IEEE TRANSACTIONS ON MAGNETICS, VOL. 51, NO.

11, NOVEMBER 2015 8112204

A Novel Dual-Rotor, Axial Field, Fault-Tolerant Flux-Switching

Permanent Magnet Machine With High-Torque Performance
Wenliang Zhao1 , Thomas A. Lipo2 , Life Fellow, IEEE, and Byung-Il Kwon1
1 Department of Electronic Systems Engineering, Hanyang University, Ansan 426-791, Korea
2 Department of Electrical and Computer Engineering, Florida State University, Tallahassee, FL 32306 USA
This paper proposes a novel dual-rotor, axial field, fault-tolerant flux-switching permanent magnet machine (FSPMM) with
high-torque performance for direct-drive applications, in which the phase-group concentrated-coil windings and the unaligned
arrangement of the two rotors are used. The adoption of the phase-group concentrated-coil windings is made to obtain a unity
displacement winding factor, and to enhance the flux-focusing effects together with the use of a spoke-type PM configuration. The
unaligned arrangement of the two rotors will help to achieve increased flux magnification and also to suppress the cogging torque
and the torque ripple. In particular, the proposed configuration for FSPMMs exhibits the advantage of fault tolerance, benefiting
from the electromagnetic isolation of phases and a dual three-phase channel of supply. The operating principle and the design
criteria of the proposed FSPMM are discussed in detail. To highlight the advantages of the proposed FSPMM, two conventional
FSPMMs are adopted for comparison under the same operating conditions based on a 3-D finite-element method. As a result, it is
demonstrated that the proposed FSPMM exhibits significantly improved performance with not only higher torque (power) density
but also lower cogging torque and torque ripple, compared with the conventional FSPMMs.
Index Terms— Axial field, direct drive, fault tolerant, finite-element method (FEM), flux-switching permanent magnet
machine (FSPMM), phase-group concentrated-coil winding, torque, winding factor.
I. I NTRODUCTION

T HE flux-switching permanent magnet machine (FSPMM)

has become increasingly popular in recent years for
various domestic and industrial applications. An FSPMM,
which embodies the combined merits of PM synchronous
machines and switching reluctance machines, offers many
desirable attributes such as high torque (power) density,
robust of rotors, and a remarkable degree of fault-tolerant
capabilities [1].
Since the proposal of a one-phase FSPMM in the 1950s [2],
a large number of topologies for FSPMMs have been
developed [3]–[7]. These include three-phase and multiphase
FSPMMs, E-core and C-core FSPMMs, linear FSPMM, axial
field FSPMM, and hybrid-excited FSPMM. In particular, the
axial field FSPMM exhibits further advantages, such as shorter Fig. 1. Machine topologies. (a) Conventional model 1 (12S/10P).
(b) Conventional model 2 (12S/14P). (c) Proposed model 3 (12S/13P).
axial length, better heat dissipation, and higher torque density, (d) Separated view of the proposed model 3.
which has been investigated by topologies with double rotors
or stators [8], [9]. However, although most of the reported
FSPMMs can obtain relatively high torque (power) density, In this paper, a novel dual-rotor, axial field FSPMM is
they also suffer from high cogging torque and torque ripple proposed for direct-drive applications, in which the
due to their doubly salient structure and high air-gap flux phase-group concentrated-coil windings and the unaligned
density caused by the flux-focusing effects; it is imperative arrangement of the two rotors are used. The whole
to minimize such torque pulsations in high-performance configuration of the proposed FSPMM exhibits the advantages
applications to avoid undesirable vibration and acoustic noise, of multiple magnet flux magnification for high torque density,
and to provide accurate position and speed control [10]. significant cogging torque and torque ripple suppression,
Although traditional approaches, such as skewing, tooth and and remarkable fault-tolerant capabilities. The operating
magnet shaping, or drive control methods, can be adopted to principle and the design criteria of the proposed FSPMM
reduce cogging torque and torque ripple, these approaches are discussed in detail. To highlight the advantages of the
inevitably introduce performance degradation and increase proposed FSPMM, two conventional FSPMMs are adopted
manufacturing difficulties. Furthermore, the fault-tolerant for comparison under the same operating conditions by
capabilities of FSPMMs are essential to be further improved a 3-D finite-element method (FEM) using the commercial
to spread them for various transportation applications. software, JMAG-Designer.

