2022 Second International Conference on Sustainable Mobility Applications, Renewables and Technology (SMART)
2022 Second International Conference on Sustainable Mobility Applications, Renewables and Technology (SMART) | 978-1-6654-7146-6/22/$31.00 ©2022 IEEE | DOI: 10.1109/SMART55236.2022.9990232
Comparative Study Among Different Rotor Topologies of
Axial Flux Permanent Magnet Machines
Salman Ali∗ , Guido Rubino∗ , Luca Ciprini∗ , Rafat Ali† , Fabrizio Marignetti∗
∗ University
of Cassino and South Lazio - Department of Electrical and Information Engineering (DIEI), ITA
† University of Engineering and Technology 25000 Peshawar - Department of Electrical Engineering, Pakistan.
∗ Emails: {salman.ali, guido.rubino, luca.ciprini, marignetti}@unicas.it, † {engr.rafatali}@gmail.com
Abstract—The optimization of the permanent magnet
shape and dimension is crucial for the performance
improvement of axial flux permanent magnet (AFPM)
machines. In this paper, different magnet shapes are
studied and compared based on the performance results.
A new magnet shape is also proposed. The cogging
torque is considered the most prominent noise source in
axial flux permanent magnet (AFPM) machines. Different
magnet shapes are analyzed and compared to optimize
the efficiency of axial flux permanent magnet (AFPM)
machines. Flat trapezoidal pole, curved pole and skewed
pole are studied and analyzed and a new shape which
is a combination of curved and skewed magnet shape
is proposed to further reduce the cogging torque and
improve the overall efficiency of axial flux permanent
magnet (AFPM) machines. The study focuses on single-
sided machines, but the results are valid even for double-
sided machines and can be easily extended to other
configurations.
Index Terms—AFPM, Performance improvement, Per-
manent magnet Optimization, Cogging Torque
I. I NTRODUCTION
In recent years, Axial Flux Permanent Magnet
(AFPM) Machines have been the focus of research in
the permanent magnet machines field due to their high
efficiency and compact size [1-3]. Due to the high
torque-to-size ratio, better ventilation for cooling, and
reduced weight, AFPM machines have become popular,
especially in Electrical Vehicles (EV) traction and Wind
Generation domains.
Along with the multiple benefits of AFPM machines,
some associated problems need to be addressed while
designing AFPM machines. One of the major issues
is the presence of significant cogging torque in AFPM
machines. Cogging torque is a prominent issue in AFPM
machines because the rotor and the stator face each
other and more surface area of magnets is exposed to
978-1-6654-7146-6/22/$31.00 ©2022 IEEE
Authorized licensed use limited to: Universita degli Studi di Cassino. Downloaded on April 07,2023 at 10:01:41 UTC from IEEE Xplore. Restrictions apply.
the core of the stator, compared to other types of per-
manent magnet machines. Hence, reducing the cogging
torque in AFPM machines is very important to improve
overall efficiency of AFPM machines. As the cogging
torque is due to the interaction between the magnets and
stator back-iron, there is significant interaction between
the straight edges of the magnets and the stator core
in AFPM machines[4]. Hence, different techniques are
being used to reduce the interaction between magnets
and stator core.
This paper focuses on some techniques to reduce
cogging torque by changing the shape of magnets. One
of the techniques to reduce cogging torque is to skew the
magnets and stator slots. Skewing the magnets reduces
the straight interaction between rotor magnets and the
stator back iron [5]. Another technique used in recent
years is to curve the surface of the magnets so that the
thickness of the magnet as well as the airgap is different
at different points and hence the attraction between the
magnet and the stator back-iron is different at different
points, which results into weakening of locking force
between the rotor and the stator [6].
Apart from these issues, Permanent magnet (PM)
usage is also very critical for permanent magnet electric
machines. As it is the most expensive part of the ma-
chine, it is very important to carefully use the magnet
volume and size to ensure that the magnet design is fully
optimized for the specific PM machine design[7]. Heat is
also a very critical issue in permanent magnet machines
[8][9]. This paper proposes a magnet shape providing an
improved magnet design for reduced cogging torque and
better ventilation for heat transfer.
II. D ESIGN P ROCESS
Machine design starts with the selection of some
values, while the air gap is selected within certain limits
for synchronous machines. The airgap, thickness as well
as diameter of rotor and stator cores depends on several
factors including the mechanical aspects of machine
design but the typical airgap is from 1-3mm. the starting
values for synchronous machines are given below in Ta-
ble I, providing a summary of various parameters which
are to be selected initially [10][11]. While dimensions
and parameters for the design are given in Table II.

