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Analysis of an axial PM flux machine with field weakening capability for

engine integration

Conference Paper · January 2014

DOI: 10.1049/cp.2014.0495

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 ANALYSIS OF AN AXIAL PM FLUX MACHINE WITH
FIELD WEAKENING CAPABILITY FOR ENGINE
INTEGRATION
Abdeslam Mebarki, David Gerada, Neil L. Brown
Cummins Generator Technologies, Barnack Road, Stamford, Lincolnshire, PE9 2NB, UK.
salem.mebarki@cummins.com
Key Words: axial flux, motor/generator, permanent
magnet, automotive, field weakening.
Abstract
With the development of new forms of vehicle drive
systems and the interest of low fuel consumption, there is
an increasing need for compact electrical machines that
can be integrated with the IC engine to form compact
power units. This paper will describe the design,
development and testing of a slotted totally enclosed
permanent magnet axial flux machine with field
weakening capability. The design addresses the conflicting
requirements for intrinsic fault tolerance, efficiency and
effective field weakening capability to reduce power
electronics cost. Test results will be presented to confirm
the consistency of the machine performance predictions.
1. Introduction
Road transportation is by large the biggest contributor to
domestic transport greenhouse gases/emission in
industrialised countries, mainly through the contributions
of cars, vans and heavy goods vehicles. One way of
reducing these greenhouse emissions is through the use of
vehicle electrification. Passenger car manufacturers have
made a significant progress by actively pursuing new
forms of hybrid electric vehicle powertrain systems to
achieve both low emissions and fuel consumption.
Light to medium (up to 7.5 tonnes) and particularly heavy
goods vehicles productions are an order of magnitude
lower than passenger cars and alterations to these vehicles
platforms are constrained by limited economies of scale,
the need to maintain payload mass/volume and by not
adding too much excess weight on the vehicle axle. To
overcome both of these economic and technological
barriers, the electrical drive technologies must be packaged
without any significant modifications to the existing
vehicle platform. They must also be economical in terms
of cost, weight and size while meeting performance and
reliability expectations. Light to medium commercial
vehicles are frequently used for urban delivery of
consumer goods and therefore should be well suited to
hybridisation due to the stop start nature of their use.
Heavy goods vehicles on the other hand, are more suited
for line haul or motorway journeys with little urban
operations. Hybridisation of this class of vehicles can be
beneficial with respect to fuel saving and C02 emissions
reduction, if used with exhaust heat recovery system [I],
[2]. The electrical machine to be used in applications such
as those described above must be efficient, compact and
integrates well with the IC engine. The axial-flux
motor/generator with a toroidal winding configuration is
an ideal candidate for this type of application as it is very
short and so can be mounted directly on the engine crank
palm replacing the engine flywheel [3], [4].
An efficient high torque and compact Axial Flux PM
(AFPM) machine that was suitable for integration into an
existing commercial vehicle drive train with least amount
of modifications has been successfully researched and
implemented in [5]. This AFPM machine adopts a simple
surface mounted permanent magnets arrangement.
PM synchronous machines in hybrid power applications
are often required to work over a wide speed range, which
could go as high as multiple times of the base speed.
Operation in field weakening mode is therefore required to
extend the machine speed range without increasing the
maximum voltage rating of the power electronics
converter and hence cost.
This paper considers design, analysis and testing of an
Inverse Saliency Axial Flux PM, ISAFPM, machine
topology, formerly introduced by Tapia et al. [6]. The
machine has been designed, developed and tested along
with the power electronics interface using multi-domain
analysis. However, this paper will tackle solely the
electromagnetic design of the machine.
2. Machine design and development
This section deals with the design, sizing and analysis of
an ISAFPM machine to meet the specification summarised
section 2.2.
2.1. Machine layout
The schematic diagram of the totally enclosed bearing-less
ISAFPM machine is shown in Fig.l . The machine is made
of one stator sandwiched between two rotor plates. The
machine stator consists of a two-part liquid cooled
aluminium heatsink sandwiched between two spirally
wound slotted laminated iron cores. This stator assembly
which contains the toroidally wound three phase armature
winding arrangement can easily lend itself to an automatic
winding process.
The machine rotating parts consist of two rotor plates, each
carrying axially polarized NdFeB magnets deployed on the
