IEEE ICSET 2010

6-9 Dec 2010, Kandy, Sri Lanka

Design and Analysis of an Air-Cored Axial Flux

Permanent Magnet Generator
for Small Wind Power Application
B. Xia, M. J. Jin, J. X. Shen and A. G. Zhang
College of Electrical Engineering, Zhejiang University, Hangzhou, 310027, China
E-mail: M_J_Jin@zju.edu.cn

Abstract-An axial flux permanent magnet (AFPM) machine with
dual rotors and single air-cored stator is studied in this paper.
The machine is applied for vertical-shaft small power off-grid
wind generating system. A 2-dimensional (2D) finite element
analysis (FEA) method is proposed to approximately solve to the
3-dimensional (3D) magnetic field inside the AFPM machine.
And a 2D analytical method is also presented to compute the air
gap flux density for this dual-rotor single-air-cored-stator axial-
flux surface-mounted permanent magnet machine structure.
Then, a 3D FEA model is developed to validate the accuracy of
these two proposed 2D methods. Finally, a prototype machine is
fabricated, and experiments are carried out to test its
performances and electromagnetic features. Experimental
results confirm that the 2D FEA and analytical approaches are
both efficient and simple with sufficient accuracy.
I. INTRODUCTION
Wind power, considered as one of the cleanest renewable
energies, is now receiving more and more attention. In some
developing countries like China, with the supportive policies
of the government, the utility of wind power is growing fast.
Many wind power stations with large scale wind turbines
have been built to provide electricity to the grid in places with
good wind resources. However, in some remote but windy
areas where grid is not available, small low-speed stand-alone
high-efficiency wind generators can be very attractive for
household electrical appliance as well as outdoor monitor
equipments [1]. Axial flux permanent magnet (AFPM)
machine, with its compact structure, flat shape, and high
torque density, fits perfectly for these applications. In this
paper, a 1kW, 300rpm, air-cored outer-rotor surface-mounted
AFPM synchronous machine is studied as a direct-drive
vertical-shaft wind generator (VSWG).
Due to its instinct structure, the flux inside an AFPM
machine flows in both axial and circumferential directions.
Therefore, 3-dimensional (3D) field analysis is necessary for
precise resolving [2]. Though finite element analysis (FEA)
software has been extensively used nowadays with
development of computer technologies, 3D FEA modeling
and simulation are still too complex and quite time-
consuming, and even unworkable for low-grade computers.
Thus, they are not very practical in optimizing designs. To
overcome this problem, a 2-dimensional (2D) FEA method
with sufficient accuracy is proposed in Section III, which
simplifies the modeling and reduces the computing time.
Besides, analytical methods are also solutions to the
computation of magnetic field. Some analytical methods for
AFPM machines have been presented, in both 2D and 3D
models for different AFPM machine topologies [3-5]. These
solutions enable quick parametric analysis, yet have certain
limitations since simplifications are made. A 2D analytical
method is developed for double-rotor, single-air-cored-stator
AFPM machine in Section IV.
3D FEA model is also set up to validate the proposed 2D
FEA and analytical methods. Finally, a prototype machine is
tested to validate both the 2D FEA and analytical methods
and confirm the machine performance.
II. MACHINE STRUCTURE
The AFPM machine structure is showed in Fig. 1. It
consists of two external rotors and one internal stator
sandwiched between the two rotors. Air-cored stator structure
is adopted to reduce the machine weight. Concentrated
trapezoidal coils are assembled with non-magnetic non-
conducting material epoxy resin. As a result, cogging torque
is eliminated, which improves the dynamic characteristics [6]
and gives the generator a much lower cut-in speed. Besides,
stator core loss does not exist due to the absence of iron core,
and the magnetic force between the stator and the rotor is
minimized. Sector-shaped high energy sintered Nd-Fe-B
magnets are glued onto the rotor back iron surfaces,
positioned with aluminum frames which are not illustrated in
Fig. 1. Magnets in red make the air gap flux flow downwards,
whilst those in blue make the flux go upwards. Vertical-shaft
Fig. 1. Machine structure.