TABLE I
S TATRING PARAMETERS OF AFPM MACHINE DESIGN

Outer to inner dia ratio 0.57-0.60

Airgap flux-density 0.2-1.1 T
Stator tooth flux-density 1.5-2.0 T
Rotor core flux-density 1.1-1.7 T
Current density 3-5 (A/mm2 )

Fig. 1. Stator with Winding

TABLE II
D IMENSIONS AND PARAMETERS
selected fixed stator are carried out to compare the output
Q Number of stator 18
slots from the different magnet shapes.
P Number of poles 12
G Air-gap 1 mm
Dout Outer diameter 152 mm
Din Inner diameter 91.2 mm
Nph No of turns per 180
phase
a Pole width to 0.6
pole pith ratio
Sw Stator slot width 5.5mm-11mm
(InnerSide-
OuterSide)
Pv ol Volume of PM 2757 mm2

The open slot stator is selected for its constructive

simplicity. The stator of all studied configurations is the
same, while the rotor is designed with different magnet
shapes and simulated with FEA software to investigate
the cogging torque. The slot width is almost 10 mm,
concentrated double-layer winding is implemented, the
space available for one coil is 20mm x 5mm, and 20
mm is the height of the stator teeth. The thickness of
the stator core is dependent on the magnetic loading.
It is also dependent on the number of magnetic poles.
For a fixed volume of magnets, the higher the number
of poles, the smaller the thickness of the core. However
mechanical strength must be given due importance in the
selection of the thickness of cores. The stator design is
given in Fig.1.
The four different rotors designed for the research and
FEA analysis of all the four-magnet designs with our
Fig. 2. Flat Trapezoidal Pole Rotor
Fig. 2 shows a flat trapezoidal pole rotor, Fig. 3
illustrates a 20-degree skewed pole with a plain face.
Fig. 4 is a curved face pole, the maximum height is
4.50mm including a 2.2 mm curved height. Fig. 5 is
curved and skewed by 20 degrees. All these models are
to be simulated to compare cogging torque results while
keeping the stator unchanged. The volume of the magnet,
the inner and outer diameter of the rotor core, and the
thickness of the core are also kept constant.

Authorized licensed use limited to: Universita degli Studi di Cassino. Downloaded on April 07,2023 at 10:01:41 UTC from IEEE Xplore. Restrictions apply.
 Fig. 3. Skewed pole Rotor
Fig. 4. Curved Pole Rotor
III. E XPERIMENTAL R ESULTS
Cogging torque and Back EMF of the flat top trape-
zoidal magnet, Skewed magnet, curved shape magnet,
and curved skew magnet are compared to prove the
reduction of cogging torque and its effect on the back
EMF.
A. Cogging Torque and Back-EMF
1) Flat Trapezoidal pole Rotor: The following graphs
are the results of a conventional model that has
trapezoidal-type poles with a plain top. The results show
that the peak-to-peak value for cogging torque is 3.88
Nm. And the EMF is 59.56 rms volts. Fig. 6 and Fig.
Authorized licensed use limited to: Universita degli Studi di Cassino. Downloaded on April 07,2023 at 10:01:41 UTC from IEEE Xplore. Restrictions apply.
Fig. 5. Curved Skew pole Rotor
7 are illustrating cogging torque and back-emf of flat
trapezoidal pole machine, respectively.
Fig. 6. Cogging torque of Flat Trapezoidal pole Machine
2) Skewed pole Rotor: Results for a 20-degree
skewed pole with the plain top are as below. Skewing
is an effective method for cogging torque reduction and
is used widely. The peak value of cogging torque peak
to peak value is 2.7 Nm. EMF peak value is 58.25 rms
volts. Fig. 8 and Fig. 9 illustrate the cogging torque and
back-emf of skewed pole machine, respectively.
3) Curved pole Rotor: For the curved face, the back-
emf is 54.51 rms volts and cogging torque peak-to-peak
value is 1.63 Nm. The cogging torque is reduced by a
significant amount with the curved face pole. Fig. 10
and Fig. 11 illustrate the cogging torque and back-emf
 Fig. 7. Back EMF of Flat Trapezoidal pole Machine
Fig. 10. Cogging Torque of the Curved pole machine