outer region of the rotor disk face and soft magnetic
composite (SMC) poles positioned inboard of the magnets
as seen in Figure I. Field weakening capability can be
typically achieved using the d-axis component of the
armature current to produce a flux component in
opposition to the flux of the permanent magnets. However,
a low rotor surface reluctance path is required to produce
significant flux with a moderate d-axis current. This is
achieved by the SMC pole located inboard the main
magnet pole on the common rotor disk. The coaxial liquid
cooled heatsink integrated within the stator assembly
shares a common coolant circuit with the combustion
engine, eliminating the need for duplicate components
such as pump, heat exchanger and fan with the vehicle.
Rotor plate
Composite
Pole- heats ink
Figure 1: Inverse Saliency Axial Flux PM machine
structure
2.2. Machine specification
The specifications call for a high power density flywheel
motor/generator that can deliver a peak power of 60 kW,
on intermittent basis, at an operating base speed of 1300
rpm and with a maximum coolant inlet temperature of 105
II
C. The machine must maintain 60 kW peak power up to a
maximum operating speed of 2800 rpm with a phase
current no more than 174 Arms. The machine is also
required to deliver a 30 kW constant power over the same
II
speed range and with a 105 C maximum coolant inlet
temperature. The rated voltage of the machine is
influenced largely by the rating of the battery, the power
electronics switching device of the machine controller and
the operating speed. Bringing some basic degree of fault
tolerance into the electrical drive system would require a
proper mitigation of its single points of failure. One of the
preferred actions in resolving this issue is done by
imposing a balanced short circuit current on the machine
windings. This mitigation measure is based on the
reasoning that the current in the shorted turn would be
limited to the entire winding, through the strong mutual
coupling between the shorted turn and the remaining turns
[7]. An implicit requirement on the machine design is that
the winding inductance should be sufficient enough to
limit the short circuit current below maximum current
rating of the power electronics. The machine should also
be thermally capable of sustaining the short circuit for the
time taken to isolate the electrical machine from the power
electronics and bring the vehicle safely to a halt using
solely the engine for propulsion. A machine design with
an optimal per unit direct axis inductance higher than 0.5,
needs therefore to be considered.
2.3. Machine design methodology
The need of making the electrical machine light and small
enough to fit in a confined space coupled with the
necessity of meeting the aggressive targets in terms of
torque, efficiency, cost and reliability can be very
challenging. It is therefore crucial for the machine
designer to take a balanced approach to efficiency,
physical dimensions, mass and inertia of the Flywheel
Motor Generator (FMG), rather than refining one
parameter and compromising others. Equally important is
the interaction between the FMG and the power electronics
converter alongside the applied control strategies, to
ensure a close matching between both devices. To
overcome these issues the machine design is carried out in
a multi-physics design environment as shown in Figure 2.
The analytical tools were developed to study quickly and
with confidence the electromagnetic, mechanical and
thermal design aspect of the machine. High fidelity models
such as FEA and CFD were thoroughly used at the
beginning to validate the analytical tools and towards the
end of analysis. The three design fields including the
power electronics converter and control strategies are
interrelated and iteration between individual disciplines is
required to obtain an optimum design which must also
comply with the manufacturing conditions.
Figure 2: In house design capability
2.4. Machine design procedure
The analytical tools establish the back-emf and torque
performance of the machine by treating the stator and the
rotor as infinitely permeable boundaries. 3-D FE analysis
is conducted to check for the effects of magnetic
saturation. The requirements and the predicted
performance are summarised in table I. The stator core
outside diameter is restricted by a need to keep the overall
diameter, including coil ends and connections :'S 511.2 mm
(SAEl ) diameter envelope. The remaining key machine
dimensions are listed in table II. It has to be stated that
this first stator prototype was deliberately oversized on the
outer diameter by 20 mm as a new stator retention /
positioning method was still being developed. Once the
new method was proved, the second prototype stator was
manufactured with a reduced aD to match the rotors
active magnet aD. This will result in an improved overall
efficiency, a reduction in stator inactive material, weight,
manufacturing cost.
Table I: Machine requirements and predicted performance Where 'Pmd corresponds to the magnet flux linkage, Ldm =

