Feasibility of a New Ironless-stator Axial Flux Permanent Magnet Machine for Aircraft Electric Propulsion Application

With the development of aviation electrification,higher demands for electrical machines are put forward in aircraft electric propulsion systems.The aircraft electric propulsion requirements and propulsion motor features are analyzed in this paper.Comparing with conventional PM machines,ironless stator axial flux permanent magnet(AFPM)machine topologies with Litz wire windings allow designs with higher compactness,lightness and efficiency,which are suitable for high-frequency and high-power density applications.Based on the motor requirements and constraints of aircraft electric propulsion systems,this paper investigates a high-power 1 MW multi-stack ironless stator AFPM machine,which is composed of four 250kW modular motors by stacking in axial.The design guidelines and special attentions are presented,in term of electromagnetic,thermal,and mechanical performance for the high-frequency coils and Halbach-array PM rotor.Finally,an ironless stator AFPM motor is manufactured,tested and evaluated with the consideration of cost and processing cycle.The results show that the output power is up to 53.8kW with 95%efficiency at 9000r/min at this stage.The proposed ironless stator AFPM machine with oil immersed forced cooling proves to be a favorable candidate for application in electric aircraft as propulsion motors.

Design and Performance Analysis of Axial Flux Permanent Magnet Machines with Double-Stator Dislocation Using a Combined Wye-Delta Connection

Conventional fractional slot concentrated winding three-phase axial flux permanent magnet machines have an abundance of armature reaction magnetic field harmonics which deteriorate the torque performance of the machine.This paper presents a double-stator dislocated axial flux permanent magnet machine with combined wye-delta winding.A wye-delta(Y-△)winding connection method is designed to eliminate the 6 th ripple torque generated by air gap magnetic field harmonics.Then,the accurate subdomain method is adopted to acquire the no-load and armature magnetic fields of the machine,respectively,and the magnetic field harmonics and torque performance of the designed machine are analyzed.Finally,a 6 k W,4000 r/min,18-slot/16-pole axial flux permanent magnet machine is designed.The finite element simulation results show that the proposed machine can effectively eliminate the 6 th ripple torque and greatly reduce the torque ripple while the average torque is essentially identical to that of the conventional three-phase machines with wye-winding connection.

Comparative Study of Novel Axial Flux Magnetically Geared and Conventional Axial Flux Permanent Magnet Machines

In this paper,a performance comparison between the novel axial flux magnetically geared machines(AFMG)and the conventional axial flux YASA machine is presented.The AFMG and YASA machines have the same stator construction in which segments are equipped with concentrated windings to form the stator.However,the AFMG machine has two rotors with different pole-pair numbers.Magnetic gear effect can be obtained to increase the torque density.The performance comparisons at no-load and on-load conditions are then studied by 3D-finite element analysis(FEM).Moreover,both machines are prototyped,tested and compared.

Three-dimensional Analytical Modeling of Axial Flux Permanent Magnets Maglev Motor

The three-dimensional(3D)analytical model of the magnetic field in an Axial Flux Permanent Magnets Maglev Motor(AFPMMM)is proposed and investigated the influence of the structural parameters on electromagnetic characteristics.Firstly,the topology and working principle of the AFPMMM is introduced,and the model is transferred into a mathematical model in 3D cartesian coordinate.Then,the volume integral method and equivalent current sheets model is applied to find the 3D magnetic field distribution function of Halbach rotor.A unified form expression can be obtained by two dimensional discrete fourier transform(2-D DFT)is applied on the 3D magnetic field distribution function.Thirdly,the conductive and nonconductive regions of AFPMMM will be formulated by the second order vector potential(SOVP)to built the 3D analytic model.The expression of the lift force,torque and power losses was derived.Besides,the relationship between electromagnetic characteristics and structural parameters of the AFPMMM were analyzed based on 3D analytic model and validated using the 3D finite element analysis(FEA).Finally,the experiments based on a small scale prototype are carried out to verify the analytical results.

Design Optimization of Axial Flux Permanent Magnet (AFPM) Synchronous Machine Using 3D FEM Analysis

This paper deals with the investigation of the behavior of a low speed, dual rotor-single coreless stator, axial flux permanent magnet synchronous machine for small power applications. Firstly, with the use of nonlinear 3D FEM electromagnetic analysis, four models with different magnet topologies are designed, simulated and compared. With criteria such as output power, power factor and torque ripple, the best performing model is selected and a further investigation, regarding the effect of the disk rotor material on the behavior of the machine, is conducted. The simulation results show how the different types of commercially available steel types affect the magnetic field and the performance of the machine.