Manuscript received March 20, 2015; revised May 16, 2015 and II. M ACHINE M ODELING AND O PERATING P RINCIPLE
June 11, 2015; accepted June 11, 2015. Date of publication June 16, 2015;
date of current version October 22, 2015. Corresponding author: B.-I. Kwon A. Machine Topologies
(e-mail: bikwon@hanyang.ac.kr).
Color versions of one or more of the figures in this paper are available
The topologies of the investigated FSPMMs are shown
online at http://ieeexplore.ieee.org. in Fig. 1. A conventional single-rotor, axial field FSPMM with
Digital Object Identifier 10.1109/TMAG.2015.2445926 12 stator slots (S)/10 rotor poles (P) designated as model 1
0018-9464 © 2015 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.

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 8112204
TABLE I
S PECIFICATIONS OF THE I NVESTIGATED M ACHINES
Fig. 2. Configurations of the stator and the winding coils. (a) Conventional
models. (b) Proposed model.
and a dual-rotor, axial field FSPMM with 12S/14P designated
as model 2 are given as the reference models, as shown
in Fig. 1(a) and (b), respectively. The adoption of the different
rotor poles for the conventional models offers an investigation
of the effects of electric frequency. The proposed dual-rotor,
axial field FSPMM with 12S/13P, combined the two rotors to
form a joint shaft output, is designated as model 3, as shown
in Fig. 1(c) and (d), wherein β (elec.) is the offset angle
between the two rotors. Ferrite PMs are embedded in the stator
with the circumferentially magnetized direction alternately
reversed in polarity. The steel sheet NSSMC 50H470 is used
for the ferromagnetic parts in all of the investigated machines.
All the machines have the same size, with similar weights, as
listed in Table I. Differing from the conventional FSPMMs,
which use concentrated windings as shown in Fig. 2(a), the
proposed FSPMM is equipped with an advanced phase-group
concentrated-coil winding, as shown in Fig. 2(b).
B. Design Criteria of the Proposed FSPMM
Based on the design sketch in Fig. 3, a series of teeth in
the proposed FSPMM are constructed to be grouped with the
same phase winding, while the slot and the teeth width within
one-phase group are designed to be the same as θ , which
is equal to π/2 (elec.), for obtaining the unity displacement
winding factor. Alternatively, the slot width between
two different phases is 5θ /3, which is equal to 5π/6 (elec.), for
the production of a three-phase balanced back electromotive
force (EMF). Thus, a perigon relationship can be developed as
3 × [(n 1 − 1)n 2 × 4θ + n 2 × 14θ/3] = 2π. (1)
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IEEE TRANSACTIONS ON MAGNETICS, VOL. 51, NO. 11, NOVEMBER 2015
Fig. 3. Design sketch of the proposed model (developed view).
Fig. 4. Operating principle of the proposed model.
Then, the number of slots in one stator is
Q = 3n 1 n 2 (2)
and the number of rotor poles follows:
P = 3n 1 n 2 + n 2 /2 (3)
where n 1 is defined as the number of stator coils for
one-phase group, and n 2 is the number of groups for
one phase. In this paper, a model with 12S/13P (n 1 = 2 and
n 2 = 2) is investigated.
C. Operating Principle of the Proposed FSPMM
The operating principle of the proposed FSPMM is shown
in Fig. 4. Taking one-phase group into consideration, when
the rotor poles rotate to become aligned with the stator teeth
facing the upper air gap, almost all of the PM flux will flow
into the upper air gap, as illustrated in Case 1. In Case 2,
after a process, where the PM flux flows into two air gaps
simultaneously, the same effects as in Case 1 will occur
in the lower air gap, as shown in Case 3. Thus, a highly
improved air-gap flux density, resulting in a higher output
torque, can be obtained than the conventional designs, where
the two air gaps work independently [11]. Due to the alternate
operating principle for the PM flux concentration, the phase
back EMFs produced in the upper and the lower stator
windings will be shifted by π/2 (elec.), and contribute to a
dual three-phase channel. Together with the electromagnetic
isolation of the different phases that results from the modular
phase-group concentrated-coil windings, it also helps to obtain
highly improved fault-tolerant capabilities [3], [5], [12].
III. 3-D FEM A NALYSIS R ESULTS
A. Characteristics of the Proposed FSPMM
The characteristics of the proposed FSPMM are predicted
by the 3-D FEM. Fig. 5 illustrates the magnetic flux density
distribution at no-load condition and demonstrates the position
for the cases in Fig. 4, where almost all of the PM flux
flows into the upper air gap corresponding to phase-group A
(the area in the red dashed box) in Case 1. After the process
 ZHAO et al.: NOVEL DUAL-ROTOR, AXIAL FIELD, FAULT-TOLERANT FSPMM
Fig. 5. Magnetic flux density distribution of the proposed model.
Fig. 6. Back EMF and cogging torque of the proposed model.
TABLE II
BACK EMF AND C OGGING T ORQUE W ITH O FFSET A NGLE
Fig. 7. Torque profile with current density J of the proposed model.