Predicted Lqm correspond to the d-axis and q-axis inductance of the

Requirements performance PM part and Ldle> Lqle are the d-axis and q-axis inductance
l\facbiue Overall Outer diameter Imml fitSAEl 490 of the Synchronous Reluctance part receptively.
Macbine Overall Axial Lengtb Imml <: 200 148
Rated Power @ 11300-28001 rpm I 500Vde I Rearranging equation 1
105 'C inl Temp
Peak power @ 250/0 Duty Cycle@ 11300-28001
rpm 1500 Vde 1105 'c inl Temp
IkW]

IkW]
30

60
30

60
T= % [
P lffmdlq - [(Lqm +LqfJ-(Ldm +Ldfe)]IdI J (2)

Efficiency just after base speed 1%] 95-96 up to 95

Per unit machine reactance (Fail safe mode) [-] � 0.5 0.714
l\'laximuru 'Vater inlet Temperature I'q 105 105
Nominal de Bus Voltage M 650 650

Table II: Key Machine Parameters Where Ld = Ldm + Ldfc and Lq = Lqm + Lqfc
Magnet Outer diameter [mm) 410
Magnet length towards magnetisation [mm) 4.5 Ld and Lq are the d-axis and q-axis inductance of the actual
Machine physical airgap [rum) 2 machine respectively.
SMC pole area and total active pole area ratio [%) 30
Total Machine Weight includiog rotor plates [kg] 105 2.4.3. Ld and Lq inductances
(Flywheel replacement)
The machine armature reaction inductance (unsaturated),
Lard, in the d-axis can be worked out as the ratio between
2.4.1. Back EMF the flux produced by the three phase stator currents in d­
axis direction and per-phase d-axis current component.
The analytic electromagnetic program computes the open The armature reaction reactance in the d-axis can be
circuit air gap flux density distribution generated by the therefore calculated from:

((�/ - (�n
magnet source using a 2D mathematical model, based on
solution of Laplace's equation for the magnetic vector
potential resulting from a sinusoidal current sheet
L ard =koff milo (NlkWl)2r
IT
aP I ( + ) Lm

mimicking the magnet and situated between two infinitely l

2
IlrKeg

permeable boundaries [8]. The analytical method was f

((O� ef- -Cien
+ kfd.iran -'--,----
( +--;---,-- --'-
naturally modified to take the slotted nature of the
!:m.)
windings. Parameters such as the induced Back EMF can
be subsequently computed, under unsaturated conditions,
2
Ilfe Keg

based on the machine geometry and winding arrangement. (4)

Figure 3 compares the harmonic content present in the Likewise the armature reaction inductance, L arq, in the q­
axis can be evaluated as:
r ( OD 2 (ID
back EMF of both the analytic expressions and nonlinear
3-D FEA computations with the magnet temperature set to
= mi la NlkWl)2 (T) - 2"')2)
II
70 C, showing good matching between the two methods. L arq koff ( aP IT
l
( + I �) L
l2 Keg
200.00 .,------,

150.00
)2
((f -(fnl
+ kfq.iran ( + 'fJ:)
.

� 100.00
..

L
g Keg
J
2
50.00

(5)
, 3 5 7 9- 111315 17 '921
Hl:lrtT'lonlcs Where aD"" IDI/1 are the outer and inner diameters of the
Figure 3: Frequency spectrum of Back-EMF waveforms magnet pole, whereas O Die IDle are the outer and inner
,

diameters of the composite pole. The machine number of

2.4.2. Torque computation phase is m 3. NJ, kwJ, P, and g represent the number of
=

turns per-phase, the fundamental winding factor, the

Simplistically, the torque of the unsaturated ISAFPM number of pole pair and the airgap mechanical clearance
machine can be computed by considering the machine to respectively. Lm, k", Po, Pr and Pje are the thickness of the
be made up of two parts, a surface PM section and a magnet or composite pole, Carter coefficient, magnetic
Synchronous Reluctance section sharing the same stator. permeability of free space, relative magnetic permeability
The expression for the torque can therefore be given by: of the magnet and relative magnetic permeability of the
3 composite pole respectively. 1<.,'11 is the rotor disk offset
"2 [
T= P Iff"", lq - (Lqm - L dm)ldlq - (Lqi, - L,lj,)ldlq (1) 1 skew factor. Finally kjd-iron and kfq-iron denote the form
\.. / '------ ----.J factors of the armature reactions in the d-axis and q-axis
Y �
respectively. These form factors are calculated based on
PM SynRel
harmonic distribution of the flux density over the airgap
as:
 Badl (6) 2.4.5. Equivalent circuit model
Bad analysis

