Leakage Flux Adjustment and Flux Field Optimization for Coreless Axial Flux Permanent Magnet Synchronous Machine Based on U-shaped Iron

The rotor leakage flux will cause a lot of eddy current losses in the windings of coreless axial flux permanent magnet synchronous machine (CAFPMSM). This article presents a rotor leakage flux adjustment method for the CAFPMSM based on U-shaped iron, which can also achieve the optimization of the rotor flux field. The U-shaped iron can reduce the leakage flux crosses the winding and improve the spatial harmonic distribution of the air gap field at the same time. Firstly, the basic topology and its operating principle are investigated by using an equivalent magnetic circuit model. And then, the characteristics of the flux field distribution in the winding area are analyzed, and the parameters of the U-shaped iron on the leakage flux path regulation are elaborated and optimized by the three-dimensional finite-element method (3D FEM) analysis. Finally, the comprehensive experimental results show that the leakage flux path of the rotor passes through the U-shaped magnetically conductive block rather than through the windings, the total harmonic distortion (THD) of the air gap flux density waveform can be significantly decreased, and the THD of the back EMF and the eddy current losses are lower than before.