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Design and Analysis of Dual Rotor Single Stator
Slotted Axial Field Flux Switching Permanent
Magnet Machines (AFFPMM)
-MS Thesis Defense-

04-12-2019

Mirza Aakif Baig

SP18-REE-024
Supervisor: Dr. Nasarullah Khan

Department of Electrical and Computer Engineering

Comsats University, Islamabad.

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 Contents

1 Introduction

2 Literature Review

3 Problem Statement

4 Research Methodology

5 Design and Analysis

6 Optimization

7 Conclusion

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 Introduction

Electric Machines

 Electric machines are used to convert electrical energy into mechanical energy and vice
versa.

Applications

1) Electric and Hybrid Vehicles 2) Wind Energy Systems

3) Industrial Drives 4) Automations [1]

Types

 Electric machines are classified into two types based on field excitation system:

1) Wound Field Machines 2) Permanent Magnet Field Machines

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 (Cont…)

Permanent Magnet (PM) Machines

PM Machines [2]

 First Employed in 19th century.

 Have high power/torque density, high efficiency and dynamic performance.

 Two types
1) Rotor PM Machines 2) Stator PM Machines

 Different types of rotor PM machines are shown in figure

Surface Mounted Surface Inset Buried Spoke Type

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 (Cont…)

PM Machines

 Stator PM Machines are of three types [4]

Doubly Salient PM Machine Flux Reversal PM Machine Flux Switching PM

Machine

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 (Cont…)
PM Machines

 Three types of PM machines [6]

Radial Flux PM Machines Axial Flux PM Machines Transverse Flux PM Machines

 Topologies of axial flux PM machines [7]

(SSSR) (AFIR) (SSDR) (MSMR)

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 Literature Review

Reference Research Topic Results

[8] PM Flux Switching Rated voltage and rated

Synchronous Motor torque were increased.
using Segmental Rotor.
[9] Optimization and Proposed machine
Comparsion of Novel showed fault
E-core and C-core tolerance.
Linear Switched Flux PM
Machines.
[10] Design of Five Phase Proposed machine
Modular Flux-Switching was simple and
PM Machines for robust with improved
High Reliability fault tolerant
Applications. capabilities.
[11] A Modular PM Flux Proposed machine
Switching Linear showed high fault
Machine with Fault Tolerance, power
Tolerant Capability. capability and easy to
assemble.

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 (Cont…)

Reference Research Topic Merits

[12] Hybrid Excited Flux EMF waveform was
Switching PM Machines improved and cogging
with Iron Flux Bridges. torque was reduced.

[13] A Novel Dual Rotor Proposed machine

Axial Field, Fault showed excellent fault
Tolerant, Flux tolerant capabilities
Switching PM with low cogging
Machine With High torque and torque
Torque Performance. ripple.

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 (Cont…)

[13] Wenliang Zhao proposed FSPMM with

 Phase group concentrated coil (PGCC) winding.

 Spoke Type PMs.

 Dual air gaps.

 Unaligned arrangement of rotors.

Design Sketch Operating Principle

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 (Cont…)
Contribution of Design Techniques to Machine Performance

PGCC Windings
Fault Tolerant
Capability

Spoke Type PMs

High Torque

Dual Air Gaps

Shifted Rotors
Low Cogging Torque
And Torque Ripple

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 Problem Statement

Cogging torque is one of the main problems in electric machines. Cogging torque must
be kept as low as possible for proper operation of electric machines. This research is
focused on achieving fault tolerant capability and reducing the cogging torque in axial
field flux switching permanent magnet machines to minimize hurdle of motor’s smooth
operation at low speed by analyzing the interaction of stator slots and rotor poles.
When cogging torque is reduced, efficiency of machine is improved. The fault tolerant
capability is achieved with the help of phase group concentrated winding. The phase
group concentrated winding allows to obtain unity winding factor which helps to
enhance fault tolerant capability.

