Electromagnetic design of axial-ux permanent magnet machines

J.R. Bumby, R. Martin, M.A Mueller, E. Spooner, N.L. Brown and B.J. Chalmers Abstract: A general, analytic approach to the calculation of magnet elds in a slottless, axial-ux, permanent magnet generator is presented. The basic building block is the vector potential produced by a current sheet situated between two, innitely permeable, iron surfaces. By modelling the magnet by currents at its periphery, and integrating over the magnet thickness, the vector potential and magnetic eld due to the permanent magnets can be found. In contrast the armature winding is represented by a current sheet close to the stator iron surface. Magnetic eld results produced by the analytic equations have been compared with two-, and three-, dimensional nite element studies and found to produce results comparable to within 5%. In addition emf, ux and inductance measurements have been made on two generators and compared with both nite element and analytic results. The analytic model predicts the emf to within 5%. The end winding inductance of a toroidal, air-gap, armature winding, is shown to contribute signicantly to the overall inductance with the analytical model predicting the inductance to within 10% of the measured values.

List of symbols A B Brem c Dm E H i J K Kdn kL,mag Lm n Nc p Ri Ro Rm tc un w Ya Ym Y1 Y2 Y2eff

r IEE, 2003 IEE Proceedings online no. 20031063 doi:10.1049/ip-epa:20031063 Paper rst received 24th March 2003 and in revised form 17th September 2003 J.R. Bumby, R. Martin, M. Mueller and E. Spooner are with the School of Engineering, University of Durham, Science Site, South Road, Durham DH1 3LE, UK N.L. Brown is with the Newage-AVK-SEG, Barnack Road, Stamford, Lincolnshire PE9 2NB, UK B.J. Chalmers is with the Department of Electrical and Electronic Engineering, UMIST, PO Box 88, Sackville Street, Manchester M60 1QD, UK IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

vector potential ux density, T permanent magnet remanence, T running clearance, m mean core diameter, m emf, V magnetic eld strength, A/m current, A current density, A/m2 linear current density, A/m nth harmonic distribution factor effective length ratio (see (26)) magnet radial length, m harmonic number number of turns per armature coil number of pole pairs inner radius of the iron stator core, m outer radius of the stator iron core, m mean core radius, m core thickness, m 2pn/l coil width at the mean radius, m armature thickness, m magnet thickness, m position of current sheet, m distance between rotor and stator iron surfaces, m effective gap, m

Z g m0 mrec l tp tm se, sm F C

number of conductors per armature coil displacement between armature coils, m permeability of free space, H/m magnet recoil permeability wavelength l 2pRm/p, m pole pitch tp l/2, m magnet width, m coil spread, electrical or mechanical radians ux, Wb ux linkage, Wb

Subscripts arm armature coil coil n harmonic number ph phase r radial z axial

Introduction

The wide availability and reducing cost of high-remanence, neodymium-iron-boron (NdFeB) permanent magnets have made axial-ux machines a cost-effective alternative for low- and medium-power motor and generator applications. In many situations the specic torque of an axial-ux machine is better than that of its radial-ux counterpart [1, 2] whilst its geometric proportions may be more compatible with the general proportions of the machinery driving, or being driven by, the electrical machine. The very short axial length required to accommodate the magnetic and electric components can lead to designs that do not require separate bearings and the high moment of inertia of the rotor can serve a useful ywheel function. Particular examples of the use of axial-ux machines are for direct drive wind generators [35], in compact engine-generator sets, either for general applications [6] or in a hybrid electric vehicle [7], or as in-wheel electric motors [811].
151

In general an axial-ux machine comprises of at least one rotor disc carrying axially polarised magnets and one stator disc carrying either a slotless or slotted winding. The stator may be magnetic or non-magnetic depending on the machine topology. Based on these concepts a large number of axial-ux topologies are possible including single-sided [11], double-sided [7, 12] or multi-stage designs. We will concentrate on the iron-cored slotless variety with a stripwound stator core and toroidal coils forming the air-gap stator winding. Because of the winding structure this type of machine is often referred to as a torus machine [12]. The basic cross-section of such a machine is shown in Fig. 1 and consists of two rotor discs each with magnets arranged circumferentially around the rotor plates in a N-S-N-S arrangement. A north magnet on one disc faces a north magnet on the other disc so that magnetic ux travels axially across the air-gap and then turns circumferentially into the strip-wound iron core before returning to the rotors one pole pitch further on. Each armature coil is wound toroidally round the strip-wound core. For a three-phase machine there are three armature coils per pole each with a maximum spread of 601 (electrical). This machine topology is used in the compact, variable-speed integrated generating (VSIG) set commercialised by Newage-AEG-SVK [6, 7]. When the machine rotates air is drawn in at the axial centre of the machine and natural pumping action forces this cooling air radially out across the armature winding. This pumping action is further enhanced by the magnets themselves acting as fan blades so ensuring excellent cooling of the armature winding. This direct air-cooling of the winding allows current densities of up to about 20 A/mm2 to be used.
armature winding fixing ring