978-1-4244-7191-1/10/$26.00 ©2010 IEEE

wind impellers can be directly installed on the top rotor. This 2 2
s(i, j ) = (ri +1 − ri ) ⋅ Δθ / 2 (1)
direct-drive vertical-shaft configuration captures wind energy
from all directions, and the construction is simplified because ΔΦ (i, j ) = [ B(i, j ) + B(i + 1, j ) + B(i, j + 1)
(2)
the yaw, tower and gear box are unnecessary [7]. + B(i + 1, j + 1)] ⋅ s (i, j ) / 4
Consequently, efficiency and reliability are further improved.
Concentrated trapezoidal armature coil windings are
III. 2D FEA MODELING adopted in this machine. And for this slotless structure, the
width of the coil band has to be considered when calculating
Since flux travels circumferentially in the rotor back iron
the generated electromotive force (EMF). However, it will be
and goes axially in the air gap and magnets, by employing
too complicated to consider each conductor as the flux
radial cross section at different cutting radius (r) between
through each turn of coil is different. For convenience, each
outer radius (Ro) and inner radius (Ri) of the magnets, an
coil band is assumed to be a thin conductor at the middle
entire flux path is obtained in the cross section. Then, by
position of the coil band. Then, the flux of the elements
pulling the cylindrical cross section straight, a 2D FEA planar
covered by the assumed coil is added up. And the back EMF
model is obtained. As the flux distribution is periodic in the
can be calculated by:
circumferential direction and symmetrical in the axial
direction, half of the machine in the axial direction and one d ⎡Σ Σ ΔΦ(i, j )⎤
⎢i j ⎥⎦
electrical cycle (i.e., two pole-pitches) in the circumferential
direction are required for the field resolving. Thus, the 2D
e= ⎣ (3)
dt
FEA model can be simplified as that shown in Fig. 2. It where s, r, Δθ, ΔΦ, B and e represent the area and the cutting
should be pointed out that the model can be further simplified radius of the element-i,j, and the angular step, the flux
if only a quarter of electric cycle (viz., half a pole-pitch) is through element-i,j, and the back EMF in a single turn,
required by using symmetrical boundaries. Moreover, due to respectively.
the air-cored topology, the air gap is relatively large, and
armature reaction is low and negligible. As a result, coils are IV. 2D ANALYTICAL METHOD
simplified. The 2D FEA model illustrated in Fig. 2 indicates Fig. 4 shows the 2D analytical solution model. Duo to the
its simplicity, and it is quite convenient to be modified and ironless stator structure, the effective air gap including the
remodeled. With just one variable (the cutting radius of the mechanical air gap and the height of coil winding is much
cross section is chosen here), parametric models can be built.
As the cutting radius (r) changing from Ri to Ro in a proper
step, 2D FEA models are constructed to simulate the AFPM
machine at different radius.
After the parametric analysis, the results obtained from 2D
FEA are mapped back to the 3D model and a grid is formed
by lines at different radius and electrical degree (θ), as
illustrated in Fig. 3. The grid consists of elements and nodes
and every element contains 4 nodes. The flux density at
different nodes of the grid represents field distribution in the
machine air gap, and can be easily computed from the 2D
parametric FEA model. Assuming that the flux through an
element is determined evenly by the 4 nodes, magnetic flux
of each element is calculated by:
Fig. 3. Mapping relation of 3D and 2D models.