Enhancement of Wind Energy Conversion Using Axial Flux Generator

This paper investigates the application of the axial flux machine (AFM) to the wind energy conversion systems (WECS) to obtain high power and torque at reduced cost. By developing mathematical equations using the phase and active transformations, the three-phase model is transformed to two-phase equations by making both the stator and rotor as reference frames, finally converting to arbitrary reference frame, which is useful for the modelling of the axial flux machine. The torque, current, and voltage equations are expressed to improve the simulation reliability. Based on the developed equations, the mathematical model for the axial flux machine is developed using the MATLAB/Simulink. Starting with the axial flux motor model, when the load on the motor increases, how the parameters like torque, current, and speed of the motor vary are explored in this paper. Then for the axial flux generator model, when the wind speed exceeds the rated speed how the torque, line voltages, currents, power and speed of the generator behave are investigated and presented in this paper. The developed model in this paper could be extended to a twin-rotor axial flux synchronous machine, which will lead to the development of more efficient WECS.

Study on Axial Flux Hysteresis Motors Considering Airgap Variation

Axial flux hysteresis motor (AFHM) is self-starting synchronous motor that uses the hysteresis characteristics of magnetic materials. It is known that the magnetic characteristics of hysteresis motor could be easily affected by air gap and structure dimensions variation. Air gap length plays an important role in flux distribution in hysteresis ring and influences the output torque, terminal current, efficiency and even optimal value of other structural parameters of AFHM. Regarding this issue, in this study effect of air gap variation on performance characteristics of an axial flux hysteresis motor and effect of air gap length on hysteresis ring thickness and stator winding turns is investigated. Effect of air gap length on electrical circuit model is perused. Finally, simulation of AFHM in order to extract the output values of motor and sensitivity analysis on air gap variation is done using 3D-Finite Element Model. Hysteresis loop in the shape of an inclined ellipse is adopted. This study can help designers in design approach of such motors.

Electric Drive for an In-wheel Fractional-slot Axial Flux Machine

This paper describes the electric drive for an in-wheel fractional-slot axial flux machine,designed for achieving a wide flux-weakening operating region.By using a slotted stator with fractional-slot windings and additional cores enclosing end windings,the axial flux machine reaches a wide constant power speed range.The machine is designed for increasing flux-weakening capability while obtaining low harmonic back-electromotive force and low cogging torque.A 10 N.m axial flux machine exhibiting 3 to 1 flux-weakening speed range has been built.A flux-weakening controller,able to maximize the output torque in the flux-weakening region,is designed and implemented.The goodness of both design and control algorithm is proved by experimental tests.However,such a fractional-slot machine has not only advantages.Rotor losses are very high,and they have to be properly considered during the design process.

Developing a 3D-FEM Model for Electromagnetic Analysis of an Axial Flux Permanent Magnet Machine

Recently, many optimal designs for axial flux permanent magnet (AFPM) motors were performed based on finite- element (FE) analysis. Most of the models are based on reduction of 3D problem to 2D problem which is not accurate for design aspects. This paper describes an accurate electromagnetic analysis of a surface mounted, 28 pole AFPM with concentrated stator winding. The AFPM is modeled with three-dimensional finite-element method. This model in-cludes all geometrical and physical characteristics of the machine components. Using this accurate modeling makes it possible to obtain demanded signals for a very high precision analysis. Magnetic flux density, back-EMF, magnetic axial force and cogging torque of the motor are simulated using FLUX-3D V10.3.2. Meanwhile, the model is paramet-ric and can be used for design process and sensitivity analysis.

Comparative Analysis of Vibration and Noise of Axial Flux Motor with Different Pole and Slot Combinations

The electromagnetic vibration noise in axial flux motors was meticulously examined.In this study,24-slot/10-pole and 12-slot/10-pole axial flux motors were chosen as the subjects of research.The spatial characteristics of the axial electromagnetic force were derived analytically and confirmed via two-dimensional Fourier decomposition.The finite-element method was used to simulate the low-order axial modes of both motors.Furthermore,a modal experiment on the stator of a 24-slot/10-pole axial flux motor was conducted to validate the simulation’s accuracy.By integrating the electromagnetic and structural models,a comprehensive multi-physical field model was developed to calculate the vibration noise of the axial flux motor.The precision of this model was subsequently corroborated with noise experiments.The findings from this study aim to offer insights into identifying the sources of vibration noise in axial flux motors.