magnet ux and by the reactance of the armature winding. Design expressions for both emf and inductance, based on magnetic equivalent circuits, are readily evaluated and can be used to design machines that perform as predicted [7]. However, such design expressions do not readily take account of leakage and fringe elds whilst in many designs [7, 12] the magnets extend radially beyond the stator to increase armature ux linkage and emf. Analytical design expressions that inherently account for these effects are now presented. The design expressions predict magnet ux density, induced emf and armature inductance and their accuracy is supported by nite element and experimental work. Marignetti and Scarano [10] used an analytic technique to predict magnet ux density in an axial-ux machine but required a nite element solution as part of the solution process. Chalmers et al. [13] produced armature inductance expressions using a two-dimensional solution to Laplaces equation. We use a similar approach to Chalmers et al. [13] but now a unied 2-dimensional (2-D) approach is used to calculate both ux from the magnets and the armature reaction ux. Experimentally measured emf and armature inductance values will be used in a comparison with both the analytic approach and with nite element studies. The nite element solutions in 2-D are computed using both MEGA [14] and FEMLAB [15] and in 3-D by MEGA. 2 The analytical model

2.1

The model

Looking radially inwards onto the machine shown in Fig. 1, and ignoring curvature, allows the machine to be represented as shown in Fig. 2 where the x-coordinate represents the circumferential direction and the y-coordinate the axial direction. The model assumes the radial direction to be innite.

rotor disc S N y x engine shaft S N

cooling hole rotor shaft

Fig. 2

Simplied machine model

magnets

stator core

Fig. 1

Cross-section of a bearingless axial-ux, toroidal generator

Figure 3 illustrates the 2-D mathematical model used to analyse the magnetic eld in one of the air-gaps. Current sheets are used to model both the magnet and the armature current so that computing the vector potential from a generalised current sheet located between the stator and rotor iron is the basic building block used in the analysis. Similar techniques have been used in [16, 17]. In the analysis the stator and rotor are treated as innitely permeable boundaries. The current sheet has a harmonic distribution of the form: ^ n sin un x Kn x K 1

The ux inside the machine arises from the permanent magnets and from the current passing through the stator coils. To determine a machine design, and assess its performance, both ux components are required and are conveniently expressed in terms of the emf induced by the
152

where un 2pn/l and l, the wavelength, is equal to twice ^ n depends on the actual the pole pitch. The value of K current distribution and is evaluated in Section 2.3 for the magnet and in Section 2.4 for the armature winding.
IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

iron Y2 y Y1 x iron field point (x, y) y Y2

iron

region 2 sin u x current sheet Kn(x ) = K n n region 1

Y1 (0.0) x

Ym iron

Fig. 3

Current sheet model

2

I = BremYm
o rec

2.2 Vector potential and ux density from a current sheet

The vector potential and magnetic eld are found above, and below, the winding by solving Laplaces equation r2A 0 subject to boundary conditions at the iron surfaces and at the current sheet: y 0 Hx 0 y Y1 DHxn Hx2n Hx1n Kn ; Hy continuous y Y2 Hx 0 The magnetic vector potential has a z-component only, so the magnetic eld is obtained from: 1 @A 1 @A and Hy 2 Hx m0 @ y m0 @ x The solution of Laplaces equation gives the vector potential, and the normal component of magnetic eld, in regions 1 and 2 as: Region 1: Azn1 x ^ n m0 cosh un Y2 Y1 K cosh un y sinh un Y2 un sin un x cosh un Y2 Y1 cosh un y sinh un Y2 cos un x 3

p m

2 b

Fig. 4

Magnetic eld from the magnets in region 2

a Model used to compute the vector potential b Model used to compute the magnetic linear current density distribution

modifying factor to account for the effect of recoil permeability on the reluctance of the magnet region is introduced later by comparison with a magnetic circuit solution. The accuracy and implications of this approach are discussed later in Section 4. To compute the equivalent magnet linear current density ^ n each magnet is represented by a current at distribution K its edges assumed to ow in a vanishingly small thickness of angular spread 2d, Fig. 4b. The equivalent magnet current has a magnitude of: Brem Ym mo mrec and a corresponding current density:  Brem p J mo mrec 2dtp 7

^n Hyn1 x K

Region 2: Azn2 x ^ n m0 cosh un Y1 K cosh un Y2 y un sinh un Y2 sin un x 5

where tp is the pole pitch. The individual current density harmonics can now be obtained by Fourier analysis to give the equivalent current density distribution for the magnet as: X ^n sin np x J 8 J x tp n odd where:   d sin na 4 Brem sin np tm ^n 8 J J p tp m0 mrec 2 tp

