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Axial Flux Permanent Magnet (AFPM) machines with ironless rotors are an attractive and recently studied solution in low-speed applications, due to their potentially high power/weight ratio, high aspect ratio, and high efficiency. Nevertheless, these machines are prone to be affected by manufacturing tolerance during its fabrication process and consequently, the magnets may move freely inside the rotor structure. This work presents a statistical analysis of manufacturing tolerances of an AFPM machine with an ironless rotor, considering several magnet fault types. A computationally efficient superposition method is developed and implemented to obtain both the cogging torque and rated torque considering several tolerance combinations with acceptable accuracy. The results obtained from a statistical analysis of 10,000 designs of a two-stator one rotor tooth coil winding AFPM (TCW-AFPM) machine allowed us to identify the parameters with the most impact on relevant performance indicators and disclosed a substantial increase in cogging and ripple torque when unavoidable combined tolerances are present. [ABSTRACT FROM AUTHOR]

This article presents an accurate analytical model (AM) for synchronous reluctance machine (SynRM) that incorporates the effect of stator slots on the air gap flux density and torque waveforms. From the formulation of magnetic potential in the air gap for both the stator and rotor, the flux density is obtained, considering the first harmonic of the flux density and the electric loading, the average torque is calculated using the Lorentz’s force. The ripple torque is obtained from the energy stored in magnetic circuit. The method is developed for a rotor with one flux barrier per pole and then extended to a larger number of barriers. To validate the results obtained by the AM proposed finite element analysis have been carried out. Several comparisons have been derived considering different rotor positions as well as different harmonic orders, and the pros and cons of the method are highlighted. The model performs fast and can predict results with high accuracy, and can be adopted to speed up the preliminary design and optimizations of this type of motors, with respect to finite element. In addition, from the analytical expressions it is possible to obtain all the correlations between electrical, magnetic, and geometrical characteristics of the machine, with the advantage of enabling a faster machine design. [ABSTRACT FROM AUTHOR]

A novel rotor structure for a tooth-coil-winding (concentrated winding) open-slot axial-flux permanent-magnet (PM) machine that reduces the eddy currents and increases the main flux linkage is proposed in this paper. A composite-body-based rotor assembly and a steel-laminated layer inserted on top of the magnets are used to reduce eddy-current losses in the PMs. A prototype of an axial flux generator for a heavy-duty vehicle following this structure is optimized, analyzed and measured. The tooth coil windings produce high-amplitude harmonics in the air gap and the large slot openings reduce the rotor flux. Consequently, a rotor structure that decreases the amount of harmonics travelling through the magnets is required. Steel laminations covering the magnets have positive effects on both phenomena. Two-dimensional and three-dimensional finite-element analysis is used to verify and optimize the geometry of the laminations. Computations are verified by experimental measurements of a 100 kW test machine prototype. [ABSTRACT FROM PUBLISHER]

Hybrid excitation synchronous generators are a special class of electrical machines in which the total rotor current linkage is produced by the simultaneous action of two different excitation sources: permanent-magnet (PM) excitation and field winding excitation. In the island operation, there is a need to compensate the armature reaction to keep the generator terminal voltage constant. The permanent magnet excitation is used to create the no-load excitation to the generator and the rotor winding is used as an armature reaction compensating winding. This paper studies the applicability of an armature-reaction-compensated PM synchronous generator to a marine diesel genset. This paper presents an analytical approach for the electromagnetic design of the proposed topology. Finite-element analysis and experimental measurements are performed to verify the results of the analytical approach. [ABSTRACT FROM PUBLISHER]

In this paper, a negative-saliency permanent-magnet (PM) synchronous machine analysis is presented. This particular saliency feature is achieved by replacing a portion of the magnet material by a soft iron piece over the rotor pole. In this manner, the d-axis inductance is increased, whereas the q-axis inductance is almost not affected, leading to the condition that Ld is higher than Lq (negative saliency) corresponding to the inverse condition of typical PM machines. An expression for the optimum pole configuration is derived. It is shown that, with appropriate control of the stator current based on the machine's saliency, the unfavorable effects of magnet reduction on torque production can be compensated. It is also shown that the machine saliency affects the location of the operating points when it operates under vector control. Finally, the theoretical analysis is validated with experimental results obtained from a prototype axial-flux PM machine that exhibits negative saliency. [ABSTRACT FROM AUTHOR]

Cogging torque is a source of vibration and noise in permanent-magnet (PM) machines. This torque is proportional to the PM flux and the reluctance variation, and is independent of the load current. In this paper, two methods for cogging torque reduction in an axial PM machine with field weakening capability are presented. The machine's rotor configuration considers two sections: one PM pole that provides the field excitation and one iron section in charge of providing low d-axis reluctance. Significant reduction of the cogging effects is achieved by adjusting stator geometry and rotor pole configuration. Three-dimensional finite-element analysis is used to demonstrate these improvements. Conclusions and design recommendations are presented for a 5-kW eight-pole PM machine prototype under construction. [ABSTRACT FROM AUTHOR]

In this paper a description and operating principles of a consequent-pole permanent-magnet machine are presented. In addition, a sizing analysis, finite-element analysis, and experimental results for a prototype machine are addressed. Due to its particular configuration, this machine allows for a wide range of control of the air-gap flux with minimum field ampere-turn requirements and without brushes or slip rings. Two components of the field flux are produced. One, which is almost constant, is produced by the permanent magnet located on the rotor surface. The other, which is variable, is produced by a field winding positioned circumferentially in the center of the stator. These two flux components converge in the air gap. The excitation level of the machine is manipulated by controlling the dc field current. Three-dimensional finite-element analysis and experimental results demonstrate that ft is possible to vary the flux over a wide range to keep the terminal voltage constant as the speed increases. A 3-kW 1000-3000-r/min eight-pole and 32-Vac generator using this configuration is tested to verify the flux control capability of this structure. [ABSTRACT FROM AUTHOR]