Fea estimation and experimental validation of solid rotor and magnet eddy current loss in single-sided axial flux permanent magnet machines

Abstract

The rotor and magnet loss in single-sided axial flux permanent magnet (AFPM) machines with non-overlapped windings is studied in this dissertation. Finite element analysis (FEA) estimations of the loss are carried out using both 2D and 3D modeling. The rotor and magnet losses are determined separately for stator slot passing and MMF space harmonics from currents in the stator. The segregation of loss between the solid rotor plate and the magnet is addressed. The eddy current loss reduction by magnet segmentation is discussed as well. Two prototype 24 slot/22 pole single-sided AFPMs, fabricated with both single layer (SL) and double layer (DL) windings are assembled. Methods of loss segregation are illustrated in order to separate the eddy current loss. Finally, an optimal design approach to axial flux permanent magnet machines is presented.