Multi-layer Quasi Three-dimensional Equivalent Model of Axial-Flux Permanent Magnet Synchronous Machine

Axial-flux permanent magnet synchronous machine(AFPMSM)enjoys the merits of high torque density and high efficiency,which make it one good candidate in the direct-drive application.The AFPMSM is usually analyzed based on the three-dimensional finite element method(3D FEM)due to its three-dimensional magnetic field distribution.However,the 3D FEM suffers large amount of calculation,time-consuming and is not suitable for the optimization of AFPMSM.Addressing this issue,a multi-layer quasi three-dimensional equivalent model of the AFPMSM is investigated in this paper,which could take the end leakage into consideration.Firstly,the multi-layer quasi three-dimensional equivalent model of the AFPMSM with single stator and single rotor is derived in details,including the equivalent processes and conversions of structure dimensions,motion conditions and electromagnetic parameters.Then,to consider the influence of end leakage on the performance,a correction factor is introduced in the multi-layer quasi three-dimensional equivalent model.Finally,the proposed multi-layer quasi three-dimensional equivalent model is verified by the 3D FEM based on an AFPMSM under different structure parameters.It demonstrates that the errors of flux linkage and average torque obtained by the multi-layer quasi three-dimensional equivalent model and 3D FEM are only around 2%although the structure parameters of the AFPMSM are varied.Besides,the computation time of one case based on the multi-layer quasi three-dimensional equivalent model is only 6 min,which is much less than that of the 3D FEM,1.8 h,under the same conditions.Thus,the proposed multi-layer quasi three-dimensional equivalent model could be used to optimize the AFPMSM and much time could be saved by this method compared with the 3D FEM.

Design of a PCB stator coreless axial flux permanent magnet synchronous motor based on a novel topology Halbach array

A novel topology Halbach permanent magnet array is proposed and applied to the design of a printed circuit board(PCB) axial flux permanent magnet(AFPM) motor. Compared with the traditional coreless AFPM motor, this novel topology for a Halbach permanent magnet array PCB stator AFPM motor has larger air-gap magnetic flux density and air-gap flux per pole. The magnetic flux leakage is effectively reduced, and the air-gap magnetic density is close to the sine wave. Results of the finite element analysis and prototype experiments verify the feasibility and effectiveness of the novel Halbach permanent magnet array PCB stator motor. A reference basis and practical value for the design of the PCB AFPM motor are provided.

Comparative Study of Conventional, Fuzzy Logic and Neural PID Speed Controllers with Torque Ripple Minimization for an Axial Magnetic Flux Switched Reluctance Motor

Three speed controllers for an axial magnetic flux switched reluctance motor with only one stator, are described and experimentally tested. As it is known, when current pulses are imposed in their windings, high ripple torque is obtained. In order to reduce this ripple, a control strategy with modified current shapes is proposed. A workbench consisting of a machine prototype and the control system based on a microcontroller was built. These controllers were: a conventional PID, a fuzzy logic PID and a neural PID type. From experimental results, the effective reduction of the torque ripple was confirmed and the performance of the controllers was compared.

Optimization of Power Density for Axial-Flux Machinethrough Generalized Sizing Equations

With the cvolution of various high powerr-density machines, it beeomes important to optimize the power potential of machines of vastly different topologies with a variety of waveforms of back emf and current. The approach of tins paper is based oil the gencral-purpose sizing equations. which permit the optinlization method of machine power density to be applied to the axial-flux toroidal permanent-magnet (AFTPM) machine, and,furthermore, the power-production capabilities of the AFTPM machinc and the wen-known squirrel-cage indution machine are compared.

Investigation on Static Characteristics of an Axial-Flux Permanent Magnet Machine with Coreless Stator

The static characteristics of an axial-flux permanentmagnet( AFPM) machine with coreless stator were investigated.Two-dimensional analytical method for prediction of the no-load magnetic field in the AFPM machine with coreless stator was derived. Electromotive force( EMF) and axial attraction force were deduced from the analytical method. These values obtained from analytical method were compared with those from finite element method( FEM) and agree well. Finally,a prototype was built for experimental validation and back EMF was measured. The results confirmed the validity of the proposed analytical method.