^ n cosh un Y1 cosh un Y2 y Hyn2 x K sinh un Y2 cos un x

2.3

The magnetic eld from the magnet

The magnetic eld from the magnet at the armature (region 2) is calculated from (5) and (6) by representing the magnet magnetisation by a large number of layers with each layer represented by an equivalent current sheet. The vector potential at the eld point y is then found by integrating over the magnet thickness, Fig. 4. As the relative recoil permeability of the permanent magnets is greater than one this must be accounted for in the analysis. In formulating the problem the effect of recoil permeability appears in two places; rstly in the magnitude of the current used to model the magnets and, secondly, as the relative permeability of one of the regions in the eld solution. The approach taken here is to account for the effect of recoil permeability in the magnet modelling current whilst assuming mrec 1 in the eld solution. This allows (5) and (6) to be used directly. A
IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

The set of magnets are now divided into a number of current sheets each of width dy with a linear current density of: ^n dy sin un x 10 Kn x J The vector potential at any point, y, in region 2 is then found by substituting (10) into (5) and integrating over the magnet thickness Ym to obtain: ^n m sinh un Ym J cosh un Y2 y Azn2 x 2 0 un sinh un Y2 11 sin un x with: ^n m0 sinh un Ym J cosh un Y2 y un sinh un Y2 cos un x

Byn2 x

12

153

2.4 Armature magnetic elds and current distribution

The armature magnetic eld can be computed using a similar technique as above or it can simply be represented by a current sheet when (3) to (6) can be applied directly. The latter approach is used here. The armature current in each air-gap can be represented by the current distribution of Fig. 5 where Z conductors per phase band each carry a current of i A. The single-layer winding shown is simple to construct as an air-gap winding whilst more complex double-layer arrangements are readily assembled in slotted stators. Air-gap windings only are considered here.

Table 1: Axial-ux machine parameters

Parameter 40 kW generator 16 4 NdFeB trapezoidal 1.2 1.05 6 75 51/31 6 6.5 62/22.51 41 0.66 8 14 10 415 378 253 62.5 316 28.4 74 20 kW generator 12 9 NdFeB trapezoidal 1.2 1.05 6 72.5 62/32 5 5 60/301 48 0.8 9 15 10 314 290 165 62.5 227.5 22 73

Number of poles per disc Turns per armature coil Magnet material Magnet shape Brem mrec Magnet thickness, mm Magnet radial length, mm Magnet width: OD/ID, mm Magnet overhang: OD, mm Magnet overhang: ID, mm

w,
K + + + + Z, i 2 ++++ 2 x

Pole pitch, mm/deg Magnet width: mean diam, mm Magnet width/pole pitch Gap (winding+mech.clear), mm g+tm, mm Rotor disc thickness, mm Rotor OD, mm Core OD, mm Core ID, mm Core radial depth, mm Mean diameter, mm Core thickness, mm Overall machine axial length, mm

Fig. 5

Armature current sheet

For this single-layer winding the linear current density is: K Zi Zi Zi p w sm R m Rm se 13

where w is the winding width which, at the mean radius Rm (Ro+Ri)/2, can be written as w smRm where sm is the winding spread in mechanical degrees. In electrical degrees se psm. The linear current density is: X ^ n sin un x 14 K x K with the peak linear current density being obtained by Fourier analysis as: ^ n 4K sin np sin nse 2 Zpkdn sin np i K np 2 p Rm 2 2 15

Results and discussion

4.1

Magnet eld and induced emf

For a toroidally wound machine Z Nc, the number of turns per armature coil. 3 Prototype generator details

4.1.1 Analytic and nite element analysis methods: The magnetic eld produced by the permanent magnets varies circumferentially around and radially across the armature with the ux entering the stator core over one pole pitch determining the induced emf. The circumferential variation of the axial magnet eld in the 40 kW generator, computed at the mean radius and 1 mm from the stator core, is shown in Fig. 8a. This Figure shows the value predicted by (12), and computed by 3-D and 2-D nite elements. Assuming that mrec 1 in both the magnet modelling current and in the eld equation gives the ux density plot in curve A. If recoil permeability is allowed for in the modelling current only, curve B is obtained. A nal modication is to change Y2 in the denominator of (11) and (12) to an effective gap value Y2eff where:   Ym Y2;eff Ya c 16 mrec With this modication the ux density plot of curve C is obtained and is identical to the 2-D and 3-D nite element results. The justication for using an effective gap Y2eff in the denominator of (11) and (12) is based on a comparison with the ux density equation obtained from a magnetic equivalent circuit approach (see the Appendix) [7]. The Appendix shows that the magnet recoil permeability appears in the numerator of the ux density equation, due to the magnet modelling current, and in the denominator, due to the reluctance of the magnet region. In (11) and (12) the effect of mrec on the modelling current
IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

