Design of A Novel Dual Three-Phase Dual

Stator Axial Flux Permanent Magnet

Machine with Mechanical Offset
2023 IEEE 32nd International Symposium on Industrial Electronics (ISIE) | 979-8-3503-9971-4/23/$31.00 ©2023 IEEE | DOI: 10.1109/ISIE51358.2023.10228136

Rundong Huang Bowen Zhang Zaixin Song

1 1 3
School of Energy and Environment, School of Energy and Environment, Department of Industrial and Systems
City University of Hong Kong, City University of Hong Kong, Engineering, The Hong Kong
Hong Kong SAR, China Hong Kong SAR, China Polytechnic University,
2 2 Hong Kong SAR, China
Shenzhen Research Institute, Shenzhen Research Institute,
City University of Hong Kong, City University of Hong Kong, zaixin.song@polyu.edu.hk
Shenzhen, China Shenzhen, China
rundong.huang@my.cityu.edu.hk Bowen.Zhang@my.cityu.edu.hk

Yuxin Liu Yong Chen Chunhua Liu*

1 1 1
School of Energy and Environment, School of Energy and Environment, School of Energy and Environment,
City University of Hong Kong, City University of Hong Kong, City University of Hong Kong,
Hong Kong SAR, China Hong Kong SAR, China Hong Kong SAR, China
2 2 2
Shenzhen Research Institute, Shenzhen Research Institute, Shenzhen Research Institute,
City University of Hong Kong, City University of Hong Kong, City University of Hong Kong,
Shenzhen, China Shenzhen, China Shenzhen, China
yuxin.liu@my.cityu.edu.hk yongchen4-c@my.cityu.edu.hk Correspondence: chunliu@cityu.edu.hk

Abstract—Axial flux permanent magnet (AFPM) machines
are welcomed widely in propulsion systems due to their
compactness and high torque density. Thus, multiphase
topologies are also studied for AFPM machines. This paper
proposes a novel dual three-phase dual stator AFPM machine
with mechanical offset. The mechanical offset angle can achieve
any phase difference between two sets of three-phase windings.
The influence of offset angle in the cogging torque of the
machine is analyzed. It can affect the amplitude of the cogging
torque. In addition, finite element analysis is conducted to
optimize the offset angle and pole arc ratio. Finally, the offset
angle and pole arc ratio are determined to be 1.5° and 0.8,
respectively. The cogging torque of the machine is 0.31 Nm,
while the average torque is 11.91 Nm. In addition, the
modulation ratio of space vector modulation for the proposed
machine nearly remains the same when compared with
conventional dual three-phase machines.
Keywords—Axial flux machine, permanent magnet machine,
dual three-phase, mechanical offset, cogging torque.
I. INTRODUCTION
As key actuators in propulsion systems, electric machines
are applied widely in transportations such as electric vehicles,
electrified aircrafts, and ships [1-3]. However, with the degree
of transportation electrification deepening, requirements for
electric machines become demanding [4-7]. Radial-flux
This work was supported in part by a grant (Project No. 52077186) from
Natural Science Foundation of China (NSFC), China; in part by a grant
(Project No. JCYJ20210324134005015) from the Science Technology and
Innovation Committee of Shenzhen Municipality, Shenzhen, China; in part
by a Collaborative Research Fund (CRF Project No. C1052-21GF) from the
Research Grants Council, Hong Kong SAR; and in part by RGC Research
Fellow Scheme (RGC Ref. No. RFS2223-1S05) from Research Grants
Council, Hong Kong SAR. (*Corresponding author: Chunhua Liu; email:
chunliu@cityu.edu.hk).
permanent magnet (RFPM) machines are not applicable in
some special conditions [8, 9]. Axial-flux permanent magnet
(AFPM) machines attract more attention due to the
characteristics of high torque density, large aspect ratio, and
compactness [10, 11].
AFPM machines are classified into three types: single-side
type, double-side type, and multi-disc type [12, 13]. They are
equipped with a different number of discs. Accordingly, their
applications vary with their characteristics. Single-side AFPM
machines usually meet the requirement of high speed and
small torque [14]. Multi-disc AFPM machines are usually
applied in some conditions demanding large torque such as
electric ships [15]. Double-side AFPM machines are the
compromise of single-side and multi-disc ones. They are
welcomed in traction systems of EVs and aircrafts [16]. They
can relieve the problem of the uneven air gap with relatively
simple structures when rotors tilt [17]. In order to prevent the
tilt and deformation of axial rotors, an additional radial rotor
is used to improve the robustness and torque density [18].
However, it increases the cogging torque of the machine. It is
hard to reduce the cogging torque through skewing teeth of
AFPM machines due to the complex manufacture and
assembly. Then, another way to solve the problem is to
optimize the shape of PMs [19]. The sinusoidal rotor segment
can also be adopted to reduce the torque ripple by suppressing
the harmonics of the air gap magnetic flux density [20].
Apart from conventional three-phase machines,
multiphase machines are also investigated in many studies
thanks to their excellent fault-tolerant capability [21, 22]. In
addition, the multiphase configuration makes dual three-phase
AFPM machines lower the current and voltage levels of each
phase in the same condition [23]. A seven-phase AFPM
machine shows high sensitivity to the inductance and