Where Bad is the maximum value of the stator d-axis
armature reaction flux density, and BadJ is the peak value
of the first harmonic of the flux density. The procedure for
the computation of !jil.;ron and kfq.;ron form factors for this
type of machine topology is outlined in the Appendix.
The inductances Ld and Lq of the actual machine can be
The machine performances are predicted using the
equivalent circuit based on d-q reference frame shown in
Figure 5. This has been modified to take into account the
iron loss which consists of hysteresis and eddy losses, by
working out the losses generated in the R(' branch [9].
Id Ra lad

"' !l: ¢
determined as:
..
(7)
�""""
O-axis Equivalent Circuit
-O-
" '-" E- Q-
U ' ..L
Y . .,-,,-
, c'
,-e u-lt-'
Where, ILJeak is the stator winding leakage inductance Figure 5: Equivalent circuit of the ISAFPM machine in d-q
which includes the slot leakage inductance and end frame
connection leakage inductance.
Figure 4 compares predicted analytic (unsaturated) and 3- The predicted analytic peak electromagnetic torque profile
D FE values of both Ld and Lq as function of their which comprises both permanent magnet torque and
corresponding stator currents. The results show reasonable reluctance torque over a range of rotor positions is shown
agreement, with Ld commencing to saturate at currents in Figure 6 alongside the magnet and reluctance torques.
higher than twice the machine rated current. This is
500
expected owing to the machine large airgap which is 400 k., -- Me;gl'ltllOtqI.IO N
300 ", Reluaance torque /1
defined by mechanical constraints.
2Q0 " TolaIt�e I:
'<" I
1.0 i� ,O� '\ - -
09 ·'00 ---- ."10 ?ktr---'7 -.nn
"
W08 (5 -200
''''"
_____ ..J ______ -L ______ L ______ I ... ·300
07
S_o.6 I , I
"00 .'" '7
: ...... Ld (FE) ! ·500 '"," -y
� 0.5 -------: Rotor position [elecUlc.1 Degres)
-----T, _Lq If I
Ii 0.4 -----+ ....... ld IMdtytic) .. ------!
I
Figure 6: Predicted machine analytic torque profile
tl 0.3
� 0.2 -----� -LQ[Analyticll - ----- -:
- o.J ----- � - £._-----: Figure 7a compares predicted analytic peak torque with the
0.0
o as 170 255 340 peak torque generated using a non-linear 3-D FE analysis
Current (A rms) whereas Figure 7b illustrates a range of maximum
Figure 4: Comparison of predicted analytic and predicted generated torque of both analytic and 3-D FE as function
3-D FEA values Ld and Lq of their corresponding rms currents. There is a good
agreement between analytical and FE results. It can also be
2.4.4. Iron loss and eddy loss in the seen form Figure 7b that the machine magnetic saturation
composite pole is happening for applied stator currents higher than the
machine operating current limit.
Iron losses in the stator lamination of the machine are
I,ll» ,/-1 ------�
made up of hysteresis and eddy current losses. Steinmetz
equations with loss coefficients for the hysteresis and eddy
current have been used to model iron losses. These loss
coefficients are derived from Epstein tests performed on
material sections. The eddy losses in the Somaloy 700 HR .,5O
3P SMC poles were computed using 3-D FE analysis and .", +----'-0",.- '1/-----1
have been found to be negligible. Table III compares the .� �---�---....r
Ro�or �5ItlonIElectTlcDt!1E1'1!I11
eddy loss in the soft magnetic poles for both composite a) b)
and SO iron, the same SO iron material used for the Figure 7: Comparison of both predicted analytic and 3-D
manufacturing of the machine rotor plates. FE peak torques profile