Fig. 8. Cogging torque of Skewed pole Machine

Fig. 11. Back-EMF of the Curved pole machine

and Fig. 13 illustrate the cogging torque and back-emf

of curved skew pole machine, respectively.

Fig. 9. Back-EMF of skewed pole Machine

of curved pole machine, respectively.

4) Curved Skew pole Rotor: It is clear from the results
that skewed with a curved face has the minimum cogging
torque which is 1.5 Nm. In all the other designs, the
Fig. 12. Cogging Torque of the Curved Skew pole machine
curved face has a minimum CT that is 1.63 Nm. EMF
for the curved skew pole rotor is 53.87 rms volts. Fig. 12

Authorized licensed use limited to: Universita degli Studi di Cassino. Downloaded on April 07,2023 at 10:01:41 UTC from IEEE Xplore. Restrictions apply.
 TABLE III
T OTAL HARMONICS DISTORTION

Magnet design Total Harmonic Distortion

Flat Trapezoidal design 10.8 %
Skewed pole design 7.42 %
Curved pole design 3.38 %
Curved Skew pole design 3.18 %

has the least cogging torque, which is 1.32 Nm maxi-

mum peak-peak and the Flat Trapezoidal pole machine
has the maximum cogging torque among the discussed
topologies, which is 3.88 Nm.
Curved skew magnets provide the lowest cogging
Fig. 13. Back-EMF of the Curved Skew pole machine
torque but the curved top surface also affects the back
EMF. A quantitative analysis of Cogging torque and
back EMF of Flat Trapezoidal magnet design, flat top
B. Harmonics Comparison
20 degrees skewed magnet design, curved top magnet
The harmonic analysis of all four different shaped design and curved skew magnet design is given in
magnet machines has been carried out and a harmonics Table IV and harmonics comparison is given in Fig. 14.
comparison is given in Fig. 14. Total harmonics distor- Using the Curved skew magnet can be effective in noise
tion (THD) is define by the equation 1. sensitive machines as the cogging torque is minimum in
Table III shows THD in percentage for each different curved skew magnet design machine.
rotor topology, where curved skew pole design machine
has the least THD which is 3.18 %.
TABLE IV
2 3 4 5 6 7 1 C OGGING T ORQUE AND BACK -EMF COMPARISON
.T HD = (V +V +V +V +V +V +....)/V (1)
Magnet design Peak to Peak Back-EMF rms
Cogging Torque volts
Nm
Flat Trapezoidal 3.88 59.56
design
Skewed pole 2.7 58.25
design
Curved pole 1.63 54.51
design
Curved Skew 1.5 53.87
pole design

ACKNOWLEDGMENT

The authors acknowledge the support of the Italian

Fig. 14. Harmonics Comparison
IV. C ONCLUSION
Research shows that magnet shape significantly affects
cogging torque and overall efficiency. Among the differ-
ent discussed techniques, the curved skew magnet shape
Ministry of Education (MUR) through the Project of
Excellence of the Department of Electrical and Infor-
mation Engineering of the University of Cassino and
Southern Lazio on “Intelligent distributed systems”and
the financial support of Regione Lazio through LazioIn-
nova’s “Progetti di Gruppi di Ricerca, Conoscenza e Co-
operazione per un Nuovo Modello di Sviluppo finanziati
ai sensi della L.R. Lazio 13/08”.