A number of prototype axial-ux generators have been built and used to benchmark the design equations. The details of two, three-phase, machines are tabulated in Table 1 with nominal ratings of 40 kW, 4500 rpm and 20 kW, 3000 rpm respectively. Load test results for the 20 kW machine have been reported elsewhere (18). Earlier work on the 40 kW machine was used in the commercial development of the VSIG set at Newage-AVK-SEG [6]. The 40 kW machine is shown in Fig. 6 and is supported on its own bearings between two end plates. Figure 6a shows the generator on test when connected to a diesel engine whilst the stator and rotor discs are shown in Fig. 6b. The 20 kW generator is xed directly to the end of an engine in place of the ywheel (see Fig. 1) and is therefore a bearingless design. One of the main differences between the 40 and 20 kW designs is the ratio of the magnet width to pole pitch. In the 40 kW design this value is 0.66 whilst in the 20 kW design it is 0.8. The increase in magnet width to pole pitch increases output voltage and power output [19] but also changes the harmonic content of the induced voltage. Figure 7 shows the assembled 20 kW generator on test.
154

0.6 curve A 0.4 curve B normal flux density, T 0.2 0 0.2 0.4 0.6 curve C

0.8 0.10 0.08 0.06 0.04 0.02

0.02 0.04 0.06 0.08

0.10

circumferential position, m a 0.010 0.008 0.006 0.004 vector potential 0.002 0 0.002 0.004 0.006 0.008

Fig. 6

The 40 kW generator

a The generator on test b Rotor and stator discs

0.010 0.10 0.08 0.06 0.04 0.02 0 0.02 0.04 0.06 0.08 0.10 tangential position, m b

Fig. 8 Magnetic eld and vector potential in the 40 kW generator. Circumferentially around the stator core; mean radius; 1 mm axially from the core. x-coordinate is circumferential position from the pole centre (pole pitch is 0.062 m)
a Axial ux density: for curve A mrec 1; for curve B mrec 1.05 magnet current only; for curve C mrec 1.05 in magnet current and effective gap. For curve C (middle line) the analytic results and 2-D and 3-D FEA indistinguishable b Vector potential

Fig. 7

The 20 kW generator on test

Shown in Fig. 8b is the vector potential calculated by (11), the values computed by the 2-D nite element analyses (FEA) are indistinguishable from this. In 2-D the difference in the vector potential between two points is the magnetic ux/per metre so, by evaluating (11) at y Y2, the ux entering the stator core/per metre over one pole pitch can be evaluated by: ^pole;n fAzn t=2 Azn t=2g F y Y2 17

can be accounted for directly by setting mrec 1.05 in (9) whilst its effect on the reluctance can be include by using an effective gap value Y2eff in the denominator in place of Y2. The results of Fig. 8 demonstrate the validity of this approach. The results in Fig. 8a show that including the effect of the magnet recoil permeability mrec in the calculation reduces the ux density. Although the magnet permeability reduces the reluctance of the gap between the rotor and stator iron (denominator of (38)) it also reduces the magnitude of the magnet mmf (numerator of (38)). As the numerator has the stronger effect the ux density reduces.
IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

R0 Ri kL;mag

where (R0Ri) is the core radial length and kL,mag is the effective length ratio yet to be determined. This is a general equation that can be evaluated numerically in a design spreadsheet and used directly in the emf equation. Equation (17) can be evaluated algebraically using (11) and (12) and noting that at y Y2: ^ ^ ^n m0 J n sinh un Ys and Azn Bn sin un x B an sinh un Y2eff an 18
155

Substituting into (16) and noting that for a toroidal pDm machine: tp l 2 2p ^pole;n F ^n B np Dm kL;mag Ro Ri sin 2 np 19

(RoRi) core

In the stator arrangement shown in Fig. 1 the magnetic ux splits in half to the link the two coils but is reinforced by ux from the other side so that: ^core;n F ^pole;n F 20
a

magnet

For different axial-ux toroidal congurations the ux linkage might be different e.g. single rotor, double stator the core ux per coil would be half the ux per pole. In general, the emf/coil root-mean-square voltage is given by: p ^core;n kdn Ncoil 21 Ecoil;n 2pnf F The total coil emf, taking account of all harmonics, is then: q 2 2 2 Ecoil Ecoil 22 ;1 Ecoil;3 Ecoil;n For a 2p pole machine with all coils connected in series: Eph 2pEcoil 23

