Analysis and design optimization of a low-cost axial flux Vernier machine with SMC cores and ferrite magnets
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ORIGINAL PAPER
Analysis and design optimization of a low‑cost axial flux Vernier machine with SMC cores and ferrite magnets Chengcheng Liu1,2 · Kelin Wang1,2 · Shaopeng Wang1,2 · Feng Niu1,2 · Youhua Wang1,2 Received: 24 October 2019 / Accepted: 20 June 2020 © Springer-Verlag GmbH Germany, part of Springer Nature 2020
Abstract In this paper, a low-cost high-performance axial flux Vernier machine (AFVM) with soft magnetic composite (SMC) cores and ferrite magnet is proposed, analyzed and optimized. By cooperating with spoke magnet rotor configuration and 3D magnetic flux stator structure, the proposed AFVM can output higher torque compared with the traditional permanent magnet machine though low-cost low-energy-density ferrite magnet and low-permeability SMC material are adopted. The main electromagnetic topology and operation principle of the proposed AFVM are introduced; then, its main dimensions are investigated and optimized by using sequential optimization method. Moreover, a new multilevel Taguchi design optimization which is an improvement of multilevel optimization is proposed for the torque and power factor optimization. Lastly, its main performance of AFVM optimized by the sequential optimization method and multilevel Taguchi design optimization method has been compared with a normal axial flux machine in terms of torque ability, power factor and efficiency based on 3D finite element method. Keywords Axial flux machine · Vernier machine · Soft magnetic composite · Ferrite magnet · Multilevel design optimization
1 Introduction With the merit of simple structure and high torque ability, permanent magnet Vernier machines (PMVMs) have drawn great of interest from the researchers [1, 2]. In the past, its working principle was revealed and it can be found that back emf and torque of the PMVM are twice higher than those of traditional PM machine. Now, the PMVM has been recognized as a good candidate machine for the low-speed and high-torque drive applications, e.g., the wind generator and electric vehicle [3–5]. Many novel PMVMs were proposed and developed in the past years, which include the spoke magnet rotor, double stator structure, axial flux structure with toroidal winding structure, etc. The main target is to improve the torque ability and the power factor [6–8]. * Feng Niu [email protected] 1
State Key Laboratory of Reliability and Intelligence of Electrical Equipment, School of Electrical Engineering, Hebei University of Technology, Tianjin 300130, China
Province-Ministry Joint Key Laboratory of EFEAR, Tianjin 300130, China
2
Soft magnetic composite (SMC) material is a new kind of iron-based soft magnetic materials, which has the benefits of low high-frequency eddy current loss, isotropy magnetic permeability low manufacturing cost, etc. [9, 10]. In the past decades, various kinds of electrical machines with SMC cores with special topologies were proposed, designed and analyzed. Most of these machines were developed for the high-performance drive systems, e.g., the axial flux permanent
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