IEEE ICSET 2010

6-9 Dec 2010, Kandy, Sri Lanka

Design and Analysis of an Air-Cored Axial Flux

Permanent Magnet Generator
for Small Wind Power Application
B. Xia, M. J. Jin, J. X. Shen and A. G. Zhang
College of Electrical Engineering, Zhejiang University, Hangzhou, 310027, China
E-mail: M_J_Jin@zju.edu.cn
Abstract-An axial flux permanent magnet (AFPM) machine with
dual rotors and single air-cored stator is studied in this paper.
The machine is applied for vertical-shaft small power off-grid
wind generating system. A 2-dimensional (2D) finite element
analysis (FEA) method is proposed to approximately solve to the
3-dimensional (3D) magnetic field inside the AFPM machine.
And a 2D analytical method is also presented to compute the air
gap flux density for this dual-rotor single-air-cored-stator axialflux surface-mounted permanent magnet machine structure.
Then, a 3D FEA model is developed to validate the accuracy of
these two proposed 2D methods. Finally, a prototype machine is
fabricated, and experiments are carried out to test its
performances and electromagnetic features. Experimental
results confirm that the 2D FEA and analytical approaches are
both efficient and simple with sufficient accuracy.

I.

INTRODUCTION

Wind power, considered as one of the cleanest renewable

energies, is now receiving more and more attention. In some
developing countries like China, with the supportive policies
of the government, the utility of wind power is growing fast.
Many wind power stations with large scale wind turbines
have been built to provide electricity to the grid in places with
good wind resources. However, in some remote but windy
areas where grid is not available, small low-speed stand-alone
high-efficiency wind generators can be very attractive for
household electrical appliance as well as outdoor monitor
equipments [1]. Axial flux permanent magnet (AFPM)
machine, with its compact structure, flat shape, and high
torque density, fits perfectly for these applications. In this
paper, a 1kW, 300rpm, air-cored outer-rotor surface-mounted
AFPM synchronous machine is studied as a direct-drive
vertical-shaft wind generator (VSWG).
Due to its instinct structure, the flux inside an AFPM
machine flows in both axial and circumferential directions.
Therefore, 3-dimensional (3D) field analysis is necessary for
precise resolving [2]. Though finite element analysis (FEA)
software has been extensively used nowadays with
development of computer technologies, 3D FEA modeling
and simulation are still too complex and quite timeconsuming, and even unworkable for low-grade computers.
Thus, they are not very practical in optimizing designs. To
overcome this problem, a 2-dimensional (2D) FEA method
with sufficient accuracy is proposed in Section III, which
simplifies the modeling and reduces the computing time.

978-1-4244-7191-1/10/$26.00 2010 IEEE

Besides, analytical methods are also solutions to the

computation of magnetic field. Some analytical methods for
AFPM machines have been presented, in both 2D and 3D
models for different AFPM machine topologies [3-5]. These
solutions enable quick parametric analysis, yet have certain
limitations since simplifications are made. A 2D analytical
method is developed for double-rotor, single-air-cored-stator
AFPM machine in Section IV.
3D FEA model is also set up to validate the proposed 2D
FEA and analytical methods. Finally, a prototype machine is
tested to validate both the 2D FEA and analytical methods
and confirm the machine performance.
II.

MACHINE STRUCTURE

The AFPM machine structure is showed in Fig. 1. It

consists of two external rotors and one internal stator
sandwiched between the two rotors. Air-cored stator structure
is adopted to reduce the machine weight. Concentrated
trapezoidal coils are assembled with non-magnetic nonconducting material epoxy resin. As a result, cogging torque
is eliminated, which improves the dynamic characteristics [6]
and gives the generator a much lower cut-in speed. Besides,
stator core loss does not exist due to the absence of iron core,
and the magnetic force between the stator and the rotor is
minimized. Sector-shaped high energy sintered Nd-Fe-B
magnets are glued onto the rotor back iron surfaces,
positioned with aluminum frames which are not illustrated in
Fig. 1. Magnets in red make the air gap flux flow downwards,
whilst those in blue make the flux go upwards. Vertical-shaft

Fig. 1. Machine structure.

wind impellers can be directly installed on the top rotor. This

direct-drive vertical-shaft configuration captures wind energy
from all directions, and the construction is simplified because
the yaw, tower and gear box are unnecessary [7].
Consequently, efficiency and reliability are further improved.
III.

