Multi-Phase Flux-Switching Permanent Magnet

Brushless Machine for Aerospace Application

A. S. Thomas, Z.Q. Zhu, R.L. Owen, G.W. Jewell, D. Howe
Department of Electrical and Electronic Engineering, University of Sheffield, United Kingdom
Email: elp05ast@sheffield.ac.uk

Abstract Flux-switching permanent-magnet (FSPM) brushless using higher phase numbers with regards to improving
machines have attracted considerable interest as a candidate utilization of the airgap periphery, albeit often with
machine technology for applications requiring high torque diminishing return. Other advantages in terms of reducing
density and robust rotors. To date, published findings have torque pulsations are well established in induction [10] and
focused exclusively on single and three phase FSPM machines.
switched reluctance machines. In high power machines, higher
This paper investigates FSPM brushless machines of higher
phase numbers, by means a detailed comparison of the phase numbers are often preferred since for a given total
electromagnetic performance of 3-, 4-, 5-, 6-phase variants within power, they offer decreased inverter power ratings per phase,
the specific context of aerospace generators. Machines having which may well be a better fit with available semiconductor
both all poles and alternate poles wound are investigated, the technology. Further benefits include improved direct torque
latter offering scope to reduce mutual coupling between phases so control performance due to the increase in the number of
as to achieve improved fault-tolerance. The finite element voltage vectors which can be applied [11-12] and improved
predicted back-EMF waveforms are experimentally validated on fault tolerance because of the higher proportion of residual
small 5-phase FSPM machines having all poles wound and capability in the event of a faulted phase [13].
alternate poles wound. The nature of the generator specification
requires that consideration must be given to mechanical stress in
the rotor and the trade-off with electromagnetic design
considerations, notably the degree of rotor saliency which can be
incorporated. Therefore, a mechanical finite element study of the
rotor mechanical stresses of multi-phase FSPM machines is also
comparatively assessed.

Keywords fault tolerance, flux switching, permanent magnet,

mechanical stress, multiphase.

I. INTRODUCTION
Flux switching permanent magnet (FSPM) machines have
attracted considerable interest for high performance drive
applications due to their high torque and power densities [1-2].
FSPM machines are also well suited to high speed applications
since the permanent magnets and armature windings are
located on the stator and the resulting rotor structure, which is (a) all poles wound
similar to that employed in switched reluctance machines, are
simple and robust, Fig. 1. Each stator pole consists of two
teeth of two adjacent modular C-cores, between which a
circumferentially magnetized permanent magnet is
sandwiched, and over which a concentrated, non-overlapping
coil may be wound. The use of high energy permanent
magnets and flux focusing effect on the stator give rise to high
airgap flux densities, which when combined with the bipolar
nature of the winding flux-linkage offer the scope to achieve
high torque densities. These various features make FSPM
machines an attractive candidate for embedded generators in
aero-engines, since there are often onerous mechanical
integration constraints and loads applied to the rotor with a
significant premium on weight reduction. However, to meet
the challenges of this application, it is essential that the full
potential of this type of machine is exploited, a key factor
being the number of phases selected.
Previously published work on FSPM machines has been (b) alternate poles wound
focused on 1-phase [3-4] and 3-phase [1-2][5-9] machines. In Figure 1. 5-phase FSPM machine
most types of electrical machines there is an advantage in

978-1-4244-2279-1/08/$25.00 2008 IEEE 1

 To exploit the scope for improved fault tolerance, it is
beneficial to combine a high phase number with a winding in
which only alternate poles are wound as it is considered to
provide increased electrical and magnetic isolation between
phases [14]. To this end, FSPM machines with alternate poles
wound will be analysed to compare performance with more
conventional all poles wound configurations. With the specific
application of the machine, the rotor will be exposed to high
mechanical stress due to the large angular velocities and large
(a) 12/10, 3-phase
rotor bore diameter. Therefore, a generalized design approach
is done to compare the effect of rotor saliency on the rotor
stress with regards to electromagnetic performance.
This paper investigates, by means of extensive finite
element models, the performance of FSPM machines with
phase numbers ranging from 3 to 6, and compares their
electromagnetic performance and rotor mechanical stresses for
electrical power generation for aerospace application. The
finite element predicted back-EMF waveforms are validated
on small 5-phase FSPM machines having all poles wound and
alternate poles wound. (b) 16/12, 4-phase (2x2-phase)

