Axial flux PM generator Attention and Caution

Axial flux PM generators are used in a range of industries for Axial Flux Permanent Magnet Generator. They offer low maintenance and gas emissions. In addition, they come in a wide variety of air gap configurations.

This magnet is made of grade N48 neodymium magnetic material and axially magnetized. Neodymium magnet is one of the rare earth magnets, also known as NdFeB magnets. The major elements are Neodymium, Iron and Boron. Size: 1" long x 1/4" wide x 1/4" thick  Nickel (Ni) Plated (silver-like shine) Grade: N48 - Extremely powerful magnetic material

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Design parameters

The axial flux permanent magnet (AFPM) generator is a type of wind energy conversion system that generates Alternating Current (AC) as its output. This type of generator offers relatively high torque capacity and compactness. It has been used for hybrid electric propulsion drone applications. Several studies have been carried out to study the performance of AFPM generators.

In order to study the efficiency of the AFPM generator, a finite element analysis (FEA) is used. This FEA uses the m-AFPG model to simulate the rotor discs and the electrical profile. By analyzing the FEA, the core losses can be estimated.

The m-AFPG is a simplified version of the generator and can be customized to fit the application requirements. For example, it can be used to simulate the voltage and current conditions of a residential load. Moreover, the m-AFPG can be stored in batteries to produce electrical energy. A slicing technique is used to reduce the computation time.

For comparison, the reference radial flux PM motor has been chosen as a benchmark. This generator has an rated output power of 300 W at 800 rpm and an output torque of 19.1 N.m.

To determine the total magnetic flux density, the magnetic flux passing between points P4 to P7 of the coil is considered. The back iron reluctance is a function of the magnetic field density.

A comparison of the generator characteristics is performed to verify the validity of the initial design constraints. In addition, the results of the simulation indicate that the final design can satisfy the initial requirements.

In order to obtain a more accurate estimate of the copper loss, the FEA of the generator is used. In addition, the m-AFPG model is tested for its ability to fulfill various load conditions.

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Various air gap configurations

The air gap between the rotors and stator of an axial flux PM generator can be adjusted to change the power scale and the output. The length of the air-gap can be increased or decreased to achieve higher efficiency or to increase or decrease torque for Neodymium magnets.

This paper aims to analyze the effect of the air-gap on the performance of an axial flux PM machine. The experimental results are compared with a proposed calculation model.

This study investigated the effect of different air-gap sizes on the torque, current, and voltage of an axial flux PM motor. Increasing the air-gap length reduced the starting torque of the machine. It also decreased the maximum torque.

The effect of the air-gap on MMF is significant. Increased magnetic flux density in the air-gap increases the magnetic field and generates more power. However, the high values add to system integration and cost challenges.

Air-gap lengths can be varied from 2 mm to 7 mm. This variation is crucial for the optimum performance of the generator. Higher values bring the magnet past the "knee point" of the curve. A small value brings the magnet into the lower end of the curve. For example, if the air-gap is 4.5 mm, the magnet can be brought to the "knee point" of a curve with a magnetic flux density of less than 0.5 tesla.

In order to increase the output of an axial flux PM machine, an optimized Lsc is required. Besides, the total air-gap length and the corresponding magnetic flux density are affected by the height of the coil.

This research aims to determine the design parameters that affect the power density and efficiency of the axial flux PM machine. It will also establish a new computational tool for the design of axial flux PM machines.

High reliability

Axial flux Permanent Magnet (PM) generators have a higher efficiency than radial flux machines. They are also simpler to build. In addition, they have a higher power density. This technology can be used from small motors to large generators.

Axial flux machines have a single-dimensional flux path. This means that a large amount of copper is not wasted. There is no need for a rotary encoder. The magnetic bridge forces ensure a safe and stable operation of the machine.

The new rotor tooth design also decreases cogging torque. Using grain-oriented steel, the stator core losses are reduced by 85%. Furthermore, the rotor has a low temperature rise.

A new mechanical structure is also built into the rotor to protect the PM from corrosion and impact of Bonded NdFeB magnets. The rotor is made from a composite material that is strong enough to endure the axial motion. Moreover, it is a grain-oriented electrical steel.

To analyze the feasibility of the proposed design, a prototype machine is constructed. It is composed of a stator, rotor, shaft, and coils.

Using three-dimensional transient FEM simulation, the accuracy of the results is evaluated. Results show that the proposed machine is able to produce a MAP curve with a maximum of 95% efficiency. Additionally, the optimized machine has the same maximum flux densities in the yoke and teeth.

Another important feature of the proposed AFFSPM generator is the reduction of the cogging torque. This can result in reduced noise and vibration. Also, the mechanical strength of the rotor is still sufficient to meet the performance requirements.

Overall, the proposed machine offers a higher efficiency, lower costs, and a wider range of applications. Because of the high-speed nature of this machine, it is suitable for use in micro-wind turbines.

Low maintenance

Compared to the radial flux motors of the past, the axial flux PM generator has some serious advantages. These include its small size and low maintenance. It is also a good match for the L7e class of heavy quadricycles.

Axial-flux designs are a bit of a minefield. They are not as easy to manufacture as radial-flux generators. However, their efficiencies are higher. Their cost is also lower.

The triumvirate of features is the use of a non-ferromagnetic core, an axially aligned rotor and a distributed winding. Combined, they help heat to transfer from the housing to the windings.

The axial-flux technology is scalable from small motors to megawatt generators. While it isn't as efficient as its radial-flux predecessor, the axial-flux system does a good job of cutting weight and boosting power density. In addition, the axial-flux motor has a number of other benefits, including a streamlined design and zero overhang.

The axial-flux technology has been around for six years, but it still has a long way to go. The axiom of efficiency is a key determinant. As such, the axial-flux motor is a great option for the automotive industry. For example, it is designed to run on voltages up to 60 V, which is not only more efficient, but makes it easier to integrate into mainstream 48-V electrical systems.

The axial-flux motor can also be built into a swing arm with a battery. This not only makes it easier to maintain, it also helps to save space and weight. Another advantage is that it offers lower noise.

Using a swivel mile with a turbine attached to the same axial line as the power generator is another way to make the most of the system.

Low gas emissions

Gas turbines are used in various industrial applications to produce low gas emissions and low noise. They have the ability to produce a high power level with a low installation cost. The advantages of this technology include its multi-fuel capability, low maintenance costs, and its ability to provide electricity for emergency situations.

A compact axial electrical flux generator can be integrated with a gas turbine housing to produce low gas emissions and low noise. It is also suitable for direct drive wind power generation systems. This technology offers great versatility and can be applied to many other applications.

An axial flux PM generator uses a stator that is located within the turbine housing. Depending on the application, the PM material and the rotor size are important. These materials are selected to reduce the manufacturing costs and to ensure a high mechanical integrity of the machine with Neodymium (NdFeb) Pot Magnets.

Using finite element analysis (FEA), the core loss is calculated. In addition, the magnitude of the cogging torque is determined. FEA is a powerful tool that can be used to analyze and improve the performance of a PM motor.

A new analytical model is developed for the radial-flux PM generator. The results of this study verify the design constraints and help to improve the overall performance of the machine. FEA is used to simulate the electromagnetic field and design the generator.

Various types of PM have different AirGap powers. These Power Density Distributions are compared with each other at a variety of different Electrical Degrees. Fig. 8b illustrates the flux paths. Moreover, the output line voltage is calculated for varying air-gap lengths.

Axial flux machines have been considered as less reliable in analytical designs due to their complicated three-dimensional magnetic flux paths. However, they have greater power densities than radial flux PM machines.