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Design Optimisation of An Axial Flux-Switching Hybrid PDF
Design Optimisation of An Axial Flux-Switching Hybrid PDF
org
Published in IET Electric Power Applications
Received on 5th February 2014
Revised on 16th April 2014
Accepted on 6th May 2014
doi: 10.1049/iet-epa.2014.0022
ISSN 1751-8660
Abstract: This paper presents an optimization analysis of an axial flux-switching hybrid excitation synchronous machine
(AFHESM) to improve its no-load electromagnetic performances. The shapes of permanent magnet (PM), rotor-teeth and
stator slot of AFHESM are investigated for a better design scheme by finite element analysis (FEA). Some optimal results
under no-load are achieved, which mainly including the induced electromotive force (EMF), cogging torque and field control
ability. Both FEA and experimental results show that the induced EMF can be improved when PM shape coefficient is 0.95
and the rotor-teeth bevel angle is 6°.
1 Introduction The rotor teeth are radially arranged on the surface of rotor
yoke. Figs. 1b and c give the explosion of AFHESM and
Recently, axial flux permanent magnet (PM) machines are expansion of stator, respectively.
very often studied for vehicle propulsion [1, 2] and
direct-drive wind power system [3–7] because of
high-power density and excellent efficiency.
An axial flux-switching hybrid excitation synchronous 2.2 Operation principle of AFHESM
machine (AFHESM) is a new type of axial flux PM In AFHESM, the magnetic field is mainly generated by
machine with field control ability. It integrates the magnetic motive force (MMF) of PM excitation when DC
advantages of hybrid excitation synchronous machine current is not applied in field windings. According to the
(HESM), axial flux PM electrical machine and principle of least reluctance for magnetic circuit, most of
flux-switching PM electrical machine [8, 9]. Among magnetic flux passes through N pole of PM, ‘H’ type
AFHESMs, many topologies exist [10], such as single stator core, air-gap, rotor tooth, rotor yoke, adjacent rotor
stator-single rotor, single stator-double rotor and double tooth, air-gap, adjacent ‘H’ type stator core and S pole of
stator-single rotor. PM. The magnetic circuit of AFHESM varies for one
In this paper, a three-phase 12/10 pole AFHESM with period when it rotates from one ‘H’ type unit stator core
single stator-double rotor is introduced and some structural to the neighbouring one. At the same time, the flux
parameters of AFHESM are investigated for obtaining a linkage of armature winding will also vary for one
better design scheme. period, that is, it goes into and pierces out of armature
winding, as shown in Figs. 2a and b. The magnetic
2 Structure and operation principle of field in the air-gap of AFHESM is axial, and its
AFHESM magnetic circuit is different from that of a radial flux
PM electrical machine. As same as the traditional radial
2.1 Structure of machine flux HESMs [11–13], the MMF of electrical excitation
and MMF of PM excitation can also work at the
Fig. 1a shows the structure of a three-phase, 12/10 pole same time to achieve different field control abilities in
AFHESM, which consists of single stator and double rotors. AFHESM.
The stator mainly includes ‘H’ type stator core, PMs, field Figs. 3a and b describe the principle of field enhancement
windings, armature windings etc. The stator core is and weakening in AFHESM at the same rotor position. In
subdivided into an internal and external part by a Figs. 2 and 3, the magnetic flux produced by PMs and field
non-magnetiser. In external part, the field windings are current is represented by the black solid lines and magenta
axially winded on the surface of field brackets. For internal dashed lines. The direction of field current is not same
part, some alternately magnetised PMs are embedded under field enhancement and field weakening, so the
between the adjacent stator cores. The stator is magnetic flux because of field current should be reversed
symmetrically located in the middle of two rotors axially. correspondingly.
342 IET Electr. Power Appl., 2014, Vol. 8, Iss. 9, pp. 342–348
& The Institution of Engineering and Technology 2014 doi: 10.1049/iet-epa.2014.0022
www.ietdl.org
Fig. 1 AFHESM
a Structure of AFHESM
b Explosion of AFHESM
c Expansion of stator
3.1 Optimisation of PM
l1
k= (1)
l2
IET Electr. Power Appl., 2014, Vol. 8, Iss. 9, pp. 342–348 343
doi: 10.1049/iet-epa.2014.0022 & The Institution of Engineering and Technology 2014
www.ietdl.org
Table 1 Initial parameters of AFHESM
Items Values Items Value
Fig. 4 PM shape
a Cross-section
b k is 0.73
c k is 0.95
344 IET Electr. Power Appl., 2014, Vol. 8, Iss. 9, pp. 342–348
& The Institution of Engineering and Technology 2014 doi: 10.1049/iet-epa.2014.0022
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Fig. 5a shows that electromotive force (EMF) (k adopts induced EMF will increase with β increased. Figs. 6b and c
0.95) is 4 V larger than that of k adopting 0.73 and a show the structure model of rotor when β is 0 and 6°,
smaller cogging torque is obtained when k is 0.95 by finite respectively.
element (FE) analysis, as shown in Fig. 5b. In this machine, Fig. 7 gives the induced EMF and cogging torque
the rated full-load torque is 2.36 N m, so the reduction of waveforms. Fig. 7a shows that EMF becomes lowest when
cogging torque is also important. β is 0°. With β varied from 0 to 8°, the EMF will also
increase because of an increasing overlapping area between
rotor-teeth and stator-teeth. Fig. 7b shows that cogging
3.2 Optimisation of rotor torque will become large slightly with β increased, and a
From the above optimisation analysis for PMs in AFHESM, it smaller value will be obtained when β adopts 6°.
can be known that the upper of stator-teeth will become wider Considering EMF and cogging torque, an optimal value of
than that in initial scheme, and the upper of rotor teeth should β (6°) is selected for applying in AFHESM.
also become wider accordingly for the least magnetic resistance.