II. MULTI-PHASE FSPM MACHINE TOPOLOGIES

All FSPM machines considered in this investigation have
the same stator outer diameter of 540mm, rotor bore diameter
of 210mm and core axial length of 80mm. They are targetted
at rated power specification of 430kW at 4000rpm
(corresponds to a rated torque of 1026Nm). A further
important design consideration, particularly from the rotor
mechanical design point of view, is the maximum speed of
12,500rpm. For the various phase numbers considered , there (b) 16/14, 4-phase
are many possible combinations of stator and rotor pole
numbers. Given the high speed nature of this application, it is
likely to be desirable to use a relatively low number of poles
to minimise cores losses and eddy current losses in the
magnets. However, it is also desirable to select combinations
which yield symmetrical rotors with a even number of teeth,
e.g. whereas a 5-phase machine with 10 stator poles could be
used this would result in a rotor with either 9 or 11 teeth. The
phase number combinations selected using these criteria are
summarised in Table I. For each stator pole number, two
possible rotor pole numbers can be selected, viz. 2 more or 2 (c) 16/18, 4-phase
less poles, being designated as +2 and 2 variants in Table I
respectively [1], (although it is also possible to have 1 more or
1 less pole, it is not considered here due to potential
unbalanced magnetic force). A further option is that machines
with even numbers of phases can be configured with multiple
groupings of phases, i.e. a 4 phase can be grouped as 2x2
phase and 6 phase as 3x3. Fig. 2 shows finite element
predicted magnetostatic field distributions in each of the
combinations identified in Table I.
(c) 20/18, 5-phase
TABLE I. STATOR AND ROTOR POLE COMBINATIONS FOR PHASE
NUMBERS BETWEEN 3 AND 6
No. of No. of rotor No. of rotor
No. of stator poles
phases poles (-2) poles (+2)
3 12 10 14
4 16 14 18
5 20 18 22
6 24 22 26
Note: (-) No of rotor poles < no of stator poles
(+) No of rotor poles > no of stator poles
(d) 12/10, 6-phase

2
 1.2
3-phase
1 4-phase
5-phase
6-phase

Normalised Torque
0.8

0.6

0.4

(e) 24/20, 6-phase (2x3-phase) 0.2

0
0.5 1 1.5 2 2.5
Rotor Pole Width/Stator Pole Width

Figure 4. Variation of torque with rotor pole width for multi-phase

machines.
1.2

0.8

Normailsed Torque
(f) 24/22, 6-phase
0.6
Figure 2. Equipotential plots of multi-phase FSPM topologies.

0.4

III. OPTIMISATION OF MULTI-PHASE MACHINES AND

COMPARISON OF MACHINE CHARACTERISTICS 0.2

For each of the phase numbers considered, there is an 0

optimal split ratio of stator outer to inner diameter which will 0 0.5 1 1.5 2 2.5

yield the maximum torque for a given coil current density. The Rotor Slot Depth / Rotor Pole Width

optimisation of split ratio was performed using two- Figure 5. Variation of torque with saliency ratio in 12/10 three-phase FSPM
machine.
dimensional, non-linear finite element analysis. This
optimization included consideration of the rotor dimensions in TABLE II. DIMENSIONS OF MULTI-PHASE MACHINES
terms of slot depth and rotor pole width, both of which were
varied to yield the maximum saliency [2]. The resulting No. of Phases
3- 4 5 6
optimal split ratios are summarised in Table II together with Stator/Rotor 12/10 16/12 16/14 20/18 24/20 24/22
number of winding turns to match to a 350V supply. As Optimal split
0.61 0.625 0.65 0.66 0.67
shown by Fig.3, the optimal split ratio increases with the ratio
number of phases. The rotor pole width was optimized as a Rotor Pole Ratio 1.5 1.5 1.5 1.5
ratio of the stator tooth width for maximum torque at a rated Winding
12 12 12 4 8
Number, Nph
current density of J=6A/mm2, when the ratio is 1 the rotor pole
width is the same as the stator tooth width, bst (Fig. 15). Fig. 4
shows results for the stator and rotor combinations listed in A. Flux-linkage and Back-EMF
Table I with the lower rotor pole number variant. The rotor The peak airgap flux density of FSPM machines are high
saliency was also optimized in terms of electromagnetic due to the effect of the flux focusing from the permanent
performance, Fig. 5, for a 3-phase FSPM machine. It is magnets located in the stator. Fig. 6 shows finite element
evident that there is no significant gain in electromagnetic predicted airgap flux density profiles for both 3 and 5 phase
performance for a saliency ratio, above 1.5. Further work on machines, which demonstrate localized flux densities in excess
the rotor saliency will be carried out in section V. of 2T in the vicinity of aligned stator and rotor teeth.
1.2 3