The predicted performance of the ISAFPM machine under

Table III : Comparison of rotor Eddy loss in the soft
magnetic poles
(SG iron) ploes (Somaloy 700 HR 3P) poles
52.4
peak power condition is shown in Figure 8a. It can be seen
that the machine is capable of providing the required 60
kW peak power over the entire operating speed range
0.164 while remaining within the voltage and current limit. The
phase rms voltage is limited to 188 V which correspond to
460.5 VDC using discontinuous pulse width modulation
method. This is within the specified 500 VDe. The illustrated in Figure 10. It can be seen that both predicted
machine top efficiency under constant peak power is in the and measured back emf waveforms agree very closely,
vicinity of 95% at maximum operating speed, including particularly the measured and 3-D Back emf curves.
mechanical losses. Figure 8b shows the performance of the
machine under continuous power in the event constant
voltage control strategy is applied for comparison
purposes.

-Rm• ph .. "urrontiAI -Texqu·lNml

r�!!:::!" =a
-- RmsphaWl \OCfl8Qf
_MaocfliMEJ!i '
.... T�.INml
:�!"'''I'''I
,00
I -Outpul Po .... lkll1
-MadI�. Elfie ..... 1%1
...
-Rms ph ... ,�tag. 1'I1
'w

..
II Time [mSI
.. �200
.. �

f: ....
"'
., 0
>

""'-
Ill)
IOl
Figure 10: No load Back EMF for the ISAFPM machine
h. 70[ i
150
$300 ....... '" i\' � til) 1.'
�2S0 .�
--... '" E
u
10 i .:100 � 50 .i
411 "
The objective of the third test was to evaluate the per-unit
E200 -
�'150
JO w i JO� reactance of the machine needed to limit the short circuit
D:�
1,00 '" 20 current, see, below twice the machine rated current for
� ,. 10 � 111
fail safe mode reason. This test has been achieved by
" o � 0 "
'200 1700 2200 2700 '200
snanspeed[rpn) applying a sudden three phase balanced short circuit at the
a) machine terminals during which the machine was
Figure 8: Predicted machine voltage, current, and operating at no-load and at a maximum speed of 2800 rpm.
efficiency at peak and rated power requirements Figure I I compares the transient analytic and the 3-D FE
three phase balanced see along with the one conducted
3. Experimental tests and validation under test. There is a good agreement between predicted
and test results. It can be seen that the steady state rms
The water cooled prototype machine shown in Figure 9, see is only 123 Arms which is below the machine twice
has been built along with the power electronics converter. rated current of (2 x 85) Arms. This can be translated to a
Preliminary tests have been conducted to validate machine per unit phase reactance of Xdpu 0.714. =

predicted performances.

•
Figure 9: ISAFPM prototype machine on test bed

Table IV: Predicted and measured parameters e) Test

ADalytic FEA Test Figure 11: Transient three phase balanced short circuit at
IRpb [nl@17'C 0.0583 NA 0.0576 the machine terminals
I Ld[mH] 0.885 0.917 0.819

I Lq [mH] 0.747 0.8 0.796 ...... MC'JSUrN phase current

"'*""Predicted phase CUHent
....... M easured mac. hi ne efficiencY

f�������/��
The first test was aimed at evaluating the machine ,...... ...,.PrC'dictcd machine efficiency

resistance and inductance parameters. The phase resistance � i68 :r=:e;;;;;;;;:;.,.o;;;;;;;j

;;; ij;;;;:;:;4{: � �
has been measured at ambient temperature using a precise :!.
" 90
80 SO �c

