Analysis and design optimization of a low-cost axial flux Vernier machine with SMC cores and ferrite magnets

In this paper, a low-cost high-performance axial flux Vernier machine (AFVM) with soft magnetic composite (SMC) cores and ferrite magnet is proposed, analyzed and optimized. By cooperating with spoke magnet rotor configuration and 3D magnetic flux stator structure, the proposed AFVM can output higher torque compared with the traditional permanent magnet machine though low-cost low-energy-density ferrite magnet and low-permeability SMC material are adopted. The main electromagnetic topology and operation principle of the proposed AFVM are introduced; then, its main dimensions are investigated and optimized by using sequential optimization method. Moreover, a new multilevel Taguchi design optimization which is an improvement of multilevel optimization is proposed for the torque and power factor optimization. Lastly, its main performance of AFVM optimized by the sequential optimization method and multilevel Taguchi design optimization method has been compared with a normal axial flux machine in terms of torque ability, power factor and efficiency based on 3D finite element method.