Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance Analysis
Coreless axial-flux permanent-magnet (AFPM) machines have recently gained prominence as efficient power generation solutions. Eliminating the core resolves challenges such as eddy current losses and cogging torque, enhancing overall efficiency. This topology enables high power density, further ampli...
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2025-01-01
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| Online Access: | https://ieeexplore.ieee.org/document/10829570/ |
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| author | Turki M. Alsuwian Asiful Habib Muhammad Ammirrul Atiqi Mohd Zainuri Ahmad Asrul Ibrahim Nasrudin Abd Rahim Adam R. H. Alhawari Abdulkarem H. M. Almawgani Saleh Almasabi A. T. Hindi Mohamed Fauzi Packeer Mohamed |
| author_facet | Turki M. Alsuwian Asiful Habib Muhammad Ammirrul Atiqi Mohd Zainuri Ahmad Asrul Ibrahim Nasrudin Abd Rahim Adam R. H. Alhawari Abdulkarem H. M. Almawgani Saleh Almasabi A. T. Hindi Mohamed Fauzi Packeer Mohamed |
| author_sort | Turki M. Alsuwian |
| collection | DOAJ |
| description | Coreless axial-flux permanent-magnet (AFPM) machines have recently gained prominence as efficient power generation solutions. Eliminating the core resolves challenges such as eddy current losses and cogging torque, enhancing overall efficiency. This topology enables high power density, further amplified in fully coreless configurations. Nevertheless, the proliferation of coreless AFPM machines faces hurdles as to high leakage flux and weaker structural integrity. Additionally, adopting multi-phase setups in AFPM introduces challenges, requiring additional winding coils and enlarging the stator diameter, leading to bulkier machine designs. This article underscores the significance of a lightweight, fully coreless six-phase machine and proposes a modular, multi-stage, multi-phase design tailored for fault-tolerant small-scale power generation applications. Furthermore, it explores the impact of employing double-layer winding coils on air-gap-flux density and power output. To realize this aim, a six-phase multi-stage AFPM generator was designed and simulated using ANSYS Maxwell. Subsequently, a laboratory-scale prototype was fabricated accordingly. The simulation findings closely align with the experimental results obtained from the prototype, demonstrating the achievement of 1.3 kW power output. Notably, the six-phase machine with fully coreless concept exhibits a substantial power density of 205 W/kg. Multi-stage design boost efficiency and power density, presenting potential for small-scale applications. |
| format | Article |
| id | doaj-art-c8fb137fb7eb4d6ea8b88d72ece15950 |
| institution | Kabale University |
| issn | 2169-3536 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | IEEE |
| record_format | Article |
| series | IEEE Access |
| spelling | doaj-art-c8fb137fb7eb4d6ea8b88d72ece159502025-02-07T00:01:05ZengIEEEIEEE Access2169-35362025-01-0113226472265510.1109/ACCESS.2025.352616510829570Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance AnalysisTurki M. Alsuwian0https://orcid.org/0000-0001-9579-9115Asiful Habib1https://orcid.org/0000-0002-5997-4462Muhammad Ammirrul Atiqi Mohd Zainuri2https://orcid.org/0000-0001-9134-4869Ahmad Asrul Ibrahim3Nasrudin Abd Rahim4https://orcid.org/0000-0002-1834-1984Adam R. H. Alhawari5Abdulkarem H. M. Almawgani6https://orcid.org/0000-0003-0697-6103Saleh Almasabi7https://orcid.org/0000-0003-4653-190XA. T. Hindi8Mohamed Fauzi Packeer Mohamed9https://orcid.org/0000-0001-6353-0285Electrical Engineering Department, College of Engineering, Najran University, Najran, Saudi ArabiaDepartment of Electrical, Electronic and Systems Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia (UKM), Bangi, MalaysiaDepartment of Electrical, Electronic and Systems Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia (UKM), Bangi, MalaysiaDepartment of Electrical, Electronic and Systems Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia (UKM), Bangi, MalaysiaHICoE, UM Power Energy Dedicated Advanced Center (UMPEDAC), Wisma Research and Development, University of Malaya, Kuala Lumpur, MalaysiaElectrical Engineering Department, College of Engineering, Najran University, Najran, Saudi ArabiaElectrical Engineering Department, College of Engineering, Najran University, Najran, Saudi ArabiaElectrical Engineering Department, College of Engineering, Najran University, Najran, Saudi ArabiaElectrical Engineering Department, College of Engineering, Najran University, Najran, Saudi ArabiaSchool of Electrical and Electronics Engineering, Universiti Sains Malaysia, George Town, Penang, MalaysiaCoreless axial-flux permanent-magnet (AFPM) machines have recently gained prominence as efficient power generation solutions. Eliminating the core resolves challenges such as eddy current losses and cogging torque, enhancing overall efficiency. This topology enables high power density, further amplified in fully coreless configurations. Nevertheless, the proliferation of coreless AFPM machines faces hurdles as to high leakage flux and weaker structural integrity. Additionally, adopting multi-phase setups in AFPM introduces challenges, requiring additional winding coils and enlarging the stator diameter, leading to bulkier machine designs. This article underscores the significance of a lightweight, fully coreless six-phase machine and proposes a modular, multi-stage, multi-phase design tailored for fault-tolerant small-scale power generation applications. Furthermore, it explores the impact of employing double-layer winding coils on air-gap-flux density and power output. To realize this aim, a six-phase multi-stage AFPM generator was designed and simulated using ANSYS Maxwell. Subsequently, a laboratory-scale prototype was fabricated accordingly. The simulation findings closely align with the experimental results obtained from the prototype, demonstrating the achievement of 1.3 kW power output. Notably, the six-phase machine with fully coreless concept exhibits a substantial power density of 205 W/kg. Multi-stage design boost efficiency and power density, presenting potential for small-scale applications.https://ieeexplore.ieee.org/document/10829570/Coreless AFPMdouble-layer topologysix-phase prototypefault-tolerant design |
| spellingShingle | Turki M. Alsuwian Asiful Habib Muhammad Ammirrul Atiqi Mohd Zainuri Ahmad Asrul Ibrahim Nasrudin Abd Rahim Adam R. H. Alhawari Abdulkarem H. M. Almawgani Saleh Almasabi A. T. Hindi Mohamed Fauzi Packeer Mohamed Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance Analysis IEEE Access Coreless AFPM double-layer topology six-phase prototype fault-tolerant design |
| title | Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance Analysis |
| title_full | Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance Analysis |
| title_fullStr | Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance Analysis |
| title_full_unstemmed | Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance Analysis |
| title_short | Six-Phase Fully Coreless Axial-Flux Permanent-Magnet Generator: Design, Fabrication, and Performance Analysis |
| title_sort | six phase fully coreless axial flux permanent magnet generator design fabrication and performance analysis |
| topic | Coreless AFPM double-layer topology six-phase prototype fault-tolerant design |
| url | https://ieeexplore.ieee.org/document/10829570/ |
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