in Case 2, where the PM flux flows into two air gaps simulta-
neously, almost all of the PM flux flows into the lower air gap
as in Case 3. The phase back EMF and the cogging torque
(peak-to-peak) with respect to the rotor offset angle β (elec.)
are shown in Fig. 6, indicating that the proposed FSPMM with
β = 90° exhibits better performance. The simulation data are
listed in Table II.
The electromagnetic torque of the proposed FSPMM,
obtained from the joint output of both the rotors, is predicted
by feeding the stator winding with the dual three-phase
sinusoidal current excitations at 450 r/min. Fig. 7 shows the
transient torque profile with various current densities and
estimates the machine performance under different loading
conditions. It is worthy to note here that the FSPMMs
have high withstand capability against the irreversible
demagnetization, since the armature reaction flux does not
pass through the magnets [2]. A previous work on designing
dual-stator ferrite PM machines for attraction applications
in hybrid electric vehicles shows that the spoke-type
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8112204
Fig. 8. Electromagnetic torque and torque ripple of the proposed model.
Fig. 9. Power and efficiency of the proposed model.
Fig. 10. Torque density and power weight ratio of the proposed model.
PM configurations have good endurance against the
irreversible demagnetization, despite the fact that only a
slight demagnetization occurs at the edge of the ferrite PMs
when the current density is 18 Arms/mm2 [11]. Fig. 8 shows
the average torque and the torque ripple from the superposition
of both the rotors, wherein the torque ripple is obtained by
Tmax − Tmin
TR = (4)
TAVG
where Tmax , Tmin , and TAVG are the maximum, minimum, and
average values of the electromagnetic torque, respectively.
The torque ripples of the proposed FSPMM with various
current densities are suppressed to below 8.5%.
Fig. 9 shows the output power and the efficiency with
different current densities, where the outer power, efficiency,
and losses, including copper loss and iron loss, are obtained,
as depicted in [11]. The efficiencies of the proposed model,
which uses ferrite magnets, are >70% for a large operating
range of current densities. The torque densities, calculated by
the ratio of the output torque to the overall machine volume,
and the power weight ratios, which are obtained by the ratio
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Fig. 11. Cogging torque comparison of the investigated models.
Fig. 12. Electromagnetic torque comparison of the investigated models.
TABLE III
FEM A NALYSIS R ESULTS OF THE I NVESTIGATED M ACHINES
of the output power to the overall machine weight, are shown
in Fig. 10.
B. Comparison
To highlight the advantages of the proposed FSPMM,
a performance comparison is carried out between the proposed
and the conventional models. Fig. 11 shows the comparison of
the cogging torques, indicating that the proposed model greatly
reduces the cogging torque by 66.1% and 71.4%, compared
with those of the conventional models 1 and 2, respectively.
The comparison of electromagnetic torques is shown
in Fig. 12. Model 2 has a higher average torque and torque
ripple than model 1 due to the dual-rotor structure, while
model 3 (the proposed model) exhibits the highest average
torque and the lowest torque ripple (3.7%). Consequently, the
proposed model produces a greatly increased torque density
and power weight ratio, as summarized in Table III. It is
noted here that model 2 (12S/14P) has a lower efficiency
than model 1 (12S/10P) due to its higher iron loss, which is
mainly caused by its higher working frequency. However, the
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IEEE TRANSACTIONS ON MAGNETICS, VOL. 51, NO. 11, NOVEMBER 2015
proposed model 3 (12S/13P) still achieves a slightly improved
efficiency, despite the fact that it exhibits high iron loss caused
by its high working frequency and high air-gap flux density.
IV. C ONCLUSION
This paper has proposed a novel dual-rotor, axial field,
fault-tolerant FSPMM in which the phase-group concentrated-
coil windings and the unaligned arrangement of the
two rotors are used. The superiority of the proposed FSPMM
has been introduced through the design criteria and the
operating principle, and was verified by the comparison with
two conventional FSPMMs. Based on the 3-D FEM analysis
results, it has been demonstrated that the proposed FSPMM
exhibits significantly improved performance with not only
high torque (power) density but also low cogging torque and
torque ripple.
ACKNOWLEDGMENT
This work was supported in part by the BK21PLUS Pro-
gram through the National Research Foundation of Korea
within the Ministry of Education and in part by the Human
Resources Program in Energy Technology through the Korea
Institute of Energy Technology Evaluation and Planning within
the Ministry of Trade, Industry and Energy, Korea, under
Grant 20154030200730.
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