The main problem in applying (17) or (19) is in determining the effective length ratio kL,mag. This factor must take into account the fringing due to the length of the magnets. This length may be different to the length of the iron core and often the magnets are made radially longer than the core to capitalise on this effect. Figure 9 shows the fringing ux in question while Fig. 10 shows schematically the ideal and actual vector potential and the axial-ux density distribution radially across the stator core. The radial variation of the vector potential and the axial-ux density can be obtained from (11) and (12) by setting the magnet width equal to the magnet radial length with the pole pitch signicantly longer than this; typically by about a factor of 100. It is also important to include a large number of space harmonics in the computation to guarantee convergence. The basic 2-D analysis assumes that the ux density is constant over the radial length of the stator core. As Figs. 9 and 10 imply this is not the case and account must be taken of the fringing ux. This is normally allowed for by introducing an effective length factor kL,mag. In the past this factor has been evaluated geometrically depending on the ratio of the magnet length to the core radial length [7]. An alternative approach is to base the effective length ratio on the vector potential (magnetic ux) calculated analytically using the 2-D analytic model to account for the actual length of the magnet in the radial direction. Unfortunately the 2-D analytic model does not account for the nite length of the iron core (it is assumed innite) but nevertheless an acceptable effective length ratio can be obtained. If fringing ux is neglected, Fig. 9a, the basic analysis ^ n constant over the core length (RoRi) and, as assumes B Bn @ A/@ x (the normal is in the y-direction): ^ n Dr B ^ n Ro R i DAbasic B 24

Fig. 9

Magnet fringing ux

a Schematic b Flux density vectors for 3-D FEA

(Ro Ri) Az core

magnet Bn B n r

Fig. 10 Schematic of the ideal and actual vector potential and ux density distributions

distributions the effective length ratio is given by: D AL Lm kL;mag DAbasic

26

The actual change in magnetic potential (and hence ux) allowing for fringing ux is greater and is evaluated close to the stator core over the radial length of the magnet by: DALLm fAz Lm =2 Az Lm =2gy Y2 25

As the purpose of the effective length ratio is to account for the difference between the ideal and actual ux density
156

To check the validity of this approach Fig. 11 plots the variation of vector potential and axial ux density radially across the surface of the iron stator core for the 40 kW generator. Flux density plots are obtained using the analytic expressions and 2-D and 3-D FEA computations whereas analytic and 2-D FEA are used for the vector potential. The accuracy between the different models is acceptable considering that the nite element models account for the nite length of the core and rotor discs in the radial direction whereas the analytic expressions assume these to be innite.
IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

0.040 0.035 0.030 vector potential 0.025 0.020 0.015 0.010 0.005 0 0.04 0.03 0.02 0.01 0 0.01 0.02 0.03 radial position from mean core radius, m a 0.6 0.5 normal flux density, T 0.4 0.3 0.2 0.1 0 0.1 0.06 analytic FEA analytic FEA

Table 2: Magnet ux and emf results

Parameter 40 kW 20 kW generator generator analytic 2-D FEA 3-D FEA kL Equation eq (29) 2-D FEA Core ux, mWb Analytic 3-D FEA
0.04

Bz, T

0.493 0.495 0.494 1.11 1.09 1.37 1.37 1.3 52.1 51.9 49.6

0.46 0.46 0.46 1.07 1.08 1.36 1.36 Not measured 61.9 62.2 62.2

Measured Emf Vrms/1000 rpm Analytic 3-D FEA Measured Emf harmonics rst analytic V rst measured third analytic third measured fth analytic fth measured seventh analytic seveth measured

52 49.6 1.4% F 4.0% 4.4% 0.5% 0.6%

61.6 61.6 9.7% 12.4% F 0.3% 0.2% 0.7%

0.04

0 0.02 0.04 radial position from mean core radius, m b

0.02

0.06

Fig. 11 Variation of vector potential and axial ux density with radius; 40 kW generator 1 mm from the iron core
a Vector potential b Axial-ux density

4.1.2 Test results: Results obtained from the analytic

analysis described above, FEA and measurement on the test generators are presented in Table 2. Measured results are obtained during testing using a calibrated Voltec Powermeter. All the results show good agreement with the measured and calculated emfs comparing to within 5%. The ability of the analytic method to indicate the magnitude of the harmonic emfs is also good with the effect of changing the magnet pitch/pole pitch ratio from 0.66 in the 40 kW to 0.8 in the 20 kW construction being clearly indicated. For a three-phase machine the winding spread is typically 601 (electrical). For the axial-ux toroidal machine this spread only occurs at the inner radius of the stator. As the winding is rectangular its angular spread reduces towards the outer radius and the winding spread factor changes. Generally a value taken at the mean radius will sufce and this is used in the analytic calculations of the emf. In both the 20 and 40 kW designs the stator core is supported from the outer diameter so that a 601 spread at the inner radius is possible, Figs. 6 and 7. In some applications the stator core is supported from the inner diameter when the winding spread will be reduced from the 601 maximum.