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 Research Methodology
Flow Chart for Machine Design Start

AFPM Topology Selection

Design Specification

Design and Analysis

Confirmation of initial design using

FEA

Torque investigation

No
Is cogging
torque
reduced?
Yes
Final Design

End
 Design and Analysis

Design Specifications Machine Dimensions

Parameters Unit AFPMM Parameters Unit AFPMM

Power W 2800 Outer diameter mm 255
Speed rpm 450 Inner diameter mm 152
Frequency Hz 97.5 Total axial length mm 106
Air gap length mm 1.2(0.7/0.5)
Machine Materials

COMPONENTS Materials
Rotor/Stator 50H470
Magnets Ferrite
Winding Copper

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 (Cont…)

Conventional Model

Stator

Winding

Rotor
Magnets

Conventional AFFSPMM

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 (Cont…)
Results

OFFSET ANGLE Voltage (V) Cogging Torque (Nm)

0 16.1 14.4
15 17.9 13.7
30 18.1 1.4
45 18.4 13.3
60 19.0 13.4
75 19.2 12.5
90 19.5 1.7

Voltage and Cogging Torque with respect to Offset Angle

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 (Cont…)

FEA Results

Cogging Torque
Voltage

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 (Cont…)

Proposed Shape 1

Convex Lens Shaped

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 (Cont…)

Results

OFFSET ANGLE Voltage (V) Cogging Torque (Nm)

0 18.0 10.75
15 18.1 10.47
30 18.64 5.51
45 14.0 10.45
60 10.22 10.71
75 6.29 10.09
90 18.5 5.09

Voltage and Cogging Torque with respect to Offset Angle

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 (Cont…)
FEA Results

Cogging Torque
Voltage

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 (Cont…)

Proposed Shape 2

Arc Shaped Triangle

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Results

OFFSET ANGLE Voltage (V) Cogging Torque (Nm)

0 16.1 9.7
15 17.9 9.9
30 18.1 1.1
45 18.4 6.4
60 19.0 9.4
75 19.2 8.8
90 19.5 1.3

Voltage and Cogging Torque with respect to Offset Angle

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FEA Results

Voltage Cogging Torque

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Comparison Between Conventional and Proposed Models
Stator
Stator Stator

Magnets Magnets

Conventional Proposed 1 Proposed 2 Magnets

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 (Cont…)
FEA Results Comparison

Cogging
MODELS Torque
(Nm)
Conventional 1.7

Proposed 1 5.09

Proposed 2 1.3

Cogging Torque

Percentage Difference≈ 𝟑𝟏%

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 (Cont…)
Mathematically Magnets
Magnets

1 2 𝑑𝑅
𝑇𝑐𝑜𝑔𝑔 =− ∅ 𝑔 (1)
2 𝑑𝜃
𝐿
𝑅 = 𝜇𝐴 (2)

𝑚𝑚𝑓
∅= (3)
𝑅

Stator Stator

Conventional Proposed 1 Proposed 2

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 Optimization

Objective Function
Minimization of cogging torque.

Design Variables
𝑋2
𝑋1
42𝑚𝑚 < 𝑋1 < 52mm

1.4mm < X 2 < 2.2mm

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Latin Hyper Cube sampling (LHS)

𝑋1 𝑋𝟐 Cogging Torque (Nm)

49.143 1.858 1.33
47 1.4 1.38
49.857 2.086 1.28
51.286 1.8 1.33
48.429 1.629 1.34
45.571 1.8 1.27
47 2.029 1.28
47.714 1.914 1.25
44.857 1.743 1.3
42 1.971 1.3
42.714 1.457 1.22
43.429 2.143 1.26

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 (Cont…)
Latin Hyper Cube sampling (LHS)

𝑋1 𝑋𝟐 Cogging Torque (Nm)

46.286 2.143 1.27
44.143 1.686 1.23

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 (Cont…)
Genetic Algorithm (GA)

Cogging Torque In

Proposed Model = 1.3

Optimized Model = 1.1

Cogging Torque

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 Conclusions

 Proposed FSPMM has combined benefits of PGCC winding, spoke type ferrite magnets and
unaligned arrangement of rotors.

 PGCC winding has been used to obtain unity winding factor and enhance fault tolerant capabilities.

 Unaligned arrangement of rotors has reduced cogging torque.

 Proposed machine has high efficiency, remarkable fault tolerant capabilities and low cogging torque.

 There is almost 31% decrease in cogging torque as compared to conventional model.

 The proposed model has been optimized by using Latin Hyper Cube Sampling (LHS) and Genetic
Algorithm (GA).

 The cogging torque has reduced to 1.1 in optimized model.

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 References

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 References

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