The rotor-teeth shape varies with β, as shown in Fig. 6a. It
can be seen that the magnetic resistance will reduce and the 3.3 Optimisation of stator-slot
Fig. 8 shows two structure models of unit stator core when the
shape of stator-slot is trapezoidal and rectangular,
respectively.
It can be found that the EMF adopting rectangular slot is
larger than that of adopting trapezoidal slot. Meanwhile,
and a smaller cogging torque is obtained as shown in
Fig. 9. It is because the cross area adopting rectangular slot
is smaller than that of adopting trapezoidal slot; in other
words, the stator-teeth adopting rectangular slot covers a
larger area so that the magnetic circuit reluctance is smaller
than that of adopting trapezoidal slot.
With the rectangular slot width varied from 7.5 to 10°, the
Fig. 8 Slot structure EMF will become small, but the cogging torque decreases at
a Trapezoidal slot first then becomes large, and a minimum value is obtained at
b Rectangular slot about 8.5°. Therefore considering between EMF and cogging
IET Electr. Power Appl., 2014, Vol. 8, Iss. 9, pp. 342–348 345
doi: 10.1049/iet-epa.2014.0022 & The Institution of Engineering and Technology 2014
www.ietdl.org
torque, an optimal stator-slot width will be about 8.5°. Fig. 10 comparison with the initialised AFHESM, the coil number
shows the calculated results by FE analysis. is same. Some parameters of AFHESM are given in
Table 2, which mainly consider PM shape coefficient and
rotor angle.
4 Optimisation results From Fig. 11, it is found that the optimised EMF increased
by 8 V than that of initialisation, and the cogging torque can
The effect of stator-slot optimisation is not obvious if the slot
also be reduced. Overall, the electromagnetic performance of
shape is only changed. For obtaining more reasonable
AFHESM has been improved effectively.
Table 2 Optimised parameters of AFHESM
Items Values
5 Prototype testing
stator/rotor outside radius/mm 158
stator-slot width, ° 8.5
stator-teeth width, ° 7
According to the optimised scheme of AFHESM, a prototype
PM shape coefficient 0.95 motor is manufactured shown in Fig. 12 according to some
rotor-teeth bevel angle β, ° 6 partial structure parameters are shown in Table 2.
346 IET Electr. Power Appl., 2014, Vol. 8, Iss. 9, pp. 342–348
& The Institution of Engineering and Technology 2014 doi: 10.1049/iet-epa.2014.0022
www.ietdl.org
5.1 EMF at no-load in Figs. 14a and c show a satisfactory agreement with
experimental results given in Figs. 14b and d, separately.
Fig. 13 shows the three-phase EMF at no-load without field
current at the speed of 400 rpm. It can be noted that the
three-phase symmetrical EMF waveforms are obtained. The 6 Conclusion
amplitude of initialised EMF and optimised EMF in
AFHESM is about 16 and 22 V shown in Figs. 13a and c, This paper presents an AFHESM with optimal structure
separately. The testing results were shown in Figs. 13b and parameters to improve its electromagnetic performance. The
d are in good agreement with that obtained from FE analysis. influences of PM, rotor-teeth and stator-slot shape on
induced EMF, cogging torque and field control ability are
investigated for a better design scheme of AFHESM. It is
5.2 EMF at different field currents found that the induced EMF can be improved when PM
shape coefficient is 0.95, the rotor-teeth bevel angle is 6°
The phase EMF will be varied with different field currents, as and the rectangular stator-slot is adopted. A good field
shown in Fig. 14. It can be seen that a good field control control ability of AFHESM is also obtained, which has
ability has been achieved, and the FE analysis results given been validated by the prototype motor.
IET Electr. Power Appl., 2014, Vol. 8, Iss. 9, pp. 342–348 347
doi: 10.1049/iet-epa.2014.0022 & The Institution of Engineering and Technology 2014
www.ietdl.org
7 Acknowledgments 6 Chan, T.F., Lai, L.L., Shuming, X.: ‘Field computation for an axial flux
permanent-magnet synchronous generator’, IEEE Trans. Energy
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This work was supported in part by the National Natural 7 Chan, T.F., Weimin, W., Lai, L.L.: ‘Performance of an axial-flux
Science Foundation of People’s Republic of China permanent magnet synchronous generator from 3-D finite-element
(numbers 51007033 and 51267006) and the Plan Project of analysis’, IEEE Trans. Energy Convers., 2010, 25, (3), pp. 669–676
Jiangxi Province of People’s Republic of China (numbers 8 Sulaiman, E., Tsujimori, Y., Kosaka, T., Matsui, N.: ‘Design of 12-slot
GJJ12332 and 20122BAB206031). 10-pole permanent magnet flux switching machine with hybrid
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348 IET Electr. Power Appl., 2014, Vol. 8, Iss. 9, pp. 342–348
& The Institution of Engineering and Technology 2014 doi: 10.1049/iet-epa.2014.0022