improve the utilization of magnets and reduce the costs.

Additively Manufactured Winding Design for Thermal Improvement of an Oil-Cooled Axial Flux Permanent Magnet Machine

Additively Manufactured Winding Design for Thermal Improvement of an Oil-Cooled Axial Flux Permanent Magnet Machine

A Novel Counter-Rotating AFPM Machine Based on Magnetic-Field Modulation for Underwater Propulsion System

The underwater propulsion system (UPS) with two counter-rotating propellers is very popular now. In tradition, it needs two electric machines or additional gears, which greatly increases the volume and weight of the system. Therefore, a novel counter-rotating axial-flux permanent magnet (AFPM) machine based on magnetic-field modulation (MFM) for the UPS is proposed. It contains a more pole (MP) rotor and a less pole (LP) rotor on two sides. The MFM is achieved through the split teeth on the stator. Based on the MFM, the two rotors can rotate in opposite directions. The principle of MFM and the relationships of rotary speeds between two rotors are analyzed. Furthermore, the effects of split tooth shape and dimensions on the performances of the proposed machine are also evaluated. The triangular skew fan-shaped split teeth are adopted in the counter-rotating AFPM machine. Finally, the prototype is manufactured and an experiment is conducted to validate the performance. The results show the consistency of analysis and experiment.

Design of an Integrated Magnetorheological Fluid Brake Axial Flux Permanent Magnet Machine

This paper presents the design and performance of an integrated magnetorheological fluid brake axial flux permanent magnet (IMRFB-AFPM) machine with two switchable operation modes: rotation and brake modes while the machine has two kinds of windings: armature winding in axial stators and braking winding in radial stator. In rotation mode, this machine is equal to a conventional AFPM machine with high torque density. When switching to brake mode, MR fluid is excited by braking winding and applies large damping stress to the rotor to brake it. This paper illustrates the machine topology, operation principles, and design flow of the proposed machine. Then, this paper analyzes the torque generation mechanism in two modes and applies parameters optimization to improve the torque capability of each mode. Due to the independence of the magnetic flux path, the parameters optimization is divided into two parts: AFPM part and IMRFB part. After the optimization process, the electromagnetic performances of the optimal IMRFB-AFPM machine are analyzed by finite element (FE) analysis. Finally, a prototype machine with the optimal geometric parameters is manufactured and verified experimentally. The experiment results agree well with FE analysis results, validating the feasibility and practicability of the proposed design.