Fig. 2. 2D FEA model. Fig. 4. 2D analytical model.

larger than that in slotted machines. Thus the rotor back iron 8 Br ∞
1 nπhm nπ ( L / 2 − y )
has little magnetic saturation. Consequently, the relative BxI =
π
∑ [ n sinh τp
⋅ sinh
τp
permeability is assumed to be infinitely large for simplicity. n
Rectangular coordinate system is adopted here, and x-axis nπτ p L / 2
(14)
represents the distance in the circumferential direction, whilst e nπx
⋅ ⋅ cos
y-axis represents the axial direction. Λ τp
The scalar magnetic potential φ in all regions follows
Laplace’s equation [8]: where
nπ ( L − hm )
∂ 2ϕ ∂ 2ϕ nπhm nπhm τp
+ =0 (4) Λ = (sinh + μr cosh )e
∂x 2 ∂y 2 τp τp
The general solution to (4) is given by: (15)
nπhm
∞ nπhm nπhm τp
ϕ = ∑ [( A1n cosh mn x + B1n sinh mn x)(C1n cos mn y + (sinh − μ r cosh )e
τp τp
n =1
∞ n=1, 3, 5, …
+ D1n sin mn y )] + ∑ [( A2 n cos mn x (5) μ0 is the permeability of free space and μr is the relative
n =1 recoil permeability of magnet.
+ B2 n sin mn x)(C2 n cosh mn x + D2 n sinh mn y )] V. 3D FEA VALIDATION
+ ( A0 + B0 x)(C0 + D0 y ) Since 2D FEA and analytical methods have not taken the
end effect into account, a 3D FEA model is developed to
Equation (5) must satisfy the boundary conditions below:
validate these 2D methods. The 3D model and flux density of
ϕ ( x) = ϕ ( x + 2τ p ) (6) rotor back iron, magnets and coils are showed in Fig. 5. The
H xIII = 0, ( y = L) (7) maximum flux density is 1.6 T in the back iron. It proves the
assumption that there is little saturation in the back iron.
H xII = 0, ( y = 0) (8)
⎧ ByI = ByII
⎨ , ( y = hm ) (9)
⎩ H xI = H xII
⎧ ByI = ByIII
⎨ , ( y = L − hm ) (10)
⎩ H xI = H xIII
where τp, hm and L denotes the pole-pitch, thickness of
magnets and distance between the two rotor back irons.
The relation of magnetic field strength and scalar magnetic
potential is given by:
⎧ ∂ϕ
⎪⎪ H x = − ∂x
Fig. 5. Flux density distribution from 3D FEA.
⎨ (11)
⎪ H y = − ∂ϕ
⎪⎩ ∂y θ=90 (3D FEA)
0.7
θ=11.6 (3D FEA)
And, the flux distribution density in region I is obtained as: θ=90 (2D FEA)
0.6 θ=11.6(2D FEA)
⎧ BxI = μ 0 H xI θ=90 (2D Anal.)
θ=11.6 (2D Anal.)
⎨ (12)
Flux density (T)

0.5

⎩ B yI = μ 0 H yI 0.4
Applying boundary conditions (6)-(10) to (11) and (12),
0.3
using the general solution (5), the air gap flux density in axial
direction is given by: 0.2

8 Br ∞
1 nπhm nπ ( L / 2 − y )
∑ [ n sinh
0.1
B yI = ⋅ cosh
π n τp τp 0
90 115 140 165 190
nπτ p L / 2
(13) Cutting Radius(mm)
e nπx
⋅ ⋅ cos
Λ τp Fig. 6. Air gap field distribution along radius direction,
solved with 3D FEA, 2D FEA and 2D analytical model.
 The 3D FEA method is compared with the two proposed analytical method are compared along circumferential
2D methods in Fig. 6 and Fig. 7. Results of 2D FEA and 2D direction at different radius in Fig. 7 (a) and (b) respectively.
analytical method show great agreement with each other. Fig. The results show that both 2D methods match the 3D FEA
6 reveals that as the cutting radius of the cross section method. Overall, the magnet inner and outer regions are quite
increases, the flux density in the air gap from 2D analysis small, and we believe that magnetic field distribution
increases. 3D FEA method validates the magnetic field computed from 2D methods can simulate the actual 3D flux
distribution from 2D methods, except that the flux density distribution with small error due to the inner and outer
actually decreases when getting very close to the inner and regions of the magnets.
outer radius of the magnet. That is because the end effect Since the 3D FEA method has validated the 2D FEA flux
becomes significant on the inner and outer edges of the distribution, according to (1)-(3), the phase back EMF can be
magnets, but it cannot be reflected in the 2D models. Flux calculated based on the results from 2D FEA method.
density from 3D FEA and 2D FEA, 3D FEA and 2D Waveforms of one-phase back EMF from the 3D and 2D
FEA results are compared in Fig. 8, and it confirms that the
0.6 2D FEA method totally agrees with the 3D FEA method with
r=122.5(3D FEA) an error less than 2%.
r=140(3D FEA)
0.4
r=157.5(3D FEA) VI. PROTOTYPE MACHINE EXPERIMENTS
r=122.5(2D FEA)
The prototype AFPM generator is built, Fig. 9. Design
Flux density (T)

