Comprehensive Design and Performance Analysis of Series Dual Axial Flux Permanent Magnet Machine

In order to solve the problems of high slot leakage, low power factor and low electromagnetic torque of deep-slot axial flux permanent magnet machine (AFPM), a series dual axial flux permanent magnet machine (SD-AFPM) with four stators was proposed. Firstly, the electromagnetic properties of the SD-AFPM, inner rotor machine (IR-AFPM) and multi-disc series machine (SMD-AFPM) are compared comprehensively to demonstrate the effectiveness of the proposed SD-AFPM in improving power factor and electromagnetic torque. Secondly, a three-channel cooling system for the SD-AFPM, based on the structural characteristics, is designed, and the heat dissipation capacity of the cooling system is analyzed by three dimensions finite element analysis (3D-FEA). Then, the strength of the rotor is checked under the consideration of electromagnetic force, centrifugal force and temperature. Finally, a 36kW prototype is manufactured, and the feasibility of the SD-AFPM and the effectiveness of the three-channel cooling system are verified by experiments and finite element analysis.