access icon free Analysis and design considerations of an axial-flux dual-rotor consequent-pole Vernier-PM machine for direct-drive energy conversion systems

© The Institution of Engineering and Technology
Received 06/11/2018, Accepted 05/11/2019, Revised 01/08/2019, Published 08/11/2019

The Vernier permanent-magnet (VPM) machine is known as high-torque and low-speed drive solution suitable for direct-drive applications such as electric-vehicles and wind-turbines. This study presents a high-efficiency axial-flux VPM machine with dual-rotor of consequent-pole topology and one yoke-less concentrated-winding stator. The consequent-pole VPM machine is a special VPM structure that introduces high torque-density as the conventional-VPM machine incorporating a significantly lower volume of PM material. The proposed machine represents desirable features of higher efficiency, improved reliability and lower weight and axial-length compared to the traditional motor-gearbox approach. These advantages are achieved due to: dual-PM rotors for appropriate forming the magnetic flux lines and increasing torque-to-weight ratio, yokeless-stator for reducing flux path, concentrated winding with no overhang for reducing copper-loss, using rectangular-shaped copper conductors for increasing winding fill factor and selecting the core material from high-performance grain-oriented magnetic steel for reducing core-loss. After presenting the structure, the operating principles are discussed based on the magnetic flux behaviour and a quasi-3D magnetic-equivalent-circuit model is extracted. The accuracy of the analytical model is validated by comparing the results with the FE results. Finally, the effects of the design parameters on electro-magnetic performance are analytically investigated by studying a 10 kW machine.

Inspec keywords: stators; magnetic flux; permanent magnet machines; torque; finite element analysis; rotors

Other keywords: direct-drive applications; increasing torque-to-weight ratio; axial-length; electro-magnetic performance; special VPM structure; direct-drive energy conversion systems; increasing winding fill factor; traditional motor-gearbox approach; magnetic flux behaviour; lower weight; dual-PM rotors; design considerations; Vernier permanent-magnet machine; high-efficiency axial-flux VPM machine; conventional-VPM machine; low-speed drive solution; high torque-density; flux path; axial-flux dual-rotor consequent-pole; 10 kW machine; quasi3D magnetic-equivalent-circuit model; wind-turbines; lower volume; high-performance grain-oriented magnetic steel; high-torque; consequent-pole VPM machine; consequent-pole topology; magnetic flux lines; power 10.0 kW

Subjects: Drives; Synchronous machines; Finite element analysis; Transportation; d.c. machines; a.c. machines

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