1
2
Normalised Torque

0.8
3-phase 1
Flux Density(T)

0.6 4-phase
5-phase 0
6-phase 0 90 180 270 360
0.4
-1
0.2
-2
0
0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 3-phase
Split Ratio -3 5-phase
Mechanical Degrees
Figure 3. Variation of torque with split ratio of multi-phase machines for
fixed copper loss. Figure 6. Air gap flux density

3
 The resulting bipolar flux-linkage waveforms in all multi- 0.015

phase FSPM machine variants of Table I are shown in Fig 7. Phase A

All flux-linkage waveforms show an equi-spaced phase layout 0.01 Phase B

Phase C
apart from the two 4-phase and 6-phase machines derived 0.005
Phase D
Phase E

Flux Linkage(Wb)
from Table I. The 16/14 and 16/18 4-phase machines are
essentially two 2-phase machines with a 45 phase shift. 0
Similarly, the 24/22 6-phase machine is two 3-phase 0 90 180 270 360

waveforms with a 30 phase shift. These combinations are -0.005

usually termed as split phases which are commonly used in

-0.01
induction machines to reduce torque pulsations and produce
smooth MMF similar to skewing [10]. -0.015
0.015
Electrical Degrees

(c) 20/18, 5-phase

0.01

Phase A
0.015
Phase A
Phase B Phase B
0.005 Phase C
Phase C
Flux Linkage(Wb)

0.01
Phase D
Phase E
0
Phase F
0 90 180 270 360 0.005

Flux Linkage(Wb)
-0.005
0
0 90 180 270 360
-0.01

-0.005
-0.015
Electrcal Degrees
-0.01
(a) 12/10, 3-phase
0.015 -0.015
Phase A
Phase B
Electrcal Degrees
0.01 Phase C
Phase D
(d) 24/20, 6-phase
0.02
0.005
Flux Linakge(Wb)

0.015

0 0.01
0 90 180 270 360
Flux Linkage(Wb)

0.005
-0.005
0
0 90 180 270 Phase A 360
-0.01 Phase B
-0.005
Phase C
Phase D
-0.015 -0.01 Phase E
Electrical Degrees Phase F
-0.015
(b) 14/12, 4-phase
0.04 -0.02
Electrical Degrees
0.03
(e) 24/22, 6-phase
0.02 0.015
Flux Linkage(Wb)

0.01
0.01 Phase A
Phase B
0 Phase C
0 90 180 270 360 0.005 Phase D
Flux Linkage(Wb)

-0.01 Phase E
Phase F

-0.02 Phase A 0
Phase B 0 90 180 270 360
Phase C
-0.03
Phase D -0.005
-0.04
Electrical Degrees -0.01
(c) 16/14, 4-phase
-0.015
0.015
Rotor Position (Mechanical Deg)

0.01 (f) 12/10, 6-phase

Figure 7. Finite element predicted flux-linkage waveforms of FSPM
0.005 machine topologies (shown as per turn values)
Flux Linkage(Wb)

0 The 12/10 machine can potentially be designed as a six

0 90 180 270 360
phase machine, by splitting the four coils in one phase of 3-
-0.005 Phase A
Phase B
phase machine into two separate phases, resulting in
-0.01
Phase C
Phase D
asymmetric waveforms as described in [2], Fig. 7(f).
The machine designs that are considered in the remainder
-0.015 of this paper are restricted to those machines in Table I which
Electrical Degrees have a lower rotor pole number than stator pole number, i.e.
(d) 16/18, 4-phase those designated as 2 variants. These give rise to a lower

