Analysis of mechanical flux-weakening by using the end-cap of the switched flux permanent magnet machines

Purpose The purpose of this study is to develop a novel mechanical flux-weakening topology for the switched flux permanent magnet (SFPM) machine to extend the speed range, which will be suitable for the electric vehicles and hybrid electric vehicles. Design/methodology/approach The 3 dimensional mechanical flux-weakening model with flux adjusters (FAs) in the end-cap is established. Subsequently, the electromagnetic performance is compared between the SFPM machine with FAs in the end-cap and without FAs. The open circuit flux-linkage is calculated by finite element analysis (FEA) to investigate the influence of this mechanical flux-weakening topology together with the d/q-axis inductance. The flux-weakening capability and torque-speed curve is also calculated. Findings The proposed topology decreases the permanent magnet flux-linkage and increases the d-axis inductance, which improve the flux-weakening capability simultaneously. Subsequently, the speed range and constant power region are much wider than those without FAs. Finally, the prototype is fabricated and the measured result of the open circuit back electromotive force has good agreement with the FEA result. Originality/value This paper provides a novel mechanical flux-weakening topology with FAs in the end-cap for the SFPM machine, whose volume is smaller than another mechanical flux-weakening topology with FAs at the stator outside. Thus, higher torque and power density can be obtained compared with the SFPM machine with FAs at the stator outside.