Optimal Design of Coreless Axial Flux Permanent Magnet Synchronous Generator with Reduced Cost Considering Improved PM Leakage Flux Model

AbstractThis paper presents an optimal design of coreless axial flux permanent magnet (AFPM) synchronous generator using particle swarm optimization method based on sizing equations of the machine. The design optimization is performed in order to reduce the active material cost of the generator. General practical and mechanical limitations are considered as optimization constraints. A magnetic circuit model based on quasi three-dimensional (3-D) model of the coreless AFPM machine is taken into account to calculate the permanent magnet leakage flux (PMLF) accuracy. A computer-aided program is evaluated according to the proposed optimized design procedure that is used to design a 2-kW, 16-pole AFPM generator with two rotors and one coreless stator. Finally, the 3-D finite-element model (FEM) of the machine is prepared to confirm the validity of the proposed PMLF model and proposed optimized design algorithm.