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electromotive force (EMF) in [24]. In addition, a six-phase arbitrarily once the pole-slot combination is determined. Take
double stator AFPM machine with detached winding is a conventional dual three-phase RFPM machine as an
proposed in [25]. It reduces the rotor eddy loss without example, the position difference ∆θm between two sets of
sacrificing torque output. The phase difference between two windings must be the integer multiples of slot pitch, shown in
sets of three-phase windings is 30°, which is determined by Fig. 2(a). Thus, the phase difference ∆θe is determined
the symmetrical arrangement of two stators. Asymmetric according to the structure as shown in Fig. 2(b).
stators in a dual stator AFPM machine are also studied to Phase F Phase E
reduce space harmonics, whereas windings on two stators are Phase D
Phase B UA
in series to form a set of three-phase winding [26]. Phase C UD

In this paper, a dual three-phase AFPM machine is

proposed for flying EVs. The machine is a double stator inner ∆θm
∆θe = 30°
rotor AFPM machine. The two sets of three-phase windings Phase A
UE

are arranged on two stators separately. Then, the phase

difference between two sets of windings is achieved through UB UC

mechanical offset of on stator. The topology and winding UF

configuration of the dual three-phase dual stator AFPM
machine with mechanical offset are introduced firstly. Second,
the basic equations of the machine are analyzed. Then, finite
element analysis (FEA) is conducted to study the machines is
studied to validate the performances. After the machine is
designed, the voltage vectors of the proposed dual three-phase
machine are analyzed. Finally, the conclusion is drawn.
II. DUAL THREE-PHASE TOPOLOGY WITH MECHANICAL
OFFSET
A. Dual Stator Topology
For the proposed dual stator AFPM machine, the rotor is
sandwiched between two stators, as shown in Fig. 1. To link
the magnetic field of two stators, an inserted PM rotor is
adopted. Compared with surface mounted PM rotor, the
inserted PM rotor can save half of PMs and silicon steel sheet.
In addition, the reinforcement ring can enhance the rotor
robustness. It is made of composite plastic material, so it can
reduce the eddy current loss and torque ripples.
(a) (b)
Fig. 2 Conventional dual three-phase RFPM machine. (a). Topology, (b).
Phase voltage vector diagram
However, in the proposed dual stator dual three-phase
AFPM machine, the phase difference can be set as any value
due to the separate layout of windings. It is achieved through
the mechanical offset of one stator, shown in Fig. 3(a). Fig.
3(b) shows the phase difference of two sets of windings of the
proposed machine. The relationship between the phase
difference of two sets of windings and the position difference
of two stators is expressed as (1), where pr is the number of
pole pairs of the rotor.
∆θ e = pr ∆θ m (1)
UA
UD

Reinforcement
Stator iron PM Winding
ring
∆θe = pr∆θm
UE

UB UC

UF
∆θm

(a) (b)
Fig. 3 Winding configuration with mechanical offset. (a). Mechanical offset
of one stator, (b). Phase voltage vector diagram.

Although two sets of three-phase windings are placed on

Fig. 1 Explored view of the double stator AFPM machine
Fractional-slot concentrated winding can improve the flux
weakening capability of the machine, so the double stator
AFPM machine adopts a 24-slot-20-pole configuration.
Besides, this configuration can achieve a high winding factor.
Different from conventional dual three-phase machines, two
sets of windings in the proposed machine are placed on two
stators, respectively. Thus, the phase difference between two
sets of three-phase windings is achieved through the
mechanical offset of one stator.
B. Winding Configuration with Mechanical Offset
The phase difference between two sets of three-phase
windings is usually 30° for conventional double three-phase
machines [27]. The phase difference cannot be changed
two stators separately, a star connection is also adopted and
their neutral nodes are connected together. Thus, the voltage
of each phase is listed as (2), where ωe is the electrical angle
frequency. Besides the achievement of dual sets of windings,
the mechanical offset can also improve the performance of the
machine. The cogging torque is mainly produced by the
interaction among PMs and teeth, so the misaligned teeth of
two stators can affect the cogging torque of the rotor. Then,
the position difference of two stators needs to be determined.