2D FEA MODELING

Since flux travels circumferentially in the rotor back iron

and goes axially in the air gap and magnets, by employing
radial cross section at different cutting radius (r) between
outer radius (Ro) and inner radius (Ri) of the magnets, an
entire flux path is obtained in the cross section. Then, by
pulling the cylindrical cross section straight, a 2D FEA planar
model is obtained. As the flux distribution is periodic in the
circumferential direction and symmetrical in the axial
direction, half of the machine in the axial direction and one
electrical cycle (i.e., two pole-pitches) in the circumferential
direction are required for the field resolving. Thus, the 2D
FEA model can be simplified as that shown in Fig. 2. It
should be pointed out that the model can be further simplified
if only a quarter of electric cycle (viz., half a pole-pitch) is
required by using symmetrical boundaries. Moreover, due to
the air-cored topology, the air gap is relatively large, and
armature reaction is low and negligible. As a result, coils are
simplified. The 2D FEA model illustrated in Fig. 2 indicates
its simplicity, and it is quite convenient to be modified and
remodeled. With just one variable (the cutting radius of the
cross section is chosen here), parametric models can be built.
As the cutting radius (r) changing from Ri to Ro in a proper
step, 2D FEA models are constructed to simulate the AFPM
machine at different radius.
After the parametric analysis, the results obtained from 2D
FEA are mapped back to the 3D model and a grid is formed
by lines at different radius and electrical degree (), as
illustrated in Fig. 3. The grid consists of elements and nodes
and every element contains 4 nodes. The flux density at
different nodes of the grid represents field distribution in the
machine air gap, and can be easily computed from the 2D
parametric FEA model. Assuming that the flux through an
element is determined evenly by the 4 nodes, magnetic flux
of each element is calculated by:

s(i, j ) = (ri +1 ri ) / 2
(i, j ) = [ B(i, j ) + B(i + 1, j ) + B(i, j + 1)
+ B(i + 1, j + 1)] s (i, j ) / 4

(2)

Concentrated trapezoidal armature coil windings are

adopted in this machine. And for this slotless structure, the
width of the coil band has to be considered when calculating
the generated electromotive force (EMF). However, it will be
too complicated to consider each conductor as the flux
through each turn of coil is different. For convenience, each
coil band is assumed to be a thin conductor at the middle
position of the coil band. Then, the flux of the elements
covered by the assumed coil is added up. And the back EMF
can be calculated by:

d (i, j )
i j

e=
dt

(3)

where s, r, , , B and e represent the area and the cutting

radius of the element-i,j, and the angular step, the flux
through element-i,j, and the back EMF in a single turn,
respectively.
IV.

2D ANALYTICAL METHOD

Fig. 4 shows the 2D analytical solution model. Duo to the

ironless stator structure, the effective air gap including the
mechanical air gap and the height of coil winding is much

Fig. 3. Mapping relation of 3D and 2D models.

Fig. 2. 2D FEA model.