4
fundamental frequency than their +2 counterparts, with 3-phase machine, the mutual inductance is almost half of the
consequent benefits in terms of reduced core losses. The finite self inductance. However, in higher phase machines it is
element predicted back-EMF waveforms are shown in Fig. 8, considerably lower, progressively reducing as the phase to
in each case with the appropriate number of turns required to phase angular separation increases.
match a 350V supply. Alongside each EMF waveform in Fig. 8 The relatively high mutual inductance can be attributed to
is the corresponding terminal voltage waveforms required to the stator topology in that half the armature flux in one phase
achieve rated torque at 4000rpm. directly links the phase that is wound within the same stator
400 C-core. From Table III it is clear that the machine self
300
Back-EMF inductance increases as phase number increase for the same
Vt
stator OD and winding number (3-5phase Nph=12). This
200
suggests slot leakage plays an increasingly important role in
100
determining self-inductance.
Voltage(V)

-100
0 6 12 18 24 30 36 TABLE III. SELF INDUCTANCE VALUES AND PERCENTAGE OF MUTUAL
INDUCTANCES RELATIVE TO PHASE A
-200
Phase A Mutual inductance components as % of self-
-300 No. of self inductance
-400 phases inductance
AB AC AD AE AF
Rotor Position (Mechanical Deg) (mH)
3 0.01589 47.6% 47.6% - - -
(a) 12/10, 3-phase 4 0.02029 30.8% 0.005% 30.8% - -
400
5 0.0214 38.7% 9.6% 9.6% 38.7% -
300 6 0.01194 35.6% 4.8% 0.6% 4.8% 35.6%
Back-EMF

200
Vt
C. Cogging Torque and Torque Output
100 FSPM machines are doubly salient machines and therefore
Voltage(V)

0 have cogging torque, although the level of cogging torque is

0 90 180 270 360 found to decrease with increasing in phase number. The
-100
frequency of the cogging torque also increases with phase
-200
number and is proportional to the half of the stator pole
-300 number, (Ns/2), Fig. 9.
-400
The output torque is compared in Fig. 10 for various
Rotor Position (Mechanical Deg) current densities. It is clear that above 6 A/mm2 that the output
(b) 16/14, 4-phase torque suffers significantly from magnetic saturation.
400
However, as the number of phases increases the influence of
300 Back-EMF
Vt
magnetic saturation is decreased.
200 20

100 15
Voltage(V)

0 10
Cogging Torque(Nm)

0 90 180 270 360

-100 5

-200
0
-300 0 60 120 180
-5
-400
-10
Rotor Position (Mechanical Deg) 3-phase
4-phase
(c) 20/18, 5-phase -15 5-phase
400 6-phase
-20
300 Electrical Degrees

200
Back-EMF
Vt
Figure 9. Finite element predicted cogging torque of different phase
machines.
100
1800
Voltage(V)

0 1600
0 90 180 270 360
-100 1400

-200 1200
Torque(Nm)

-300 1000

-400 800
Rotor Position (Mechanical Deg) 600 3-phase
4-phase 16/14
(d) 24/22, 6-phase 400 5-phase
Figure 8. Back-EMF waveforms. 6-phase - 24/22
200
B. Inductance 0
Table III shows the finite element predicted phase self 0 2 4 6 8 10 12 14 16 18
Current Density(A/mm^2)
inductances with the various components of mutual inductance
Figure 10. Two-dimensional FEA predicted torque output of multi-phase
presented as a percentage of the phase self-inductance. For the FSPM machies.

