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Anal Ysis of An Axial PM Flux Machine With FW
Anal Ysis of An Axial PM Flux Machine With FW
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Key Words: axial flux, motor/generator, permanent [2]. The electrical machine to be used in applications such
magnet, automotive, field weakening. as those described above must be efficient, compact and
integrates well with the IC engine. The axial-flux
Abstract motor/generator with a toroidal winding configuration is
an ideal candidate for this type of application as it is very
With the development of new forms of vehicle drive short and so can be mounted directly on the engine crank
systems and the interest of low fuel consumption, there is palm replacing the engine flywheel [3], [4].
an increasing need for compact electrical machines that An efficient high torque and compact Axial Flux PM
can be integrated with the IC engine to form compact (AFPM) machine that was suitable for integration into an
power units. This paper will describe the design, existing commercial vehicle drive train with least amount
development and testing of a slotted totally enclosed of modifications has been successfully researched and
permanent magnet axial flux machine with field implemented in [5]. This AFPM machine adopts a simple
weakening capability. The design addresses the conflicting surface mounted permanent magnets arrangement.
requirements for intrinsic fault tolerance, efficiency and PM synchronous machines in hybrid power applications
effective field weakening capability to reduce power are often required to work over a wide speed range, which
electronics cost. Test results will be presented to confirm could go as high as multiple times of the base speed.
the consistency of the machine performance predictions. Operation in field weakening mode is therefore required to
extend the machine speed range without increasing the
1. Introduction maximum voltage rating of the power electronics
converter and hence cost.
Road transportation is by large the biggest contributor to This paper considers design, analysis and testing of an
domestic transport greenhouse gases/emission in Inverse Saliency Axial Flux PM, ISAFPM, machine
industrialised countries, mainly through the contributions topology, formerly introduced by Tapia et al. [6]. The
of cars, vans and heavy goods vehicles. One way of machine has been designed, developed and tested along
reducing these greenhouse emissions is through the use of with the power electronics interface using multi-domain
vehicle electrification. Passenger car manufacturers have analysis. However, this paper will tackle solely the
made a significant progress by actively pursuing new electromagnetic design of the machine.
forms of hybrid electric vehicle powertrain systems to
achieve both low emissions and fuel consumption. 2. Machine design and development
Light to medium (up to 7.5 tonnes) and particularly heavy
goods vehicles productions are an order of magnitude This section deals with the design, sizing and analysis of
lower than passenger cars and alterations to these vehicles an ISAFPM machine to meet the specification summarised
platforms are constrained by limited economies of scale, section 2.2.
the need to maintain payload mass/volume and by not
adding too much excess weight on the vehicle axle. To
2.1. Machine layout
overcome both of these economic and technological
barriers, the electrical drive technologies must be packaged
The schematic diagram of the totally enclosed bearing-less
without any significant modifications to the existing
ISAFPM machine is shown in Fig.l . The machine is made
vehicle platform. They must also be economical in terms
of one stator sandwiched between two rotor plates. The
of cost, weight and size while meeting performance and
machine stator consists of a two-part liquid cooled
reliability expectations. Light to medium commercial
aluminium heatsink sandwiched between two spirally
vehicles are frequently used for urban delivery of
wound slotted laminated iron cores. This stator assembly
consumer goods and therefore should be well suited to
which contains the toroidally wound three phase armature
hybridisation due to the stop start nature of their use.
winding arrangement can easily lend itself to an automatic
Heavy goods vehicles on the other hand, are more suited
winding process.
for line haul or motorway journeys with little urban
The machine rotating parts consist of two rotor plates, each
operations. Hybridisation of this class of vehicles can be
carrying axially polarized NdFeB magnets deployed on the
beneficial with respect to fuel saving and C02 emissions
outer region of the rotor disk face and soft magnetic
reduction, if used with exhaust heat recovery system [I],
composite (SMC) poles positioned inboard of the magnets
as seen in Figure I. Field weakening capability can be 2.3. Machine design methodology
typically achieved using the d-axis component of the
armature current to produce a flux component in The need of making the electrical machine light and small
opposition to the flux of the permanent magnets. However, enough to fit in a confined space coupled with the
a low rotor surface reluctance path is required to produce necessity of meeting the aggressive targets in terms of
significant flux with a moderate d-axis current. This is torque, efficiency, cost and reliability can be very
achieved by the SMC pole located inboard the main challenging. It is therefore crucial for the machine
magnet pole on the common rotor disk. The coaxial liquid designer to take a balanced approach to efficiency,
cooled heatsink integrated within the stator assembly physical dimensions, mass and inertia of the Flywheel
shares a common coolant circuit with the combustion Motor Generator (FMG), rather than refining one
engine, eliminating the need for duplicate components parameter and compromising others. Equally important is
such as pump, heat exchanger and fan with the vehicle. 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.
Rotor plate
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
Composite
Pole- heats ink interrelated and iteration between individual disciplines is
Figure 1: Inverse Saliency Axial Flux PM machine required to obtain an optimum design which must also
structure comply with the manufacturing conditions.
IkW]
30
60
30
60
T= % [
P lffmdlq - [(Lqm +LqfJ-(Ldm +Ldfe)]IdI J (2)
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
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
,
Where Bad is the maximum value of the stator d-axis The machine performances are predicted using the
armature reaction flux density, and BadJ is the peak value equivalent circuit based on d-q reference frame shown in
of the first harmonic of the flux density. The procedure for Figure 5. This has been modified to take into account the
the computation of !jil.;ron and kfq.;ron form factors for this iron loss which consists of hysteresis and eddy losses, by
type of machine topology is outlined in the Appendix. working out the losses generated in the R(' branch [9].
Id Ra lad
The inductances Ld and Lq of the actual machine can be
"' !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
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
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
f�������/��
The first test was aimed at evaluating the machine ,...... ...,.PrC'dictcd machine efficiency
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 6. Appendix
that measured machine parameters closely match
predictions. The machine being analysed has a two part rotor, where in
the d-axis upper segment consists of a magnet, and the
4. Conclusion lower segment an iron pole. As magnet permeability is
close to unity, the d and q-axis form factor for the magnet
This paper investigated the design, analysis and testing of section is:
an ISAPM machine suitable for integration with an IC (AI)
engine which can be used in HEV applications. The details
of the electromagnetic design and analysis have been For the iron pole section, the high permeability of the iron
presented. It has been demonstrated that the predicted makes a large penetration of the armature reaction into the
machine parameters are in full agreement with the test rotor, as shown in Figure. AI. The ratio glh takes into
results. It can be concluded that this type of machine can account the larger airgap between the poles. Bad! is then
be designed to meet most the specification provided in calculated from:
Table 1.
/Jadl =M17 /J"dcos28d8+ f�f,/J"dCOS28d8]
5. Reference
_Iron ( lr h
] (
= a_Sinalr + K (l_a)+Sin alr
lr
] (A3)
1
Figure A2 Magnetic field of Q-axis armature reaction