March 26-29

Coil Connections and Winding Factors

in Flux-Switching PM Brushless AC Machines
J. T. Chen, Z. Q. Zhu, and Z. P. Xia
Department of Electronic and Electrical Engineering
University of Sheffield, Sheffield S1 3JD, U.K.
E-mail: z.q.zhu@sheffield.ac.uk

Copyright © 2009 MC2D & MITI

Abstract: The coil-emf vectors in flux-switching permanent magnet (PM) brushless ac machines are
analyzed, the corresponding phase coil connections and winding factors are determined when the
machines have all poles and alternate poles wound, different number of phases, and different
combination of stator and rotor pole numbers. The differences from analyzing the conventional
fractional-slot PM machines with concentrated non-overlapping windings are highlighted, while the
conditions for symmetrical back-emf waveforms are obtained. The analysis is validated by finite
element analyses.

Keywords: brushless, flux-switching, permanent magnet, winding configuration.

1. Introduction connections and winding factors are determined

Due to short end-winding, high torque density
and efficiency, the fractional-slot PM machines
with non-overlapping windings are widely
employed in many applications [1-12], such as
servo, spindle and traction drive systems. As
another kind of machines with non-overlapping
windings, flux-switching PM (FSPM) machines
are being considered and under extensive
investigation [13-15] since FSPM machines
exhibit some novel features, such as PMs on the
stator, simple rotor structure, bipolar and
sinusoidal phase flux-linkage. The FSPM
machines with alternate poles wound was also
proposed in [16][17].
Although the winding configurations and
factors of the fractional-slot PM machines were
analyzed in [5], the method for determining the
phase coils and winding factors of the FSPM
machines is different. However, existing papers
of FSPM machines focus on specific
combination of stator and rotor pole numbers,
viz. 12/10 stator/rotor poles [14][15]. In this
paper, the coil-emf vectors in FSPM machines
are analyzed, the corresponding phase coil
when the machines have all poles and alternate
poles wound, different number of phases, and
different combination of stator and rotor pole
numbers. The differences from analyzing the
conventional fractional-slot PM machines with
concentrated non-overlapping windings are
highlighted, while the conditions for
symmetrical back-emf waveforms are obtained.
The analysis is validated by finite element
analyses.
2. Coil-emf Vectors
There are a lot of feasible combinations of
stator and rotor pole numbers in FSPM
machines, viz.:
N s = k1m (k1 = 1,2...) (1)
N r = N s ± k 2 (k 2 = 1,2...) (2)
where m is the number of phases. k1 is an
integer number when m is an even number, but
k1 should be an even number when m is an odd
number since the number of stator poles must
be even.
The coil connection in a FSPM machine can be
determined from the coil-emf vectors. By way
of example, as shown in Fig. 1(a), for 12-stator
pole machines with all and alternate poles
wound, Fig. 1(b) illustrate the stator coil
positions in mechanical degrees. In order to
obtain the coil-emf vectors in electrical degrees,
the electrical degrees αe between two vectors
can be derived from the mechanical degrees αm
as:
α e = N rα m (3)
(d) Phase coils
It should be noted that the rotor pole number in
a FSPM machine is equivalent to the number of
pole pairs of rotor magnets in a conventional
fractional-slot PM machine. Hence, Fig. 1(c)
and Figs. 2-4(b) shows the corresponding coil-
emf vectors in electrical degrees for 10-, 11-,
13-, and 14-rotor pole machines with all and
alternate poles wound. Coils n and n´ are of
opposite polarity, accounting for alternate
(e) Illustration of coil connections
magnetisation directions in stator poles, for Fig. 1. 12/10 stator/rotor pole FSPM machine.
example coils 1 and 2. However, for the FSPM
machines with alternate poles wound, the (I) All poles wound (II) Alternate poles wound
4
magnetisation direction is the same for all the 5 3
coils, coil n´ will not appear in the coil-emf
vectors, Figs. 1-4(II).

(I) All poles wound (II) Alternate poles wound

9 11
10

(a) Stator coils (mech. deg.)

9 11

(a) Schematic of 12-stator poles and coils

4
5 3 3
5

(b) Emf vectors (elec.deg.) and sectors (dash

lines)for determining phase coils
9
3' ,

9 11
10

(b) Stator coils (mech. deg.)