5
 IV. ALL POLES WOUND AND ALTERNATE POLES WOUND
In preceding sections, the electromagnetic performance of
multiphase FSPM machines having all poles wound coils has
been compared. In common with more conventional PM
machines [14], it is also possible to produce a FSPM machine
in which only alternate poles are wound, i.e. modular FSPM
machines in which the phase windings are effectively isolated,
both magnetically and physically. By way of example, the
back-EMF and torque-current density characteristics for 5-
phase FSPM machines having all poles wound and alternate
poles wound are compared in Figs. 11-13.
250
200
150
100
50
Voltage(V)
Alternate pole wound
All pole wound
would exhibits similar characteristics and torque density, but
becomes more heavily saturated at higher current densities for
the same number of turns per phase. Fig 12 shows the static
torque of the 5-phase FSPM machine for the same current
density in both winding arrangements. It clearly shows there is
increased torque ripple in the alternate poles wound
arrangement and that there is a decrease in output torque due
to the saturation of the stator. This can be attributed to a higher
armature reaction flux in a given slot for the alternate winding
arrangement. In the case of an all poles wound arrangement,
the flux produced by phase A, A, is given by NCIA/R with the
flux given by phase B, B, as NCIB/R, where NC is the number
of turns per coil, I is the phase current and R is the reluctance
path of the flux. For AC operation IB=-IA/2 therefore total slot
armature flux can be given as equation 1.
3 NC I A
T 1 = (1)
2 R

0 In the alternate poles wound topology, for the same phase

0 90 180 270 360
-50 winding number, the individual coil number will be doubled
-100 therefore total armature flux for one slot can be given as in
-150 equation 2.
N I
-200
T 2 = 2 C A (2)
-250 R
Electrical Degrees This demonstrates that the armature reaction flux for the
Figure 11. Back-EMF of 5-phase FSPM machines having all poles wound and alternative teeth wound machine is 1/3 higher than that in the
alternate poles wound. all poles wound machine, hence their greater tendency to
1400
magnetically saturate.
1200
TABLE IV. SELF INDUCTANCES AND MUTUAL INDUCTANCE OF ALL POLES
1000 AND ALTERNATE POLES WINDING MACHINES (AS PERCENTAGE OF SELF
INDUCTANCE) FOR 5-PHASE FSPM MACHINE.
Torque(Nm)

800
Self Mutual coupling components
inductance (expressed as % of self-
600
of phase A inductance)
All pole wound
Alternate pole wound (mH) AB AC AD AE
400
All poles 0.0214 38.7% 9.6% 9.6% 38.7%
200
Alternate 0.0383 8.02% 2.15% 1.86% 6.14%
poles
0
0 90 180 270 360 V. ROTOR MECHANICAL STRESS
Electrical Degrees

Figure 12. Output torque of the 5-phase all poles wound and alternate poles
As noted earlier, the combination of high rotational speed
wound machine predicted in 2D FE. (12,500rpm) and large rotor diameter (~350mm for split ratio
1800 of 0.65) will inevitably give rise to significant centrifugal
1600
loading of the rotor. Its mechanical design, and the need for
possible trade-offs in electromagnetic performance, is a key
1400
issue in assessing the suitability of FSPM machines for
1200
applications of this type.
Torque(Nm)

1000 The mechanical stress induced in the rotor was calculated

800 using two-dimensional finite element analysis (ANSYS
600
All pole wound package). The electromagnetic performance predictions
Alternate pole wound
presented in section III, were based on machines whose rotor
400
geometries were optimized from the perspective of
200 electromagnetic performance only, i.e. with regard optimal
0 split ratio and rotor slot depth. As a starting point, the
0 2 4 6 8 10 12 14 16 18
mechanical stress distribution in each of these rotors was
Current Density(A/mm^2)
calculated. Fig 14 shows a typical stress distribution
Figure 13. Torque comparison between 5-phase FSPM machines having all
poles wound and alternate poles wound. throughout one rotor pole, the specific case shown being a 10
pole rotor with an outer diameter of 324mm rotating at the
A high self-inductance and reduced mutual inductance, maximum speed of 12,500rpm. The maximum value of Von-
Table IV, can be realized in alternate poles wound FSPM Mises stress in each of the rotors considered is summarised in
compared to an all poles wound counterpart, which is Table V. As will be apparent, the maximum values of stress
beneficial in terms of minimizing undesirable coupling during fall within a relatively narrow range, being slightly higher in
a fault in one phase, providing a higher degree of fault- the case of the rotor with the largest number of teeth. The
tolerance. As will be evident, the machine with alternate poles stress distribution of Fig. 14 illustrates the potential for