predict machine performance. The analysis of Section 2 is used to compute the armature inductance directly from the vector potential in a general way whilst FEA is used to show the importance of end-winding leakage. The armature winding is represented by a current sheet so that (3) and (4) for the vector potential and the ux density respectively can be used directly. With the armature winding located at Y1 Ya/2 the ux produced by the armature winding over one pole pitch in region 1 of the radial active region of the machine is: ^ n;active fAzn t=2 Azn t=2g F y 0;Y1 ta =2 27 R0 Ri where Azn is obtained from (3). As it is the eld at the armature surface that is of interest, the eld point is set to y 0. (R0Ri) is the radial length of the core. Equation (27) is most easily evaluated numerically directly in the design spreadsheet. As the ux calculated by (27) splits in half as it passes into the stator core only half of this ux links an armature coil. However, this ux is reinforced by the same amount from the current on the other side of the core so that (27) gives the value of the core ux. Equation (27) only accounts for armature ux produced by the armature current as it passes radially across the core surface; it takes no account of the ux produced by the current as it passes axially along the core ends at the inner and outer radii. This leakage ux can be calculated in a similar way as for the main ux in (27) but now with the iron surface representing the rotor removed (i.e. increase Y2 to a large value) and with the active length changed to the core thickness i.e.: ^n;leakage F 28 fAzn t=2 Azn t=2gy 0;Y1 ta =2;Y2 !1 tc
157

4.2

Armature inductance

4.2.1 Analytic considerations: Accurately known

armature inductance values are important in order to
IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

The total armature ux is obtained from the sum of (27) and (28) as: ^n;arm F ^n;active F ^n;leakage F 29

4.2.2 Analytic and FEA comparisons: The accuracy to which (4) predicts the armature magnetic eld is examined in Fig. 12 by plotting the circumferential variation of the axial component of the armature magnet eld at the surface of the stator core over one pole pair at the mean radius. The excitation current is 5 A and one-phase only of the 40 kW machine is excited. Both 3-D FEA and analytical results are shown. Both methods give very similar results being the same midway between the coils with a difference of about 10% at the coil edges due to edge-effects being taken into account by 3-D FEA but not by the analytic method.
0.0015
3D FEA Analytic

flux density, T

The armature inductance can be evaluated by the following procedure: Step 1: Evaluate the ux per metre from (29) using the current distribution of (15). ^ coil;n F ^ n;arm Nc kdn . Step 2: Compute the ux linkage C Step 3: Compute the coil inductance by dividing by the armature current. Step 4: Computation of mutual inductance follows steps 1 to 3 with ux computed from (29) but with the coil displacement g from the exciting coil introduced into the equation i.e. evaluate between (gt/2) and (g+t/2). If required, algebraic expressions for armature ux and inductance can be evaluated from (27), (28) and (29). For example, if the armature current sheet is assumed at the stator iron surface, then: ^ ^n 2Kn m0 R0 Ri coth un Y2 tc sin np F 2 un 30

0.0010 0.0005 0 0 0.0005 0.0010 0.0015 angle, degrees 5 10 15 20 25 30 35 40 45

Substituting for Kn from (15), introducing the distribution factor kdn and noting that l 2t 2pRm/p and Z Nc the coil ux linkage is: X 4m 0 2 2 ^ coil N k iRo Ri coth un Y2 tc 31 C np c bn ^ coil;n =i Finally the coil inductance is obtained from Lcoil;n C to give: 4m0 2 2 N k Ro Ri coth un Y2 tc 32 n p c dn The coil mutual inductance is computed in the same way but now with the coil displacement g included to give: Lcoil;n Mcoil;n 4m0 2 2 N k Ro Ri coth un Y2 tc n p c dn cos un g 33

Fig. 12 Three-dimensional FEA and analytic plots of the circumferential variation of the axial armature ux density 1 mm above the core surface and at the mean core diameter: 5 A excitation, 40 kW machine

The way in which the axial-ux density changes radially across the active region was calculated by 3-D FEA and is shown in Fig. 13. The ux density stays sensibly constant over most of the active region with peaks at the edge of the iron core.
0.0018 0.0016 0.0014 flux density, T 0.0012 0.0010 0.0008 0.0006 0.0004 0.0002
winding thickness core boundaries

The actual phase inductance depends on the coil connection and for all 2p coils connected in series is 2p times the above values while the phase effective inductance is: Leff ;n 2pLcoil;n Mcoil;n 34

Equations (32) and (33) are identical to those derived by Chalmers et al. [13]. A progressive number of simplications can be made to the above inductance expressions. If the airgap is assumed to be small compared to the pole pitch, Y2{tp, and the effect of the end-winding leakage ux is neglected then, considering the rst harmonic only, gives: Lcoil 2 Ro R i m N 2 k 2 Dm p p o coil d1 Y2 35

0 0 0.05 0.10 0.15 0.20 0.25 radial distance, m

Fig. 13 Three-dimensional FEA plot of the radial variation of the axial armature ux density 1 mm above the core surface mid-way between two armature coils: 5 A excitation, 40 kW machine

with the effective inductance being: 6 Ro R i 2 2 kd1 Dm Ld mo Ncoil p Y2 36

These are identical to the values obtained from the magnetic equivalent circuit approach described in [7]. Alternatively if the air-gap Y2 is assumed to be small compared to the pole pitch, the effect of the end-winding leakage ux is neglected and the coils are assumed concentrated then the self-inductance expression in (32) reduces to that originally used by Spooner et al. [20].
158