Micro-Ohmmeter, Tinsley device, whereas the unsaturated

stator winding inductance Ld and Lq have been measured
�
660
� �
/ 70
��
70

40 �
.�

� 30 30�
using static tests with locked rotor. Experimental test � 20 20 �
results are sown in conjunction with the analytic and FEA l� 2S 3S
Met:hllnleal output powll!lr [kW]
findings in Table IV. On the whole, both predictions and
test results are in good agreement. The second test
Figure 12: On-load current and efficiency comparison with
conducted on the machine was to evaluate its open circuit
Back-emf waveforms to assess its magnet flux linkage the machine operating at 1300 rpm base speed
characteristics in comparison with the predictions. The no­
load Back emf waveform obtained from test results with The machine performance operating as motor delivering a
the machine operating at a set speed of 1300 rpm is range of mechanical power outputs at a set speed of 1300
compared with the predicted analytic and 3-D FE back emf rpm is shown in Figure 12. The measured machine phase
waveforms under the same operating conditions as currents and efficiencies are compared to their
 corresponding predicted values. Here again, it can be seen
that measured machine parameters closely match
predictions.
4. Conclusion
This paper investigated the design, analysis and testing of
an ISAPM machine suitable for integration with an IC
engine which can be used in HEV applications. The details
of the electromagnetic design and analysis have been
presented. It has been demonstrated that the predicted
machine parameters are in full agreement with the test
results. It can be concluded that this type of machine can
be designed to meet most the specification provided in
Table 1.
5. Reference
6. Appendix
The machine being analysed has a two part rotor, where in
the d-axis upper segment consists of a magnet, and the
lower segment an iron pole. As magnet permeability is
close to unity, the d and q-axis form factor for the magnet
section is:
(AI)
For the iron pole section, the high permeability of the iron
makes a large penetration of the armature reaction into the
rotor, as shown in Figure. AI. The ratio glh takes into
account the larger airgap between the poles. Bad! is then
calculated from:
/Jadl =M17 /J"dcos28d8+ f�f,/J"dCOS28d8]

adl ad [(a+ Sinlr lr)+K((I_al_ Sinlr lr)]

B =B
a a
[1] M. Algrain, and U. Hopmann. "Diesel engine waste h
heat recovery utilizing electric turbo-compound
technology", DEER Conf., Newport, Rhode Island, From equation (6) it follows that:
Aug 25-28, 2003
[2] C. R. Nelson. "Exhaust Energy Recovery, Advanced kJeUron =(a+ sin:JZ}f,((I_al_sin:Jr) (A2)

Combustion Engine Technologies, Annual Progress

D-a)(is
Report, 2006.
[3] N. Brown, L. Haydock, and J. R. Bumby. "Foresight
vehicle: A Toroidal, Axial Flux Generator for Hybrid
IC engineibattery electric Vehicle Applications", Proc.
SAE Conference, Detroit, paper 2002-01-0829, March
2002.
[4] E. Spooner and B. J. Chalmers. "TORUS: A slotless,
toroidal-stator, permanent-magnet generator", lEE
Proceedings, Part B, Vol. 139, No. 6, November 1992,
pp 497-506.
[5] A. Mebarki, K. Wejrzanowski, M. Shanel and N. L.
Brown. "A high-power, totally enclosed, permanent
1 1 T "2
magnet, axial flux machine for engine integration," in
Proc. 5th lET lnt. Conf. on Power Electronics, Figure Al Magnetic field of D-axis armature reaction
Machines and Drives (PEMD 2010), pp. 1-6.
In a similar way, for the q-axis section, see Figure A2:

aql = aq [(a-S nlr lr] +K ((l-al+S nlr lr]]

[6] J. A. Tapia, D. Gonzalez, R. Wallace, and A.
Valenzuela, "Axial flux surface mounted PM machine /J /J
i a i a
with field weakening capability," in Int. Conf. h
Electrical Machines, ICEM'2004, Krakow, Poland.
[7] P. H. Mellor, T.J. Allen, R. Ong, and Z. Rahma, Which from (6), it follows that:
"Faulted behaviour of permanent magnet electric
vehicle drivetrains," in Proc. lnt. Conf. Electrical
k
fq
.

_Iron ( lr h
] (
= a_Sinalr + K (l_a)+Sin alr
lr
] (A3)

Machines and Drives, lEMDC'2003, pp.554-558.

[8] 1. R. Bumby, R. Martin, M. A. Mueller, E. Spooner,
N. L. Brown, and B. J. Chalmers. "Electromagnetic
design of axial flux permanent magnet machines", lEE
PROC.-ELECTR. POWER APPL., Vol. 151, No.2,
2004, pp. 151-160
[9] S. Morimoto, Y. Tong, Y. Takeda, and T. Hirasa.
"Loss Minimization Control of Permanent Magnet
Synchronous Motor Drives" lEEE Transaction on
Industrial Electronics, Vol. 41, No.5, October 1994

1
Figure A2 Magnetic field of Q-axis armature reaction

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