6
increasing stress concentration in the region between TABLE V. COMPARISON OF MAXIMUM VON MISES STRESS AT 12500
RPM OF MULTI-PHASE MACHINES FOR OPTIMISED ELECTROMAGNETIC
successive rotor teeth and the care that must be taken in PERFORMANCE
ensuring that an appropriate fillet radius is used as the
Number of Number of Rotor Maximum Von
intersection of the rotor teeth with the main cylindrical hub Phases Poles Mises Stress (MPa)
region. Indeed, whereas the peak stress in a plain cylindrical 3 10 373
ring occurs on the inner bore, in a salient rotor of the type 4 14 364
shown in Fig. 12, it is possible to exceed the bore stress in the 5 18 380
inter-pole region [16, 17], particularly if the rotor slot depth is 6 22 399
800
a significant fraction of the annular thickness of the rotor.
However, whereas decreasing the rotor slot depth tends to 700

Maximum Von Mises Stress(MPa)

relieve the maximum localized stress (to the degree where it 600
approaches that of a plain cylindrical ring) this can
500
compromise the inductance ratio and hence the torque
capability of the machine. 400

In terms of generalizing the relationship between 300 Thick walled cylinder

mechanical and electromagnetic performance, it is useful to 200

krs=0.5
krs=1

consider Fig. 15 from which the dimensionless ratio of krs krs=1.5

krs=2
100
(=hrs/wst) can be derived. It has been demonstrated that the krs=2.5

benefits in terms of enhanced torque of increasing krs tend to 0

0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
diminish for values beyond 1.5 or so [5,15]. Split Ratio
Fig. 16 shows the variation in maximum predicted Von (a) 10-pole
Mises rotor stress with split ratio for a number of different 800
values of krs. Also shown in each case is the stress calculated 700

Maximum Von Mises Stress(MPa)

in a plain cylindrical rotor of the same inner and outer
600
diameter and material using a standard expression for a thick-
walled cylinder [16].Fig 16 shows that for all the phase 500

numbers considered, split ratios above 0.6 there is little 400

compromise in mechanical stress levels from accommodating
300 Thick walled cylinder
krs values of >1.5. krs=0.5
200 krs=1
krs=1.5
krs=2
100 krs=2.5

0
0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
Split Ratio
(b) 14-pole
800

700
Maximum Von Mises Stress(MPa)

600

500

400

300 Thick walled cylinder

krs=0.5
200 krs=1
krs=1.5
100 krs=2
krs=2.5

0
Figure 14. Von Mises stress plot of 10-pole rotor, split ratio=0.6, slot 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
depth=1.4 Split Ratio
(c) 18-pole
800

700
Maximum Von Mises Stress(MPa)

600

500

400

300 Thick walled cylinder

krs=0.5
200 krs=1
krs=1.5
krs=2
100
krs=2.5

0
0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8
Split Ratio
(d) 22-pole
Figure 16. Maximum stress in rotor laminations for various split ratio and
Figure 15. Dimensions of rotor saliency rotor slot depth.

7
 VI. CONCLUSIONS VII. APPENDIX EXPERIMENTAL VALIDATION ON A SMALL
This paper has demonstrated that FSPM machines with 5-PHASE FSPM MACHINE
high phase number offer benefits over more conventional
three-phase machines in terms of torque density. By adopting The validation was carried out on small 5-phase FSPM
a winding in which coils are wound around alternate poles, an machines having all poles wound and alternate poles wound,
enhanced degree of fault-tolerance can be achieved. The finite as shown in Fig.17. Its stator outer diameter is 90mm, rotor
element predicted back-EMF waveforms are experimentally outside diameter is 29.25mm, rotor bore diameter is 15mm,
validated on small 5-phase FSPM machines having all poles airgap length is 0.5mm, and core axial length of 25mm,
wound and alternate poles wound. It has also been NdFeB magnet is employed and its remanence is 1.2T.
demonstrated that higher phase numbers are less sensitive to Fig.18 compares the 2D finite element predicted and
the level of rotor saliency with consequent benefits in measured back-EMF waveforms in 5-phase FSPM machines
mechanical design. having all poles wound and alternate poles wound. As can be
seen, the back-EMF waveform of all poles wound machine is
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