(1)

Fig. 4. 2D analytical model.

larger than that in slotted machines. Thus the rotor back iron
has little magnetic saturation. Consequently, the relative
permeability is assumed to be infinitely large for simplicity.
Rectangular coordinate system is adopted here, and x-axis
represents the distance in the circumferential direction, whilst
y-axis represents the axial direction.
The scalar magnetic potential in all regions follows
Laplaces equation [8]:

2 2
+
=0
x 2 y 2

(4)

8 Br

BxI =

n p L / 2

cos

= (sinh

nhm

+ (sinh

+ D1n sin mn y )] + [( A2 n cos mn x

(5)

n =1

Equation (5) must satisfy the boundary conditions below:

( x) = ( x + 2 p )

(6)

H xIII = 0, ( y = L)
H xII = 0, ( y = 0)

(7)

n ( L / 2 y )

nx

(14)

+ r cosh

nhm

nhm

r cosh

n ( L hm )

)e

nhm

nhm

)e

(15)

n=1, 3, 5,
0 is the permeability of free space and r is the relative
recoil permeability of magnet.

+ B2 n sin mn x)(C2 n cosh mn x + D2 n sinh mn y )]

+ ( A0 + B0 x)(C0 + D0 y )

sinh

where

= [( A1n cosh mn x + B1n sinh mn x)(C1n cos mn y

nhm

The general solution to (4) is given by:

n =1

[ n sinh

3D FEA VALIDATION

V.

Since 2D FEA and analytical methods have not taken the

end effect into account, a 3D FEA model is developed to
validate these 2D methods. The 3D model and flux density of
rotor back iron, magnets and coils are showed in Fig. 5. The
maximum flux density is 1.6 T in the back iron. It proves the
assumption that there is little saturation in the back iron.

(8)

ByI = ByII
, ( y = hm )

H xI = H xII
ByI = ByIII
, ( y = L hm )

H xI = H xIII

(9)

(10)

where p, hm and L denotes the pole-pitch, thickness of

magnets and distance between the two rotor back irons.
The relation of magnetic field strength and scalar magnetic
potential is given by:

H x = x

H y =

Fig. 5. Flux density distribution from 3D FEA.

(11)

(12)

Applying boundary conditions (6)-(10) to (11) and (12),

using the general solution (5), the air gap flux density in axial
direction is given by:

B yI =

8 Br

[ n sinh

nhm

n p L / 2

cos

nx

cosh

n ( L / 2 y )

Flux density (T)

0.6

BxI = 0 H xI

B yI = 0 H yI

=90 (3D FEA)

=11.6 (3D FEA)
=90 (2D FEA)
=11.6(2D FEA)
=90 (2D Anal.)
=11.6 (2D Anal.)

0.7

And, the flux distribution density in region I is obtained as:

0.5
0.4
0.3
0.2
0.1
0

(13)

90

115

140

165

Cutting Radius(mm)

Fig. 6. Air gap field distribution along radius direction,

solved with 3D FEA, 2D FEA and 2D analytical model.

190

The 3D FEA method is compared with the two proposed

2D methods in Fig. 6 and Fig. 7. Results of 2D FEA and 2D
analytical method show great agreement with each other. Fig.
6 reveals that as the cutting radius of the cross section
increases, the flux density in the air gap from 2D analysis
increases. 3D FEA method validates the magnetic field
distribution from 2D methods, except that the flux density
actually decreases when getting very close to the inner and
outer radius of the magnet. That is because the end effect
becomes significant on the inner and outer edges of the
magnets, but it cannot be reflected in the 2D models. Flux
density from 3D FEA and 2D FEA, 3D FEA and 2D
0.6

r=122.5(3D FEA)
r=140(3D FEA)
r=157.5(3D FEA)
r=122.5(2D FEA)
r=140(2D FEA)
r=157.5(2D FEA)

Flux density (T)

0.4

0.2

VI.

0
0

120

240

360

-0.2

-0.4

-0.6

Angular distance(elect. deg)

(a)

0.6

r=122.5(3D FEA)
r=140(3D FEA)
r=157.5(3D FEA)
r=122.5(2D Anal.)
r=140(2D Anal.)
r=157.5(2D Anal.)