Design of Axial-Flux Motor for Traction Application

This paper deals with the design of high power – low dimensions axial-flux permanent-magnet motor intended for trac-tion application. First, two motor configurations are analytically designed and compared using finite element calcula-tion. Then, the configuration yielding the best performances is integrated and modelled with the whole traction chain under MATLAB/SIMULINK environment in order to demonstrate the motor operation on a large speed band.

YASA轴向磁通永磁电机定子槽漏感计算

定子槽漏感是定子无轭模块化(yokeless and segmented,YASA)轴向磁通永磁电机电感的主要分量,会降低电机的功率因数和最大输出转矩。该文提出定子槽内微小单元磁场能量法计算YASA电机的定子槽漏感,通过建立计及铁心饱和影响的二维等效磁网络模型准确计算槽内微小单元储存的磁场能量,进而计算定子槽漏感。基于所提出的方法,进一步研究定子结构参数以及极槽配合对YASA电机定子槽漏感的影响规律。有限元仿真和实验结果表明,该文所提出的YASA电机定子槽漏感计算方法的可行性和准确性。

半直驱MW级轴向磁通永磁风力发电机电磁设计与分析

在大功率直驱式风力发电机设计中,针对轴向磁通永磁发电机径向尺寸大、后期维护成本高的问题,文章将轴向磁通永磁发电机设计为大功率半直驱式风力发电机。以2 MW半直驱轴向磁通永磁发电机为研究对象,研究其参数设计原则和方法。通过探究不同极对数对发电机输出性能的影响,确定满足设计目标的发电机优选方案。采用3D有限元分析法对发电机空载和额定负载工况下的气隙磁密、电压、电流波形以及输出功率、损耗和效率进行分析,验证发电机电磁设计的正确性,发电机效率可以达到97.79%,具有损耗小、效率高的优点。通过与现有发电机进行对比,文章所提出的半直驱MW级轴向磁通永磁发电机径向尺寸显著减小,且在轴向尺寸和齿槽转矩方面比现有径向磁通结构的大功率半直驱永磁发电机表现更优。

新型三段Halbach永磁阵列无铁芯AFPMG设计与分析

为解决传统Halbach永磁阵列无铁芯轴向磁通永磁发电机(AFPMG)由于磁极永磁体用量增加而导致功率密度降低的问题,提出了一种变辅助磁极参数(极角和充磁夹角)的新型三段Halbach永磁阵列无铁芯AFPMG.采用三维有限元法,对新型三段Halbach永磁阵列辅助磁极极角和充磁夹角进行了多目标优化设计,从而确定了最佳辅助磁极参数.最后对比了无铁芯AFPMG中采用不同磁极结构对发电机电压波形质量和功率密度的影响.结果表明:新型永磁发电机可以使发电机电压正弦波畸变率由2.40%下降为0.44%;相较传统两段Halbach和传统三段Halbach永磁阵列的无铁芯AFPMG,新型永磁发电机功率密度得到显著提高;新型永磁发电机的永磁体用量减少了16.68%,进而减轻了转子盘质量,使发电机更加适于低风速下稳定发电.

温度影响下的开槽盘式磁力耦合器调速特性

针对温度影响下盘式磁力耦合器调速问题,以一台6对极16槽的开槽盘式磁力耦合器为研究对象,基于矢量磁位法,结合修正三维端部效应的卡特系数并考虑温度对永磁体剩磁的影响,依据磁力耦合器轴向介质不同与导体盘轭铁和铜导体交替排列的结构,推导出其整体的电磁转矩公式。再分别建立恒转矩负载、二次方率负载和恒功率负载工况下的调速关系解析模型。通过有限元模拟分析,确定了不同温度、不同气隙下的开槽盘式磁力耦合器在3种不同负载工况下的调速范围与调速特性。最后,搭建试验平台进行调速性能试验,将不同负载工况下磁力耦合器电磁转矩与输出转速的理论、仿真、实验值三者进行对比,结果表明理论模型有较高的准确性,为开槽型磁力耦合器在调速系统中的智能调控提供了理论依据。