12

2´,
6´,

'
11
5,

(c) Phase coils

(c) Emf vectors (elec.deg.) and sectors (dash lines)

for determining phase coils

(d) Illustration of coil connections

Fig. 2. 12/11 stator/rotor pole FSPM machine.
 (I) All poles wound (II) Alternate poles wound
4
5 3 5 3

9 11 9 11 (b) Emf vectors (elec.deg.) and sectors (dash lines)

10 for determining phase coils
(a) Stator coils (mech. deg.)
4´
5 3

9 11
10´

(b) Emf vectors (elec.deg.) and sectors (dash lines) (c) Phase coils
for determining phase coils

(d) Illustration of coil connections

(c) Phase coils Fig. 4. 12/14 stator/rotor pole FSPM machine.
3. Coil Connections
-A
-B

The methods for determining phase coils are

different when the number of phases is odd
number or 2 and even numbers excluding 2.
They are described separately as follows.
B
A

A. Odd number of phases of 2 phases

(d) Illustration of coil connections In order to obtain the largest winding factor, the
Fig. 3. 12/13 stator/rotor pole FSPM machine. coil vectors or their opposite vectors for the
same phase should be as close as possible, i.e.
with minimum phase angle difference. Hence,
(II) Alternate poles
(I) All poles wound the coils for one phase can be determined by
wound
4
drawing two opposite sectors which contain
5 3 2π/m radians, viz. each of the sectors contains
π/m radians. Fig. 1(c) and Figs. 2-4(b) show the
sectors in dash lines in 3-phase, 12/10, 12/11,
12/13, and 12/14 stator/rotor pole machines
with all and alternate poles wound. The coil-
emf vectors within the sectors belong to the
9
10
11
same phase, and the vectors in the opposite
sector should be connected with opposite
(a) Stator coils (mech. deg.) polarity. For other phases, two opposite sectors
are rotated by 2nπ/m (n=1, 2, …, m-1) radians,
and the corresponding phase coils can also be
determined, Fig. 1(d) and Figs.2-4(c). It should
be mentioned that each coil-emf vector has an
opposite vector in the same phase for the
machines with all poles wound and the 12/11
and 12/13 stator/rotor pole machines with (I) Emf vectors (II) Phase coils
alternate poles wound, Figs. 2(b) and 3(b),
while it has no opposite vector in the 12/10 and

11

11
15

15
12/14 stator/rotor pole machines with alternate

16'
10'
poles wound. Since the back-emf waveform of

A
1
9
individual coil exhibits even order harmonics in

2'
8'
the FSPM machines [18], the even order
harmonics are cancelled in the resultant back-

3
3

7
7
emf of the vector and its opposite vector. Hence,
the 12/10 and 12/14 stator/rotor pole machines (a) 4-phase, 16/15 stator/rotor poles (Q=4, α=22.5o)
with alternate poles wound exhibit asymmetric 18' 19 20' 21
17
back-emf waveform, while other machines

22
'
22
'

16
16

'
'

23
present symmetrical back-emf waveforms.

12' 13 14' 1

24' 1
Similarly, the emf vectors and phase coils of a

A
15º
2-phase 8/7 stator/rotor pole and a 5-phase

2'
20/19 stator/rotor pole machines are illustrated

11

3
F
in Fig. 5.

'

0'
10

4'

4'
1
9 5
8' 7 6'

(I) Emf vectors (II) Phase coils (b) 6-phase, 24/23 stator/rotor poles (Q=4, α=15o)
Fig. 6. Emf and phase coil vectors (elec. deg.) of 4-
and 6-phase FSPM machines.
8'
6'

6 ' 4,
2, 8' 4. Winding Factors

A. Distribution factor
The calculation method for the distribution
4'

2'