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 u A = U m cos (ωe t ) Λ 2down (θ s , r ) =
Λc0 ( r )
 ∞

= u U cos  ω t − 2π  + ∑  Λ ci ( r ) cos ( iN s (θ s − ∆θ m ) )
Λ down (θ s , r ) = (5)
 B m  e 
 3  i =1

  2π  +Λ di (r ) sin ( iN s (θ s − ∆θ m ) ) 
Λ down (θ s , r ) =
=uC U m cos  ωe t + 3 
 (2) where Fm is the MMF of PMs, Λup and Λdown are the
= uD U m cos (ωe t + ∆θ e ) permeances of up layer and down layer air gaps, respectively,
 Fmi, Λai, Λbi, Λci, and Λdi are the coefficients of Fourier series.
uE U m cos  ωe t + ∆θ e − 2 
π According to the main flux paths in the machine, the air gap
=
  3  magnetic flux density is affected by both permeances of stator
 1 and stator 2. If slots are seen as fan-shaped, the relative
u  2π 
= F U m cos  ωe t + ∆θ e +  permeances will be independent of the radius r. Then, Λup and
  3  Λdown can be simplified as λup and λdown. The equivalent relative
III. BASIC EQUATIONS permeance λeq of the main flux paths is given as
Due to the mechanical offset of the proposed dual three- λeq2 = λup2 λdown
2

phase dual stator AFPM machine, the base equations have to ∞ (6)
take the whole model into consideration. In the analysis, the λeq 0 + ∑ λeqai cos ( iN sθ s ) + λeqbi sin ( iN sθ s ) 
=
magnetic saturation of tooth tips and flux leakage of PMs are i =1
neglected for simplifying the calculation. For the convenience
of calculation, this paper derives the Fourier series of the 1
λa 0 λc 0 + ( λa1λc1 + λb1λd 1 ) cos ( N s ∆θ m )
λeq 0 =
square of air gap magnetic flux density directly. 2 (7)
A. Aig Gap Magnetic Flux Density ≈ − ( λa1λd 1 − λb1λc1 ) sin ( N s ∆θ m ) 
As shown in Fig. 4, the center of slot 1 in stator 1 is defined
as the zero position of the circumference. The circumferential f ( ∆θ m ) , λeqbi =
λeqai = g ( ∆θ m ) (8)
position of stator 2 is ∆θm because of the mechanical offset. It
(8) means λeqai and λeqbi are the functions of ∆θm,
is assumed that the center of one PM is coincide with the zero
respectively. The functions will not affect the analysis in the
position of stator 1.
following paper, so they are not listed here. Thus, the air gap
θs = 0 magnetic flux density Bg can be calculated as (9). It shows that
the mechanical offset affects the amplitude of the air gap flux
density, but the period will not change.
Stator 1
Slot 1
Bg2 (θ s , r , t ) = Fm2 (θ s , r , t ) λeq2
∞
Rotor λeq 0 Fm 0 + λeq 0 ∑ Fmj cos ( jprθ s − jωe t )
=
j
∞

Stator 2
Slot 1 = + Fm 0 ∑ λeqai cos ( iN sθ s )
i =1 (9)
= + λeqbi sin ( iN sθ s ) 
θs = ∆θm
1 ∞ ∞
Fig. 4 Simplified analysis model
=+ ∑∑ λeqai Fmj ( cos θ + + cos θ − )
2 i j 
Then, the square of magnetomotive force (MMF) of the = +λeqbi Fmj ( sin θ + + sin θ − ) 
rotor can be expressed as (3) according to the symmetry and
periodicity. The influence in air gap permeances of stator 1 where
and stator 2 is different because they are not symmetrical.
θ = iN sθ s + jprθ s − jωe t
+
They can be expressed by Fourier series by (4) and (5) ,  − (10)
respectively [28]. θ = iN sθ s − jprθ s + jωe t
∞
Fm 0 ( r ) + ∑ Fmi ( r ) cos ( iprθ s − iωe t )
Fm2 (θ s , r , t ) = (3) B. Cogging Torque
i =1 The cogging torque of a machine can be calculated with
∞
the energy method. The expression is shown as (11)
2
Λ up Λ a 0 ( r ) + ∑  Λ ai ( r ) cos ( iN sθ s )
(θ s , r ) = ∂W (θ )
i =1 (4) Tcog (θ ) = − (11)
Λ up (θ s , r ) =
+ Λ bi (r ) sin ( iN sθ s )  ∂θ
1
W (θ ) =
2 µ ∫V
Bg2 dV (12)

where θ is the rotor position angle and θ = ωet/pr, W is the

magnetic energy of the machine, µ is the permeability. The

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magnetic energy of a machine mainly exists in air gaps, so it 1.0

is still accurate to analyze cogging torque when only 0.8

considering the air gap flux density in the calculation [29]. 0.6

Magnetic Flux Density (T)