0.2 r=140(2D FEA)

r=157.5(2D FEA) parameters of the machine are illustrated in TABLE I.
0 A test rig is then set up, where the generator is put in a
0 120 240 360
horizontal position and driven with the geared induction
-0.2 motor, Fig. 10. For laboratory experiments, the induction
motor is fed with a commercial programmable frequency
-0.4
converter, thus, its speed can be adjusted to simulate various
wind condition.
-0.6
Angular distance(elect. deg) To test the machine and verify the analysis methods
(a)
proposed in this paper, the machine back EMF at rated speed
0.6
(300 rpm) is measured in the experiment. Fig. 11 shows the
r=122.5(3D FEA) line-line voltage of 2D FEA, 3D FEA and the prototype. The
0.4
r=140(3D FEA) experimental waveform is similar to the 2D and 3D FEA
r=157.5(3D FEA) results. The measured peak value is a little smaller than the
r=122.5(2D Anal.)
FEA-predicted data, and the error is about 6%. This error is
Flux density (T)

0.2 r=140(2D Anal.)

r=157.5(2D Anal.) caused possibly by the model inaccuracy, the characteristic
0 inconsistency of the permanent magnets, or the
0 60 120 180 240 300 360
manufacturing imperfection. However, the error is acceptable.
-0.2 Thus, the 2D FEA method is validated to be simple, time-
saving and sufficiently accurate. Moreover, as proved
-0.4
previously, the 2D analytical model agrees well with the 2D
FEA, therefore, both 2D approaches, viz., 2D FEA and 2D
-0.6
Angular distance(elect. deg) analytical model, are verified by both 3D FEA and
(b)
experiments.
Fig. 7. Air gap field distribution along circumferential direction.
(a) 3D FEA and 2D FEA methods. (b) 3D FEA and 2D analytical method.
VII. CONCLUSIONS
250 AFPM machines are among the most suitable candidates
2D FEA
200 for direct drive small and medium wind power generators. In
3D FEA
150 this paper, a dual-rotors and single-air-cored-stator AFPM
generator for low-speed small wind power application is
Phase back EMF (V)

100
analyzed, using proposed 2D FEA and 2D analytical methods.
50
3D FEA model is also developed, validating both proposed
0
2D approaches. The machine back EMF is also calculated
-50 0 60 120 180 240 300 360
based on the 2D FEA methods. A prototype machine is tested.
-100 Experimental results are compared with the FEA results,
-150 confirming that the 2D approaches are simple, efficient and
-200 sufficiently accurate.
-250 The proposed 2D FEA method can also be applied to other
Electrical Degree
structures of AFPM machines with slotted stators and
Fig. 8. One-phase back EMF from 3D FEA and 2D FEA. different shape magnets.
 400
2D FEA
300 3D FEA

No-load Line Voltage (V)

200 Experimental

100
0
-100 0 60 120 180 240 300 360

-200
-300
-400
Electrical Degree
Fig. 11. Line-line back EMF of 3D FEA, 2D FEA and prototype.
Fig. 9. Prototype AFPM Machine.

Fig. 10. Measurement Setup for Prototype Machine.
TABLE I
MAIN DESIGN PARAMETERS
Parameter
Stator coil number
Rotor pole number
Pole embrace
Magnet outer radius
Magnet inner radius
Magnet thickness
Thickness of back iron
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