factor of FSPM machine is detailed here. As

(a) 2-phase, 8/7 stator/rotor poles (Q=2, α=45o)
(b) 5-phase, 20/19 stator/rotor poles (Q=2, α=18o)
Fig. 5. Emf and phase coil vectors (elec. deg.) of 2-
and 5-phase FSPM machines.
B. Even number of phases excluding 2 phases
When the number of phases is even number
excluding 2, the foregoing two opposite sectors
belong to different phases. The phase coils can
be determined by drawing one sector which
contains 2π/m radians. The sector for
determining phase coils of a 4-phase 16/15
stator/rotor pole and a 6-phase 24/23 stator/rotor
pole FSPM machines are illustrated in Fig. 6.
Again, the coils for the other phases can be
obtained by rotating the sector by 2nπ/m (n=1,
2, …, m-1) radians. Similarly, the machine
exhibits asymmetric phase back-emf waveform,
viz. ever order harmonics. The symmetrical
back-emf waveforms can be obtained by
doubling the number of stator and rotor poles,
viz. the new phase A consists of phase A and C,
as shown in Fig. 5(a) for the 4-phase machines.
shown in Fig. 7, the distribution factor kd can
be given by [6]:
Qvα
sin
kd = 2 (4)
vα
Qsin
2
where Q is the number of emf vectors, α is the
angle between two adjacent vectors, v is the
order of harmonic.
Fig. 7. Illustration of emf vectors.
This can also be employed to calculate the
distribution factors in FSPM machines. Hence,
the distribution factor in FSPM machine can be
calculated if Q and α are obtained, which is
determined by the number of stator poles, rotor
poles, phases, and the foregoing coil
connections. For example, in the 12/11 and
12/13 stator/rotor pole FSPM machines with all
poles wound, Figs. 2(c) and 3(c), Q=2 and
α=30o, and their fundamental winding factor
can be calculated by:
 2 × 30
sin
2 = 0.966 (C) 4-Phase
kd = (5) Nr = Ns±1 Nr = Ns±2
30
2sin Ns= All poles Alternate All poles Alternate
2 2km Nr wound poles wound Nr wound poles wound
B. Pitch-factor kd kp kw kd kp kw kd kp kw kd kp kw
3 1 0.710.71 -- -- -- -- -- -- -- -- -- --
In the FSPM machines, the single coil back-emf 4
5 1 0.710.71 -- -- -- -- -- -- -- -- -- --
is the vector sum of two adjacent slot 7 0.920.920.85 1 0.92 0.92 6 1 0.71 0.71 -- -- --
8
conductors whose angular difference θc can be 9 0.920.920.85 1 0.920.9210 1 0.710.71 -- -- --
obtained from the vth back-emf harmonic as: 12
110.910.970.88 -- -- -- -- -- -- -- -- -- --
130.910.970.88 -- -- -- -- -- -- -- -- -- --
N 150.910.980.890.920.98 0.90 140.92 0.92 0.85 1 0.92 0.92
θ c = 2πv r − 1 (6) 16
170.910.980.890.920.980.90180.920.920.85 1 0.920.92
Ns
190.900.990.89 -- -- -- -- -- -- -- -- -- --
20
Furthermore, the coil pitch-factor of the vth 210.900.990.89 -- -- -- -- -- -- -- -- -- --
harmonic can be calculated as follows: 230.900.990.890.910.99 0.90 220.91 0.97 0.88 -- -- --
24
250.900.990.890.910.990.90260.910.970.88 -- -- --
θc  N 
k p = cos = cos πv r − 1  (7)
2  N  (d) 5-Phase
 s 
Nr = Ns±1 Nr = Ns±2
Hence, the winding factor kw can be obtained by: Ns= All poles Alternate All poles Alternate
kw = kd k p (8) 2km Nr wound poles wound Nr wound poles wound
kd kp kw kd kp kw kd kp kw kd kp kw
The winding factors of the multi-phase FSPM 10
9 1 0.950.95 1 0.950.95 8 1 0.810.81 1 0.810.81
machines with different combination of stator 11 1 0.950.95 1 0.950.9512 1 0.810.81 1 0.810.81
190.990.990.98 1 0.990.9918 1 0.950.95 1 0.950.95
pole and rotor pole numbers are calculated for 20
210.990.990.98 1 0.990.9922 1 0.950.95 1 0.950.95
number of phases from 2 to 6, Table 1. All the 290.990.990.980.990.990.98280.990.980.970.990.980.97
30
machines exhibit high distribution factor 310.990.990.980.990.990.98320.990.980.970.990.980.97
390.981.000.980.991.000.99380.990.990.98 1 0.990.99
although it reduces with the increase of stator 40
410.981.000.980.991.000.99420.990.990.98 1 0.990.99