Then, the magnetic energy can be obtained as 0.4

0.2
πg R ∞ ∞
W (θ ) = r ∑∑ ( λeqai Fmj cos ( jprθ )
µ ∫R i j
o
0.0 0°
i
(13) -0.2 1°
2°

W (θ ) = +λeqbi Fmj sin ( jprθ ) ) dr -0.4 3°

4°
-0.6 5°
6°
where Ro and Ri are the outer and inner radius of the machine, -0.8 7°
respectively, g is the length of the air gap. The equation, iNs = -1.0
0 20 40 60 80 100
jpr, has to be met for (13). Hence, the cogging torque can be Angle (deg)
expressed as
Fig. 5 Normal air gap flux density with different offset angle
πg R ∞
Tcog (θ ) = r ∑ ( kQλeqak Fmk sin ( kQθ )
µ ∫R k
o

i
(14) 80 0°
1°
Tcog (θ ) = −kQλeqbk Fmk cos ( kQθ ) ) dr 60 2°
3°
40
4°
where Q is the least common multiple of Ns and pr. It tells that

Back EMF (V)

20 5°
6°
the period of cogging torque does not change with mechanical 0 7°
offset, but the value is related to the offset angle.
-20

IV. FEA FOR DUAL THREE-PHASE DUAL STATOR AFPM -40

MACHINE -60

In order to get the optimal offset angle, FEA is conducted -80

for the proposed dual three-phase dual stator AFPM machine. 0 5 10 15 20 25 30 35

Angle (deg)
The initial design parameters are listed in Table I. A one-
fourth partial model of the proposed machine is built in the Fig. 6 No-load back EMF with different offset angle
finite element software JMAG 16.0. The objective is to get the
topology with high torque density and low cogging torque. It is shown that the no-load back EMF is nearly not
affected by the mechanical offset. It also reflects that the air
TABLE I. INITIAL PARAMETERS gap magnetic flux density changes slightly. Therefore, torque
ripples have to be reduced by reducing the cogging torque. Fig.
Parameter Value 7 shows the average torque and cogging torque when the
offset angle changes.
Outer radius Ro 90 mm
Inner radius Ri 50 mm
10
Air gap length g 1 mm
Average torque
Slot height hs 8 mm 8 Cogging torque

PM height hm 4 mm
Torque (Nm)

6
Slot opening width wso 2 mm
Pole arc ratio αp 0.6 4

A. Effect of Offset Angle 2

The slot pitch angle of the machine is 15° thanks to the 24-
slot-20-pole configuration. According to the periodicity and 0
0 1 2 3 4 5 6 7 8
symmetry, the mechanical offset angle has to vary from 0° to Offset angle (°)
7.5° to cover all possibilities. Fig. 5 shows the variation of air
gap flux density when the offset angle changes. Fig. 7 Torque variation with offset angle

It tells that the period does not change with the offset angle,
whereas the amplitude is affected. It validates (9) derived in
Section III. The gap on the waveform moves with the change
of offset angle obviously. This is caused by slot displacement.
No-load back electromotive force (EMF) is closely related to
the air gap flux density, as shown in Fig.6.
It can be seen that the average torque changes slightly,
which means it is almost unaffected by the mechanical offset
angle. The axial force on the rotor also nearly keeps constant
because the dimensions of PMs and teeth are not changed. As
the analysis in Section III, the cogging torque changes a lot
with the offset angle. It is obvious that the cogging torque is
very small when the angle is 1.5° or 7.5°. They are 0.52 Nm
and 0.42 Nm, respectively. At the same time, the average
torques are 10.12 Nm and 9.94 Nm, respectively. Finally, the
mechanical offset angle is determined to be 1.5° considering
the average torque. Thus, the phase difference between two
sets of windings is 15°.