Although the core thickness is small in most axial-ux machines, end winding-ux can still be signicant. For example in the 40 kW design, Table 1, the stator core is 29 mm thick compared to an active radial core length of 62.5 mm and (30) implies that the core ends account for about 23% of the fundamental component of ux. To examine the effect of the core ends in more detail Fig. 14 plots the circumferential variation of the radial ux density across the inner and outer core ends computed by the 3-D FEA method. Also plotted is the variation predicted by (4). The eld point is taken just above the core surface at the mean thickness. The two FEA calculations take account of the machine radius so that the ux at the inner radius is restricted to a smaller area thereby resulting in a larger ux
IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

0.0015 0.0010 flux density, T 0.0005 0 0.0 0.0005 0.0010 0.0015

outer

inner

analytic

Table 3: Armature ux and inductance results; 5 A excitation in the armature coils

Parameter 40 kW generator analytic 3-D FEA Core ux, mWb analytic 3-D FEA measured Lph, mH analytic 3D FEA measured Mph, mH analytic 3-D FEA Measured 0.90 0.90 5.23 5.12 5.48 62.9 65.5 70.8 18.5 23.6 24.7 20 kW generator 1.97 1.89 10.5 10.6 10.0 212 229 226 62.6 82.1 78.6

5.0

10.0 15.0

20.0

25.0 30.0

35.0 40.0 45.0

Bz, active region, mT

angle, degrees

Fig. 14 Three-dimensional FEA and analytic plots of the circumferential variation of the radial armature ux density halfway across the core end and at the core surface. 5 A excitation, 40 kW machine

density than at the outer radius. As plotted, the analytic model does not account for machine curvature and assumes that the coil pitch is dened at the mean core radius. To complete the ux density plots Fig. 15 shows how the radial ux density varies axially across the core ends as computed by the 3-D FEA model.
0.0014 0.0012 flux density, T 0.0010 0.0008 0.0006 0.0004 Core boundaries 0.0002 Winding thickness 0.03 0.02
outer inner

0.0000 0.01 0.00

0.01

0.02

0.03

axial distance from centre of core, m

winding is situated on the stator core surface, as experience has shown that this consistently produces results comparable with measured data. These inductance calculations also take account of the winding distribution through the use of the harmonic distribution factor calculated at the mean winding radius. This is an approximation as the winding spread varies from a maximum at the inner radius to a minimum at the outer radius. The analytic approach calculates the end-winding ux separate to the ux from the active region and, for the 40 kW machine, these calculations show that the end-winding ux is 1.24 mWb (for a 5 A excitation) and thereby constitutes 24% of the total ux and is an important component in assessing the winding inductance. 5 Conclusions

Fig. 15 Three-dimensional FEA plot of the axial variation of the radial armature ux density across the inner and outer core ends, 1 mm above the core surface: 5 A excitation, 40 kW machine

4.2.3 Test

Results: High pole-number, air-gap wound, axial-ux machines such as those described here generally have a low inductance so that measuring it accurately is difcult. Standard short-circuit tests can not be used as these can only be carried out at very low speeds when the armature reactance is negligible and is totally swamped by resistance effects. If a standard inductance bridge is used eddy-currents are induced in the rotor and the magnets and the inductance measured is not the required one. Once the machine is built this is probably the best that can be achieved. This problem can be overcome if the armature inductance is measured before the generator is assembled by using other strip-wound armature cores, in place of the two rotor discs, placed above and below the actual armature at a distance equal to the separation of the stator and rotor discs in the nal machine assembly. The strip-wound rotors do not allow eddy-currents to be induced in them and the inductance measurements (by an inductance bridge) are frequency independent. The results presented in Table 3 were obtained by this means at a typical stator frequency and is the average across the phases (equivalent to a running speed of 1500 rpm). The 2-D analytic inductance results are calculated assuming that the current sheet representing the armature

We have shown how a unied approach can be adopted to the analytic calculation of the magnetic eld in a permanent magnet, axial-ux generator. A comparison of the results obtained using FEA and measurements on two prototype laboratory generators has demonstrated the validity of the approach. Armature reactance is particularly difcult to measure using conventional methods as, in these types of air-gap wound machines, it is very small and, in many instances, armature resistance dominates. However, a simple, reliable, method of measuring armature inductance before the machine is assembled has been described. The analytic approach is ideally suited for use in design spreadsheets. 6 Acknowledgments

Most of this work was completed under a DTI/EPSRC Foresight Link Project and the nancial support of EPSRC and Newage-AVK-SEG is gratefully acknowledged. 7 References