Authorized licensed use limited to: Universita degli Studi di Cassino. Downloaded on April 07,2023 at 10:01:41 UTC from IEEE Xplore. Restrictions apply.
 R EFERENCES
[1] Liu, C. T. and S. C. Lee, “Magnetic field modeling and optimal
operational control of a single-side axial-flux permanent magnet
motor with center poles,”Journal of Magnetism and Magnetic
Materials, Vol. 304, No. 1, 454–456, September 2006.
[2] Di Gerlando, A., Foglia, G., Iacchetti, M.F., Perini, R.: ‘Axial
flux PM machines with concentrated armature windings: design
analysis and test validation of wind energy generators’, IEEE
Trans. Ind. Electron., 2011, 58, (2), pp. 3795–3805
[3] Curiac, P., Kang, D.H.: ‘Preliminary evaluation of a MW-class
low-speed AFPMSM with self-magnetisation function of the
armature coils’, IEEE Trans. Energy Convers., 2007, 22, (3), pp.
621–628.
[4] S. . Ali, “Reduction of Cogging Torque in AFPM Machine
Using Elliptical-Trapezoidal-Shaped Permanent Magnet”, ACES
Journal, vol. 36, no. 08, pp. 1090–1098, Oct. 2021.
[5] Rafat Ali Amjadullah Salman Ali Hamid Ullah “Cogging-
Torque Reduction Techniques in Axial Flux Permanent
Magnet Machine” International Journal of Engineering
Works Vol. 8 Issue 10 PP. 262-266 October 2021
https://doi.org/10.34259/ijew.21.8010262266.
[6] J. Ikram, N. Khan, Q. Junaid, S. Khaliq, and B. I. Kwon,
“Analysis and optimization of the axial flux permanent magnet
synchronous generator using an analytical method,” Journal of
Magnetics, vol. 22, pp. 257-265, 2017.
[7] R. Di Stefano and F. Marignetti, ”Electromagnetic Analysis
of Axial-Flux Permanent Magnet Synchronous Machines With
Fractional Windings With Experimental Validation,” in IEEE
Transactions on Industrial Electronics, vol. 59, no. 6, pp. 2573-
2582, June 2012, doi: 10.1109/TIE.2011.2165458.
[8] J. Shazly, S. Wahsh, A. Yassin, Thermal modeling of an AF-
PMSM: A review, Journal of Electrical Systems and Information
Technology, Volume 2, Issue 1, 2015, Pages 18-26, ISSN 2314-
7172, https://doi.org/10.1016/j.jesit.2015.03.003.
[9] F. Marignetti, V. D. Colli and S. Carbone, ”Comparison of Axial
Flux PM Synchronous Machines With Different Rotor Back
Cores,” in IEEE Transactions on Magnetics, vol. 46, no. 2, pp.
598-601, Feb. 2010, doi: 10.1109/TMAG.2009.2034021.
[10] Gieras, Jacek Wang, Rong-Jie Kamper, Maarten. (2008). Axial
Flux Permanent Magnet Brushless Machines. 10.1007/978-1-
4020-8227-6.
[11] Pyrhönen, J. Jokinen, Tapani Hrabovcová, Valéria. (2013).
Design of Rotating Electrical Machines, Second Edition. i-xxvii.
10.1002/9781118701591.fmatter.

Authorized licensed use limited to: Universita degli Studi di Cassino. Downloaded on April 07,2023 at 10:01:41 UTC from IEEE Xplore. Restrictions apply.
View publication stats