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B. Effect of Pole Arc Ratio The average output torque increases with the increase of
Apart from the mechanical offset angle, the pole arc ratio pole arc ratio., but the growth becomes slow when the pole arc
can also affect the average output torque and cogging torque. ratio achieves 0.8. As for the cogging torque, it decreases
Thus, an appropriate pole arc ratio has to be adopted for PMs. sharply when the pole arc ratio changes from 0.3 to 0.4.
Fig. 8 shows the air gap magnetic flux density waveforms at However, the cogging torque nearly remains constant when
different pole arc ratios. the pole arc ratio increases to 0.7. Hence, the pole arc ratio is
determined to be 0.8 with the consideration of the amount of
1.0 PMs. The cogging torque and average torque of the proposed
0.8 machine are 0.31 Nm and 11.91 Nm, respectively, when the
0.6 pole arc ratio is 0.8. The optimized offset angle and polr arc
Magnetic Flux Density (T)

0.4 ratio are determined to be 1.5° and 0.8, respectively.

0.2
αp=0.3
V. ANALYSIS OF VOLTAGE VECTOR
0.0
-0.2
αp=0.4 For a dual three-phase machine, vector space
-0.4
αp=0.5
decomposition is necessary to analyze phase voltages. The
αp=0.6
-0.6 αp=0.7
phase difference between two sets of three-phase windings is
αp=0.8 15° according to the mechanical offset. The phase voltages of
-0.8
αp=0.9 dual three-phase windings have to be converted to α-β plane
-1.0
0 20 40 60 80 100 and x-y plane. The harmonic components whose order is
Angle (deg) n=6k±5 (k=1,2,3…) are mapped into α-β plane, while the
harmonic components whose order is n=6k±1 (k=1,2,3…) are
Fig. 8 Normal air gap flux density with different pole arc ratio
mapped into x-y plane. The conversion equation for the
As can be seen, there are many harmonics in air gap flux machine is given as
density when the pole arc ratio is small. It will also lead to
many harmonics in the no-load back EMF which is shown in  1 1 6+ 2 2 2− 6 
1 − − − 
Fig. 9.  2 2 4 2 4 
uα   2 2 6− 2 2 6+ 2  u A 
  0 − −  u 
80 αp=0.3 u β   2 2 4 2 4  B
u  1 
αp=0.4
 x  = 1 − 1 1 2 6+ 2 2− 6  uC 
60 − −   (15)
αp=0.5 u y  3  2 2 2 4 4  u D 
40  
2  u E 
αp=0.6 
u
 o1  2 2 2 6− 2 6+
0
Back EMF (V)

20 αp=0.7 − − 
u   2 2 2 4 4  u F 
αp=0.8  o2 
0
αp=0.9
1 1 1 0 0 0 
 
-20 0 0 0 1 1 1 
-40
Thus, the voltage space vector diagram can be obtained, as
-60 shown in Fig. 11. It shows the space vectors on α-β plane,
-80 which are mainly used to produce electromagnetic torque. The
0 5 10 15 20 25 30 35 red circle represents the amplitude of the voltage vector when
Angle (deg) space vector modulation (SVM) is adopted. The modulation
ratio is 0.610. Compared with conventional dual three-phase
Fig. 9 No-load back EMF with different pole arc ratios
machines, it is nearly the same.
There are many harmonics in back EMF when the pole arc
ratio is 0.3. The fundamental component of back EMF
enlarges obviously when the pole arc ratio becomes large. It
matches the simulation results of air gap magnetic flux density
shown in Fig. 8. In order to get small cogging torque and large
average torque, the exact values of them are calculated. The
cogging torque and average torque are shown in Fig. 10.

12 Average torque
Cogging torque

10

8
Torque (Nm)

6
Fig. 11 Space vectors on α-β plane
4
VI. CONCLUSION
2
A dual three-phase dual stator AFPM machine with
0 mechanical offset is proposed in this paper. In the machine,
0.3 0.4 0.5 0.6 0.7 0.8 0.9
αp the phase difference between two sets of three-phase windings
is not constrained by the pole slot combination. It is mainly
Fig. 10 Torque variation with pole arc ratio determined by the mechanical offset. The influence of

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mechanical offset in the cogging torque is analyzed. It will
affect the amplitude rather than the period of the cogging
torque. Then, the FEA is conducted to design the mechanical
offset angle and pole arc ratio, which are determined to be 1.5°
and 0.8, respectively. Finally, the cogging torque and average
torque can achieve 0.31 Nm and 11.91 Nm, respectively.
Furthermore, the modulation ratio of SVM for the proposed
dual three-phase AFPM machine does not decrease.
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