1 Huang, S., Aydin, M., and Lipo, T.A.: A direct approach to electrical machine performance evaluation: Torque density assessment and sizing optimisation. Presented at the Int. Conf. on Electrical machines, Bruges, Belgium, Aug. 2002 2 Brown, N., Haydock, L., and Bumby, J.R.: An idealised geometric approach to electromagnetically comparing axial and radial PM 159

IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004

3 4

10 11

12 13

machines. Presented at the Int. Conf. on Electrical machines, Bruges, Belgium, Aug. 2002 http:// www.jeumont-framatome.com, Jeumont J48, 750 kW, Direct drive discoidal wind turbine generator (last accessed October 2002) Muljadi, E., Buttereld, C.P., and Wan, Y.: Axial-ux modular permanent magnet generator with a toroidal winding for wind-turbine applications, IEEE Trans. Ind. Appl., July/August 1999, 35, (4), pp. 831836 Brown, N., Scott, K., Lye, E., Bumby, J.R., and Spooner, E.: A comparison of iron-cored and ironless axial-ux PM machines. Presented at the 36th Universities power engineering conference, Swansea, September 2001 Brown, N., and Haydock, L.: Full integration of an axial ux machine for reciprocating engine variable speed generating sets. Proc. IEE Seminar on axial air-gap machines, London, UK, May 2001, pp. 6/16/10 Brown, N., Haydock, L., and Bumby, J.R.: Foresight Vehicle: A Toroidal, Axial Flux Generator for Hybrid IC Engine/Battery Electric Vehicle Applications. Proc. SAE Conf. paper 2002-01-0829, Detroit, USA, March 2002 Ramsden, V.S., Mecrow, B.C., Lovatt, H.C., and Gwan, P.: A high efciency in-wheel drive motor for a solar-powered vehicle. Proc. IEE Colloqium on Electrical machine design for all-electric and hybrid-electric vehicles, Savoy Place, London, October 1999, pp. 3/13/6 Carricchi, F., and Crescimbini, F.: Design and construction of a wheel-directly coupled axial-ux PM motor for EVs. Proc. IEEE Industrial Applications Society Conf., New York, USA, 1994, pp. 254261 Marignetti, F., and Scarano, M.: Mathematical modelling of an axialux PM motor wheel. Proc. Int. Conf. on Electrical machines, Helsinki, August 2000, pp. 12751279 Patterson, D., and Spee, R.: The design and development of an axial ux permanent magnet brushless DC motor for wheel drive in a solar powered vehicle. Proc. IEEE Industrial Applications Society Conf., Denver, 1994, Vol. 1, pp. 188195 Spooner, E., and Chalmers, B.J.: TORUS: A slotless, toroidal-stator, permanent-magnet generator, IEE Proc., Electr. Power Appl., November 1992, 139, (6), pp. 497506 Chalmers, B.J., Green, A.M., Reece, A.B.J., and Al-Badi, A.H.: Modelling and simulation of the TORUS generator, IEE Proc. Electr. Power Appl., November 1997, 144, (6), pp. 446452

14 MEGA version 6.29m (University of Bath, Applied Electromagnetic Research Centre, Bath, UK, 2003) 15 FEMLAB, Users Guide and Introduction, Version 2.2, COMSOL AB, http://www.comsol.com (last accessed October 2002) 16 Smith, A.C., Williamson, S., Benhama, A., Counter, L., and Papadopolous, J.M.: Magnetic Drive Couplings. Proc. IEE Conf. on power electronics machines and drives, London, UK, September 1999, pp. 232236 17 Wallace, A., von Jouanne, A., Williamson, S., and Smith, A.: Performance prediction and test of adjustable permanent magnet load transmission systems. Presented at the IEEE Industrial Proc. Applications Society, Chicago, IL, USA, 2001 18 Brooking, P., and Bumby, J.R.: An integrated engine-generator set with power electronic interface for hybrid electric vehicle applications. Proc. IEE Conf. on Power electronics machines and drives, Bath, UK, 2002, pp. 153158 19 Brown, N., Haydock, L., Spooner, E.S., and Bumby, J.R.: Optimistation of Axial Flux Generators by Pre-Computed 3D-FEA Modelling. Proc. Int. Conf. on Electrical machines, Helsinki, Finland, 2000, pp. 14711474 20 Spooner, E., Chalmers, B.J., El-Missiry, M.M., and Kitzmann, I.: The design of an axial-ux, slottless, toroidal-stator, permanent-magnet machine for starter alternator applications. Proc. Universities power engineering Conf., Aberdeen, 1990, pp. 171174

8 Appendix Assuming all the ux from the magnets crosses the air-gap to the stator core then applying Amperes law to Fig. 4 gives: Brem Ym Hair Ya c Hmag Ym 37 m0 mrec but since B m0Hair m0mrecHmag, then: Brem Ym =mrec B Ym =mrec Ya c

38

160

IEE Proc.-Electr. Power Appl., Vol. 151, No. 2, March 2004