pole numbers when the number of phases is
even. However, the pitch-factor increases as the (e) 6-Phase
stator pole numbers increase. When the stator Nr = Ns±1 Nr = Ns±2
pole number ≥ 12, the machines have high Ns= All poles Alternate All poles Alternate
2km Nr wound poles wound Nr wound poles wound
pitch-factor, and consequently, high winding kd kp kw kd kp kw kd kp kw kd kp kw
factor since the distribution factor is also high. 5 1 0.870.87 -- -- -- 4 1 0.500.50 -- -- --
6
7 1 0.870.87 -- -- -- 8 1 0.500.50 -- -- --
110.970.970.94 1 0.97 0.97 10 1 0.870.87 1 0.87 0.87
TABLE 1: Winding Factors of Key Combinations 12
130.970.970.94 1 0.970.9714 1 0.870.87 1 0.870.87
of Stator and Rotor Pole Numbers in Multi-Phase 170.960.980.94 -- -- -- 160.960.940.90 -- -- --
18
FSPM Machines 190.960.980.94 -- -- -- 200.960.940.90 -- -- --
230.960.990.950.970.99 0.96 220.970.970.94 1 0.97 0.97
(A) 2-Phase 24
250.960.990.950.970.990.96260.970.970.94 1 0.970.97
Nr = Ns±1 Nr = Ns±2 290.960.990.95 -- -- -- 280.960.980.94 -- -- --
Ns= All poles Alternate All poles Alternate 30
310.960.990.95 -- -- -- 320.960.980.94 -- -- --
2km Nr wound poles wound Nr wound poles wound 350.961.000.960.961.00 0.96 340.960.980.940.960.98 0.94
kd kp kw kd kp kw kd kp kw kd kp kw 36
370.961.000.960.961.000.96380.960.980.940.960.980.94
3 1 0.710.71 -- -- -- -- -- -- -- -- --
4
5 1 0.710.71 -- -- -- -- -- -- -- -- --
7 0.920.920.85 1 0.92 0.92 6 1 0.71 0.71 -- -- -- 5. Validation
8
9 0.920.920.85 1 0.920.9210 1 0.710.71 -- -- --
110.910.970.88 -- -- -- -- -- -- -- -- -- In order to validate the foregoing analysis, the
12
130.910.970.88 -- -- -- -- -- -- -- -- --
150.910.980.890.920.98 0.90 140.92 0.92 0.85 1 0.92 0.92 flux-linkage and back-emf waveforms of the 3-
16
170.910.980.890.920.980.90180.920.920.85 1 0.920.92 phase, 12/10 and 12/11 stator/rotor pole FSPM
190.900.990.89 -- -- -- -- -- -- -- -- -- machines with all and alternate poles wound are
20
210.900.990.89 -- -- -- -- -- -- -- -- --
230.900.990.890.910.99 0.90 220.91 0.97 0.88 -- -- -- predicted by 2-D finite element analyses using
24 the Flux 2D software package. The major
250.900.990.890.910.990.90260.910.970.88 -- -- --
design parameters of the machines are given in
(b) 3-Phase Table 2, having equal magnet width, slot
Nr = Ns±1 Nr = Ns±2 opening, stator tooth width, and rotor tooth
Ns= All poles Alternate All poles Alternate
2km Nr wound poles wound Nr wound poles wound width. The open-circuit field distributions are
kd kp kw kd kp kw kd kp kw kd kp kw shown in Fig. 8.
5 1 0.870.87 1 0.870.87 4 1 0.500.50 1 0.500.50 The coil and phase back-emf waveforms and
6
7 1 0.870.87 1 0.870.87 8 1 0.500.50 1 0.500.50
110.970.970.94 1 0.970.9710 1 0.870.87 1 0.870.87 their spectra are shown in Figs. 9 and 10,
12
130.970.970.94 1 0.970.9714 1 0.870.87 1 0.870.87 respectively. The individual coil back-emf is
170.960.980.940.960.980.94160.960.940.900.960.940.90 asymmetric, viz. including even order
18
190.960.980.940.960.980.94200.960.940.900.960.940.90
230.960.990.950.970.990.96220.970.970.94 1 0.970.97 harmonics. However, the phase back-emf
24 waveforms, coils 1+4+7+10 for the 10-rotor
250.960.990.950.970.990.96260.970.970.94 1 0.970.97
poles and coils 1+2´+7´+8 for the 11-rotor poles, wound machine exhibits ~3.4% higher back-
are symmetrical for both 10- and 11-rotor pole emf than the all poles wound machine in the
machines with all poles wound. For alternate case of 11-rotor poles due to different
poles wound, the 10-rotor poles exhibits distribution factor, Table 1. The 11-rotor pole
asymmetric back-emf waveform (coils 1+7), machines exhibit larger back-emf than 10-rotor
while it is symmetrical for 11-rotor poles (coils pole machines.
1+7´).
8
Coil 1 Coil 4
Coil 7 Coil 10
(I) All poles wound (II) Alternate poles wound Coils 1+7 Coils 4+10
4 Coils 1+4+7+10

