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We designed and tested a new axial flux permanent-magnet machine (AFPM) with field weakening capability. This paper provides a summary of key design features, optimization, and test results of an AFPM prototype. The proposed field weakening method is based on the control of the d-axis component of the armature reaction flux. The paper focuses on the air-gap flux control capability of the topology. Index Terms--Axial flux machine, field weakening, permanent-magnet machines.

In designing new topologies for permanent-magnet machines based on rare earth magnets, it is necessary to diminish the undesired cogging torque. This paper presents a 3-D finite-element analysis to evaluate the effect of magnet shape and stator displacement on cogging torque reduction, for axial flux machines. It analyzes the final electromagnetic torque for the proposed configurations. Finally, it presents the resultant cogging torque waveform for a 5.0 kW prototype, based on our optimization techniques. Index Terms--Axial flux machine, cogging torque, permanent-magnet machine.