Flux density (T)

0.4

0.2

0
0

60

120

180

240

300

360

-0.2

-0.4

-0.6

Angular distance(elect. deg)

(b)
Fig. 7. Air gap field distribution along circumferential direction.
(a) 3D FEA and 2D FEA methods. (b) 3D FEA and 2D analytical method.
250

2D FEA
3D FEA

Phase back EMF (V)

200
150
100
50
0
-50 0

60

120

180

240

300

-100
-150
-200
-250

Electrical Degree
Fig. 8. One-phase back EMF from 3D FEA and 2D FEA.

analytical method are compared along circumferential

direction at different radius in Fig. 7 (a) and (b) respectively.
The results show that both 2D methods match the 3D FEA
method. Overall, the magnet inner and outer regions are quite
small, and we believe that magnetic field distribution
computed from 2D methods can simulate the actual 3D flux
distribution with small error due to the inner and outer
regions of the magnets.
Since the 3D FEA method has validated the 2D FEA flux
distribution, according to (1)-(3), the phase back EMF can be
calculated based on the results from 2D FEA method.
Waveforms of one-phase back EMF from the 3D and 2D
FEA results are compared in Fig. 8, and it confirms that the
2D FEA method totally agrees with the 3D FEA method with
an error less than 2%.

360

PROTOTYPE MACHINE EXPERIMENTS

The prototype AFPM generator is built, Fig. 9. Design

parameters of the machine are illustrated in TABLE I.
A test rig is then set up, where the generator is put in a
horizontal position and driven with the geared induction
motor, Fig. 10. For laboratory experiments, the induction
motor is fed with a commercial programmable frequency
converter, thus, its speed can be adjusted to simulate various
wind condition.
To test the machine and verify the analysis methods
proposed in this paper, the machine back EMF at rated speed
(300 rpm) is measured in the experiment. Fig. 11 shows the
line-line voltage of 2D FEA, 3D FEA and the prototype. The
experimental waveform is similar to the 2D and 3D FEA
results. The measured peak value is a little smaller than the
FEA-predicted data, and the error is about 6%. This error is
caused possibly by the model inaccuracy, the characteristic
inconsistency of the permanent magnets, or the
manufacturing imperfection. However, the error is acceptable.
Thus, the 2D FEA method is validated to be simple, timesaving and sufficiently accurate. Moreover, as proved
previously, the 2D analytical model agrees well with the 2D
FEA, therefore, both 2D approaches, viz., 2D FEA and 2D
analytical model, are verified by both 3D FEA and
experiments.
VII.

CONCLUSIONS

AFPM machines are among the most suitable candidates

for direct drive small and medium wind power generators. In
this paper, a dual-rotors and single-air-cored-stator AFPM
generator for low-speed small wind power application is
analyzed, using proposed 2D FEA and 2D analytical methods.
3D FEA model is also developed, validating both proposed
2D approaches. The machine back EMF is also calculated
based on the 2D FEA methods. A prototype machine is tested.
Experimental results are compared with the FEA results,
confirming that the 2D approaches are simple, efficient and
sufficiently accurate.
The proposed 2D FEA method can also be applied to other
structures of AFPM machines with slotted stators and
different shape magnets.

400
No-load Line Voltage (V)

300
200

2D FEA
3D FEA
Experimental

100
0

-100 0

60

120

180

240

300

360

-200
-300
-400

Electrical Degree

Fig. 11. Line-line back EMF of 3D FEA, 2D FEA and prototype.

Fig. 9. Prototype AFPM Machine.

REFERENCES
[1]

[2]
[3]

[4]
Fig. 10. Measurement Setup for Prototype Machine.
[5]

TABLE I
MAIN DESIGN PARAMETERS
Parameter
Stator coil number

Value
21

Rotor pole number

28

Unit

[7]

Pole embrace

0.89

Magnet outer radius

175

mm

Magnet inner radius

105

mm

Magnet thickness

7.5

mm

mm

Thickness of back iron

[6]

[8]

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