Back-emf (V)
0

-4

-8
0 60 120 180 240 300 360
Rotor position (electrical degree)

(a) 10-rotor poles (a) Waveforms

6

Coil 1
5
Coil 4
Coil 7
4 Coil 10

Back-emf (V)
Coils 1+7
3 Coils 4+10
Coils 1+4+7+10
2

0
1 2 3 4 5 6 7
(b) 11-rotor poles Orders
Fig. 8. Open-circuit field distributions and phase (b) Spectra
coils of 12-stator pole FSPM machines. Fig. 9. Back-emf of 12/10 stator/rotor pole FSPM
TABLE 2: Major Parameters of FSPM Machines machine.
8
Number of phases 3 Coil 1 Coil 2'
Coil 7' Coil 8
Outer radius of stator 45 mm Coils 1+7' Coils 2'+8
Inner radius of stator 27.5 mm 4 Coils 1+2'+7'+8

Airgap length 0.5 mm

Back-emf (V)

Active axial length 25 mm

0
Magnetic remanence 1.2 T
Relative PM permeability 1.05
Number of turns / phase 72 -4
Rated current 10 A (rms)
Rated speed 400 rpm
-8
0 60 120 180 240 300 360
rd
The 3 harmonic back-emf exists in 11-rotor Rotor position (electrical degree)

pole machines, but does not exist in 10-rotor (a) Waveforms

pole machines since the pitch-factor for 3rd 6

Coil 1
harmonic can be given by: 5
Coil 2'
For the 12/10 stator/rotor pole machines: Coil 7'
4
Back-emf (V)

Coil 8
θc 180 o
cos = cos =0 (8) 3
Coils 1+7'
Coils 2'+8
2 2
Coils 1+2'+7'+8
and for the 12/11 stator/rotor pole machines: 2

θc 90 o
cos = cos = 0.707 (9) 1
2 2
Hence, the 3rd harmonic back-emf is zero in the 0
1 2 3 4 5 6 7
10-rotor pole machines. Orders

In addition, the phase back-emf waveforms and (b) Spectra

their spectra of the 12/10 and 12/11 stator/rotor Fig. 10. Back-emf of 12/10 stator/rotor pole FSPM
pole machines are compared in Fig. 11. All machine.
poles and alternate poles wound machines
exhibit the same fundamental back-emf in the
case of 10-rotor poles, while the alternate poles
 8
winding configurations of synchronous machines,”
10-rotor poles, all poles wound IEEE Trans. on Industry Applications, vol. 42, no.4,
10-rotor poles, alternate poles wound
11-rotor poles, all poles wound
pp. 997-1006, July/Aug. 2006.
4 [5] N. Bianchi, and M. D. Pré, “Use of the star of slots
Phase back-emf (V)
11-rotor poles, alternate poles wound
in designing fractional-slot single-layer
0 synchronous motors,” Proc. IEE Electr. Power
Appl., vol. 153, No.3, pp. 459–466, 2006.
[6] N. Bianchi, M. D. Pré, L. Alberti, and E.
-4
Fornasiero, Theory and Design of Fractional-Slot
PM Machines. CLEUP, 2007.
-8 [7] A.M. El-Refaie, and T.M. Jahns, “Optimal flux
0 60 120 180 240 300 360 weakening in surface PM machines using
Rotor position (electrical degree)
concentrated windings,” Proc. IEE Electr. Power
(a) Waveforms Appl., vol.41, no.3, pp.790-800, May/June 2005.
[8] A.M. El-Refaie, T.M. Jahns, and D. W. Novotny,
6
“Analysis of surface permanent magnet machines
5 10-rotor poles, all poles wound with fractional-slot concentrated windings,” IEEE
10-rotor poles, alternate poles wound Trans. on Energy Conversion, vol.21, no.1, pp.34-
Phase back-emf (V)

4 11-rotor poles, all poles wound 43, March 2006.

11-rotor poles, alternate poles wound
3
2 optimal flux weakening in surface PM Machines
1 Industry Applications, vol.42, no.2, pp.443-453,
0
1 2 3 4
Orders
(b) Spectra
Fig. 11. Phase back-emf of 12/10 and 12/11
stator/rotor pole FSPM machines with all and
alternate wound.
6. Conclusions
The coil-emf vectors of multi-phase FSPM
machines with all poles and alternate poles
wound are analyzed, and the method for
determining the corresponding phase coils is
described. In determining the phase coils, the
asymmetry, i.e. even order harmonics, in the
phase back-emf waveform can be predicted by
employing the proposed method. Moreover, the
winding factors of machines having all poles
and alternate poles wound and different
numbers of phases, from 2 to 6, and different
combinations of stator pole and rotor pole
numbers are determined.
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