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This study presents the design and performance analysis of a prototype axial-flux permanent-magnet (AFPM) synchronous machine. First, the design of AFPM machine is optimised by genetic algorithm based sizing equation and finite element analysis. The design objectives of this machine are maximum power density, minimum total harmonic distortion (THD) of the sinusoidal back-electromotive force (back-EMF) waveform and low cogging torque. Based on the optimised design of the machine a prototype 1 kW, three-phase, 50 Hz, four-pole AFPM synchronous machine is built. Then, the performance of the prototype machine is tested to see the cogging torque, torque-speed characteristic, efficiency and the THD of the induced voltage. It is found that the prototype machine validates the design in terms of high-power density, lowest possible THD of the back-EMF, low cogging torque while maintaining high efficiency.

Abstract-This paper presents two design-and-analysis cases of a linestart axial-flux permanent-magnet motor: with solid rotor and with composite rotor. For a novel structure of the motor, two concentric unilevel spaced raised rings are added to the inner and outer radii of its rotors to enable auto-start capability. The composite rotor was coated by a thin (0.05 mm) layer of copper. The basic equations for the solid rotor ring were extracted. The motor's lack of symmetry necessitated 3D time-stepping finite element analysis, conducted via Vector Field Opera 14.0, which evaluated the design parameters and predicted the motor's transient performance. Results of the FEA show the composite rotor significantly improving both starting torque and synchronization capability over solid rotor.

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